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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation application of U.S. patent application Ser. No. 10/015,583, filed Dec. 17, 2001, now U.S. Pat. No. 6,960,244 and claims the benefit of priority thereto”.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to air filtration systems, and more particularly to a system and method for removing contaminates and other particulate matter from the air in a mail sorting room. The invention has particular application to reducing cross-contamination caused by a letter laced with anthrax or another harmful biological substance.
2. Description of the Related Art
Mail security has more than ever before become a vital national security interest. For the first time in our nation's history, the mail has been used as a vehicle of terrorism both by domestic and foreign enemies. The World Trade Center tragedy made every American painfully aware of the scope of destruction a determined terrorist could exact. This tragedy resulted in the loss of more than six thousand lives in the two most prominent cities of this nation, and is generally considered to be the defining event which marked a new age in terrorism.
While these cataclysmic acts have left their emotional mark on the American psyche to be sure, an evil far greater than suicide highjackers serves as the most serious threat today. This evil has the potential of operating as a silent killer and of taking far more lives than most wars. In fact, experts acknowledge that bioterrorism, if exacted in epidemic proportions, can result in a loss of life measurable in the tens or even hundreds of thousands.
In our most recent experiences with terrorism, what was once thought of as an unlikely threat became a grim reality. Letters addressed to prominent media figures and public officials were sent through the mail laced with anthrax. This resulted in infecting not only the staff of the intended recipients but also members of their families. Perhaps even more shockingly, many post office employees who carried and sorted the unopened letters also contracted and died from the disease.
In at least two cases, anthrax infection resulted from cross-contamination, a phenomenon which occurs, for example, when anthrax spores migrate from one letter to another letter or person. Authorities have determined that this could happen when the anthrax-contaminated letter comes into physical contact with another letter or when the spores become airborne and susceptible to inhalation.
A number of approaches have been proposed for dealing with anthrax exposure and other bio-terrorist acts perpetrated through the mail. One approach involves equipping mail sorting personnel with gloves and masks designed to protect against airborne particulates. This approach has often proven to be ineffective for protecting the facility. If small enough, anthrax spores will become suspended in the air for long periods of time. This makes them exceptionally difficult to protect against. For example, any patch of exposed skin could become infected even if gloves and a mask are worn. The spores could also attach themselves to the workers clothes, which could result in infecting anyone coming into contact with them.
Another approach involves irradiating the mail at some point prior to delivery. While this may prove to be effective in a certain percentage of cases, there is no guarantee that irradiation will kill all of the biological contaminates associated with a given letter. Irradiation does not solve the problem of contamination or cross-contamination resulting from airborne anthrax spores one-hundred percent of the time. Furthermore, security issues exist from the irradiation unit to the end-user or client.
In view of the foregoing considerations, it is clear that there is a critical need for an improved system and method of protecting mail-sorting personnel and facilities from biological contamination, and moreover one which is especially effective in preventing infection resulting from cross-contamination.
SUMMARY OF THE INVENTION
It is one object of the present invention to provide an improved system and method for protecting mail-sorting personnel from exposure to anthrax and other forms of deadly biological substances that have a tendency to become airborne during handling.
It is another object of the present invention to provide a system and method of the aforementioned type which is especially effective in protecting facilities and workers from infection resulting from cross-contamination effects.
It is another object of the present invention to provide a system and method of the aforementioned type which may be used by both the public and private sector.
It is another object of the present invention to provide a system of the aforementioned type which is transportable, easy to implement, and easy to adapt to any user's particular needs or space requirements.
It is another object of the present invention to provide a system and method of the aforementioned type which may be used in combination with other approaches to provide an integrated solution to decontaminating a mail sorting room.
It is another object of the present invention to provide a system and method of the aforementioned type which also protects personnel against chemical hazards during a mail sorting process.
The foregoing and other objects of the invention are achieved by a decontamination system which includes a sealed mail sorting room having an air inlet and an air outlet, a vacuum unit which creates a negative pressure within the mail sorting room, and a filter unit which filters air on its way out of the outlet of the mail sorting room. The vacuum unit creates negative pressure by suctioning air, first, through the air inlet and, then, from inside the sorting room into an inlet of the vacuum unit. The filter unit filters the air which is suctioned into the inlet of the vacuum unit.
The mail sorting room preferably has a modular construction with walls, a ceiling, and a floor which may all be removable. The walls may be transparent or opaque and one of them includes a door. If desired, the room may be constructed with multiple rooms, each of which may be used as a separate mail sorting area with a separate table. To prevent contaminates from escaping, an air lock room may be connected to the mail sorting room. The negative suction created in the mail sorting room draws air from an outside source into the air lock room, and then air from the lock room is then sucked into the mail sorting room. The air lock room, thus, serves as a buffer area. If desired, a filter unit may be used to filter the air before it is drawn into the air lock room. A door is included for allowing persons to pass from the air lock room to mail sorting room. The door is preferably self-sealing. The system may further include an intercom system and a warning device for informing outside personnel that a room is in use.
In operation, the vacuum unit creates a downwardly directed flow of air which passes from the air inlet into the mail sorting room. Once in the sorting room, the air enters the inlet of the vacuum unit, after which it is then filtered and expelled. For stability and consistency reasons, the air flow is preferably laminar in nature. The filter may have multiple stages, where in a first stage larger size particles are removed and in a second stage smaller sized particles are removed. A third filter may be used to remove chemical threats. The present invention is advantageous because it provides a work environment which protects personnel both inside and out of the room from exposure to contaminates.
The present invention is also a mail cleaning system suitable for use in the mail sorting room. This system includes a chamber, a vacuum unit, and a filter. The chamber has an air inlet and an air outlet and the vacuum unit is connected to the air outlet. The vacuum unit suctions air through the air inlet to create a high-velocity air flow through the chamber. Mail is then inserted into an entrance of the chamber by hand or by a conveyor. The high-velocity air flow removes contaminates from the mail, and the filter removes contaminates from the air flow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing a preferred embodiment of the system of the present invention for removing contaminates from the air in a mail sorting room.
FIG. 2 is a diagram showing steps included in a preferred embodiment of the method of the present invention for removing contaminates from the air in a mail sorting room.
FIG. 3 is a diagram showing an embodiment of a mail cleaning device in accordance with the present invention which is suitable for use in the mail sorting room.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is a system and method for removing contaminates from the air in a mail sorting room. The mail sorting room may be one which includes letters, packages, parcels, or any other type of container or object that may be sent through the mail or shipped by a carrier. The contaminates may be ones that are harmful or even deadly to human beings. Examples include anthrax spores, smallpox, botulism, salmonella and other types of pathogens, viruses, or bacteria. By removing these types of contaminates from the air, the invention will protect U.S. Postal Service workers and employees in private mail rooms exposure to bio-terrorist attacks, especially in the case where infection could occur as a result of cross-contamination.
The present invention may also be useful in removing airborne contaminates which are not particularly harmful to humans, but instead are merely considered to be a nuisance. Examples include dust and pollen which may produce an allergic or even asthmatic reaction in mail-sorting personnel. While the invention is preferred for use in sorting mail, those skilled in the art can appreciate that other objects or areas may be contained using the invention.
Referring to FIG. 1 , a preferred embodiment of the system of the present invention includes an air inlet 1 , a sorting table 2 , a vacuum unit 3 , and a filter unit 4 . The sorting table is located within a sealed enclosure 5 which includes an air lock room 6 and a mail sorting room 7 , the latter of which is large enough to accommodate at least one worker and a collection of mail. The sealed enclosure may have any shaped desired with a parallelopiped being preferable. The enclosure may also have a footprint which corresponds to other geometrical shapes (e.g., triangular, hexagonal, etc.) or may even be irregularly shaped. As will be explained below, one particularly advantageous feature of the invention is that the room may be designed to be portable with removable walls, floor, and ceiling. The dimensions of such a room are adapted to meet the space requirements given. For example, a media company may have set aside a certain limited amount of space in a mail room to accommodate the invention and the invention may be designed accordingly. The room may be a permanent room if desired.
To simplify installation, the room is preferably constructed to be modular in nature, fabricated from a frame comprising a plurality of interconnected support members 8 . The support members may be made from any type of rigid material including metal, plastic, polymers, composites, and even wood. For convenience and ease of use, the members are made from a light but strong metal (e.g., aluminum) and are removably connected to allow the room to be portable and thus relocatable within, for example, an office building, warehouse, or the like.
The walls 9 of the room are made from plastics, polymers, composites, or any other material which is capable of enclosing a volume of air without leakage. In terms of appearance, the walls may be transparent, translucent, or even opaque for privacy reasons. Preferably, the walls are made from shatter-resistant Lexan which provides an easy-to-clean interior surface. In terms of structure, the walls may be rigid or flexible and a door or other entrance (not shown) is formed in one of the walls to allow personnel to pass into and out of the room. Like the walls, the door is sealed, or self-sealing, to prevent contaminates from escaping from the room.
The ceiling 10 of the room may be made from the same material as the walls. The floor 11 may be made from rubber, polymer, or a composite material which is not only airtight but which provides traction to sorting personnel while working in the room. The connections between the frame members, ceiling, and floor are all sealed using any one of a variety of conventional methods. As will become more apparent from the discussion which follows, sealing the room protects personnel outside the room from exposure to contaminates during mail sorting. Sealing the room also ensures that a sufficiently strong negative air-flow is created within the mail sorting room for cleaning the air therein.
The vacuum unit includes an air inlet 30 connected to a conduit 32 which exits the enclosure. The air inlet 30 may include a pre-filter which may be any standard heating and air filter. A mesh filter is one example. The conduit may exit the enclosure through the air lock room or through one of the walls in the mail sorting room. The air inlet is positioned under the table and suctions air from the mail sorting room as a result of a motorized blower (not shown) which may be located inside or outside of the enclosure. The blower (e.g., a thermally protected Class “B” insulated motor) may be located inside or outside the room. While the dimensions of the air inlet are shown as being smaller than the table, those skilled in the art can appreciate that the air inlet may be as large or even slightly larger than the table top.
The power of the vacuum unit is controlled to create a negative pressure within the mail sorting room. Preferably, the vacuum creates a negative pressure on the order of two atmospheres. (In this case, the vacuum unit may be said to create a double negative pressure environment.) To create such a negative pressure, the blower may create a suction on the order of 350-400 cubic feet per minute. Those skilled in the art can appreciate, however, that this range is merely illustrative and that other ranges may also be used.
The negative pressure in the sorting room draws airborne particulates 15 into the inlet of the vacuum unit and through the filter unit 4 , after which it is expelled. The vacuum unit thus creates a constant flow of air directed towards the floor, which advantageously prevents the floating effect of airborne anthrax spores which have been found to infect workers in the latest terrorist attacks. This is especially effective in preventing infection through cross-contamination. (The air flow path created by the vacuum unit is preferably a laminar flow, as illustratively shown by arrows 20 in FIG. 1 .)
The downward flow of air in the mail sorting room is created when the negative pressure created by the vacuum unit draws air through air inlet 1 . As shown, this air inlet has a first end 25 which extends into the mail sorting room and a second end 26 which opens into the air lock room. In operation, negative pressure within the sorting room draws air from the air lock into the sorting room through air inlet 1 . Air flows into the air lock room though another inlet 40 , which has an end 45 attached to a filter unit 42 . The air lock room includes at least two doors (not shown). The first door allows personnel to pass from the outside into the air lock room, and the second door passes from the air lock room into the mail sorting room. Inlets 1 and 40 may be equipped with internal valves 61 which close when negative pressure becomes reduced. These valves are advantageous because the prevent air in the mail-sorting room (which is potentially contaminated) from escaping into the air lock room or even outside of the entire enclosure. Like the mail sorting room, the air lock room may also be sealed.
The filter unit 4 may be any type conventionally known. Preferably, the filter unit includes dual-stage units which may be located inside or outside of the sealed room, or both. The filter units may also be included within a common housing with a motor of the vacuum unit. For example, the filter unit may be situated above the vacuum motor in unit 4 . Under these circumstances, the vacuum motor and filter unit may be self-contained and disposable.
The first filter stage in unit 4 removes large particulates, for example, in the size range of above 5 microns. One filter of this type is a foam pre-filter. The second filter stage removes smaller particulates down to the size range of 0.3 microns. One filter of this type is a High Efficiency Particulate Air (HEPA) filter created by the U.S. Atomic Energy Commission. Such a filter has been shown to be 99.97% efficient at removing particles which are 0.3 microns in size or greater. HEPA filters of various sizes and materials may be used in accordance with the invention. Such a filter may have a netted structure of borosilicate fibers with 100 square feet of filter surface. The use of HEPA filters is advantageous not only for the aforementioned reasons but also because they tend to have a long operating life, e.g., 2-5 years. If desired, filter 42 may also be a HEPA filtration unit, or even a double HEPA unit. Once the air flow containing the contaminates has passed through filter unit 4 , it may be expelled into the atmosphere, or it may be passed through another filter 53 which, for example, may also be a HEPA filter.
If desired, an optional third filter may be used to filter the air entering into the inlet of the vacuum unit. This third filter may be a V.O.C. filter which removes hazardous chemical threats. The third filter may be located at any position relative to the first two filter units, e.g., before them, after them, or even between them.
Referring to FIG. 2 , a preferred embodiment of the method of the present invention includes as an initial step assembling an enclosure which includes mail sorting and air lock rooms as previously discussed. (Block 100 ). This involves selecting a location within, for example, an office building where an employer has dedicated space for mail to be sorted. The frame is then connected, followed by assembly of the walls, floor, and ceiling. If desired, the floor may be a rubber mat sealed to the underside of the frame and/or walls. The vacuum and filter units are then mounted, sealed to the room as necessary, and then powered. While the air lock room is considered advantageous in preventing contaminates from migrating from the mail sorting room to the outside environment, those skilled in the art can appreciate that only the mail sorting room may be constructed if desired.
A second step includes activating the vacuum unit to create a negative pressure within the mail sorting room. (Block 200 ). This causes air to be drawn first from the outside into the air lock room through conduit 40 and filter unit 42 , and then from the air lock room into the mail sorting room through air inlet 1 . As previously indicated, a negative pressure of two atmospheres is desirable for generating this air flow.
A third step includes placing an item of mail on the top surface of the table, or merely handling the mail item at a position above the table within the downwardly directed air flow pathway. In this position, any contaminates on the outside of the mail or suspended in the art are suctioned into the air inlet of the vacuum unit.(Block 300 ). To ensure that contaminates are removed, the mail handler should rotate the mail item so that all of its surfaces are subjected to the air flow for at least a minimum amount of time.
A fourth step includes allowing the suction created by the vacuum unit to carry the contaminates from the air in the mail sorting room into the inlet of the vacuum. (Block 400 ). Once in the inlet, the contaminates are carried to filter unit 4 .
A fifth step includes filtering the air which has entered into the vacuum unit. (Block 500 ). This filtering step may be performed using one filter or multiple filters. Preferably, filtering is performed in at least two stages, where in a first stage larger sized particles are removed and in a second stage smaller size particles (e.g., 0.3 microns) are removed. A third filter stage may remove chemical threats that may exist in the air flow.
A number of optional features may be included in each of the foregoing embodiments. For example, multiple sorting rooms with separate air lock rooms or even a common air lock room may be used. These sorting rooms may be connected to a common frame structure but each may be isolated from the other for containment purposes. The rooms may be constructed such as shown in FIG. 1 , complete with their own tables, vacuums, and filter units. For cost saving and convenience, a single air source for the blowers may be used in combination with a branched conduit. Also, the conduit on the air inlet of each vacuum unit may lead into a common filter unit. Doors (not shown) may be included not only to allow personnel to enter each room from the outside but also to allow personnel to pass between the rooms. As in the first embodiment, airtight seals are provided at all locations where the conduits and other structure of the system pass through the walls and/or ceiling.
In addition to a sorting table, a mail inspection table and/or one or more mail openers may be included in every sealed room. Each room may also contain sterilization equipment which may be used to sterilize a contaminated letter once found. Each room may also be equipped with a beacon or other warning/indication device which may be activated to alert exterior personnel that the room is in use. Each room may also include its own intercom system for communicating with persons outside the room.
One optional feature which may be placed on or adjacent the sorting table is what the Inventor refers to as a high velocity, high CFM vacuum device. As shown in FIG. 3 , this device may be connected to a self-feeding mail tray 75 via conveyor 76 , which is designed to hold the mail on edge and move it rapidly to the device. The conveyor may shake the mail during transport utilizing existing technology. Rollers, wheels, tracks, or other known components may be incorporated into the conveyor for moving the mail. If desired, the conveyor may be motorized for automatically conveying the mail to the vacuum device.
The vacuum device 77 includes a chamber 78 having an entrance 79 and an exit 80 through which the mail passes from the conveyor. The vacuum device also includes an air intake port 81 and an air outlet port 82 , the latter of which is attached to a motorized vacuum unit 83 which includes a filter 84 such as a HEPA filter. A pre-filter 85 may be integrated into the housing of the chamber in advance of HEPA filter 84 .
In operation, a worker in the mail sorting room would fill the mail tray with a stack of mail. The conveyor would then transport the mail to the vacuum device. Inside the chamber of the vacuum device, a high-speed air flow is created as a result of vacuum unit 83 suctioning air through the air intake port. Preferably, the vacuum unit creates a down draft of air in the range of 50 to 400 C.F.M., but those skilled in the art can appreciate that other air flow ranges may just as easily be used. The air flow created within the chamber operates as an air wash to remove contaminates (e.g., anthrax spores, pollen, etc.) from the mail. If desired, the exhaust from the vacuum unit 83 may be ducted into a secondary filter to be re-filtered through a HEPA filter for redundant safety.
After the mail exits the vacuum chamber, it is passed either to a mail opener or stacked into a bundle for sorting. This may be accomplished by extending the conveyor through the chamber housing and exit along additional conveyor track connected to the exit, or simply by allowing the mail to drop into a bin situated below the exit. If the device is a desktop unit, the mail may be left to drop onto the sorting table. The vacuum device provides an additional measure of protection when used in combination with the mail sorting room of the present invention.
Other modifications and variations to the invention will be apparent to those skilled in the art from the foregoing disclosure. Thus, while only certain embodiments of the invention have been specifically described herein, it will be apparent that numerous modifications may be made thereto without departing from the spirit and scope of the invention.
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An air decontamination system including a sealed room to hold at least one person and the sealed room having an air inlet. The system further including a vacuum unit to create a negative pressure within the sealed room, by suctioning air through the air inlet into the sealed room and then from the sealed room into an inlet of the vacuum unit. The system still further including a work surface disposed in the sealed room at a predetermined height above a floor of the sealed room and the work surface to receive at least one mail piece and the air to be suctioned downwardly over the at least one mail piece and the work surface; and a filter unit to filter the air as the air is drawn out of the sealed room.
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FIELD OF INVENTION
[0001] The present invention concerns high strength silicon-containing titanium-based alloys with optionally additives of aluminium, boron, chromium, scandium and rare earth metals (Y, Er, and Ce and La containing misch metal).
BACKGROUND ART
[0002] A variety of two phase α/β-titanium and near α-titanium alloys, such as Ti-6Al-4V, IMI 834 (Ti-5.8-Al-4Sn-3Zr-0.7Nb-0.5Mo-0.35Si-0.06C) and TIMET 1100 (Ti-6Al-2.7Sn-4Zr-0.4Mo-0.45Si) show great potential application in the air plane and space industry.
[0003] Among them Ti-6Al-4V exhibits the broadest application due to an optimum combination of high strength and fracture toughness and excellent fatigue properties at room and elevated temperature. These alloys have, however, some disadvantages such as a poor oxidation resistance above 475° C. (α-case formation), insufficient creep strength at 600° C. and higher temperatures and a poor wear resistance at room and elevated temperatures. The α-case causes crevice formation on the oxidised surface and has a detrimental effect on the fatigue properties. The arc melting process of these relatively high melting point alloy of about 1660° C.) and the necessary melt overheating to about 1750 to 1770° C. is a very energy consuming procedure for the manufacture of investment castings for the air plane and automotive industry, and engineering purposes in general.
[0004] Low silicon-containing titanium-based alloys are well known. Thus JP 2002060871 A describes a titanium alloy containing 0.2-2.3 wt % Si, 0.1-0.7 wt % O (total content oxygen), and 0.16-1.12 wt % N and 0.001-0.3 wt % B and remainder of titanium including unavoidable impurities, used for as cast products.
[0005] These are e.g. golf club heads, fishing tackles and medical components such as tooth root, implants, bone plates, joints and crowns. The low silicon-containing titanium-based alloy does, however, suffer from a disadvantage, by forming small needle like Ti 3 Si precipates along grain boundaries, which decrease the fracture toughness and ductility of this material.
[0006] There is thus a need for an alloy that has a high strength at high temperatures, has a lower melting point than the Ti—Al—V alloys and has good casting properties.
DESCRIPTION OF INVENTION
[0007] By the present invention it is provided Ti—Si alloys with relatively high silicon contents which exhibit a relatively low melting point due to their eutectic constitution, good casting properties and high strength at higher temperatures as well as a very high resistance to oxidation and creep deformation at high temperatures.
[0008] The present invention thus relates to a Ti—Si alloy comprising 2.5-12 wt % Si, 0-5 wt % Al, 0-2 wt % Cr, 0-0.5 wt % B, 0-1 wt % rare earth metals and/or Sc, the remaining except for impurities being Ti.
[0009] According to a preferred embodiment the alloy contains 0.3-3 wt % Al, and more preferably 1.1 to 3 wt % Al.
[0010] According to another preferred embodiment the Ti—Si alloy contains 6-9 wt % Si and 1.2-2.5 wt % Al.
[0011] A particularly preferred alloy is the eutectic alloy containing about 8.5 wt % Si.
[0012] According to yet another preferred embodiment the alloy contains 0.001 to 0.15 wt % rare earth metals and/or scandium.
[0013] It has been found that the addition of rare earth metals or scandium improves the warm strength and creep strength of the Ti—Si alloy up to at least 675° C.,
[0014] The rare earths and scandium additions form a fine dispersion of thermo-dynamically stable oxides, such as Er 2 O 3 , Y 2 O 3 etc. in the Ti—Si alloy.
[0015] The alloy may further contains 0.1 to 1.5 wt % Cr. The addition of Cr will enhances solid solution hardening and therefore increases the strength and will further increase the oxidation resistance of the alloy.
[0016] In the as cast state, the Ti—Si alloy possesses fine-grained hypoeutectic, eutectic or slightly hypereutectic microstructures depending upon the silicon content. The microstructure of the eutectic Ti—Si alloy consists of finely dispersed Ti 5 Si 3 silicide particles of discontinuous rod like shape within the hexagonal close-packed α-Ti(Si) solid solution matrix. The hypoeutectic microstructure consists of primary solidified α-Ti(Si) crystals and the surrounding eutectic.
[0017] The Ti—Si alloy according to the invention has with a yield stress of at least 700 MPa, a Brinell hardness of at least 320 HB and sufficient ductility and fracture toughness -stress intensity factor K IC of more than 20 MPa √{square root over (m)}.
[0018] The Ti—Si alloy according to the invention further exhibits excellent oxidation resistance up to 650° C. and above depending upon the Si content and improved wear resistance both at room and elevated temperature. The yield strength at 650° C. will be of at least R P 0.2 ≧250 MPa and the tensile strength exceeds R m =450 MPa.
[0019] The hypereutectic microstructures consist of primary solidified Ti 5 Si 3 crystals of hexagonal shape within the fine-grained eutectic microstructure.
[0020] In the as cast state the hypoeutectic Ti—Si alloys exhibit at room temperature fractures toughness—K IC -values— of more than 20 MPa √{square root over (m)}, yield stress of more than 500 MPa with a plastic strain of more than 1.5 to 3%.
[0021] The eutectic alloy shows a fracture toughness of K IC of 15-18 MPa √{square root over (m)} and the yield stress exceeds 850 MPa at room temperature. At 600° C. and above the fracture toughness is increased to 30 MPa √{square root over (m)} and the strength is of the order of at least Rm=450 MPa.
[0022] Oxidation tests with exposure to air at 600° C. have resulted in an increase in mass of less than 5 mg/cm 2 after 500 hours. In comparison the conventional Ti—Al6-V4 alloy exhibits alpha case formation at 475° C. during long term exposure on air.
[0023] The creep stress (applied stress at given temperature where the creep rate is {dot over (ε)}=10 7 s −1 ) of the eutectic Ti—Si alloy according to the invention is higher than 200 MPa at 600° C. In contrast the Ti—Al6-V4 alloy with potential application in the air plane and space industry exhibits a creep stress of about 150 MPa at 450° C.
[0024] The Ti—Si alloy according to the invention has a low melting point of between about 1330 and about 1380° C. The alloy according to the invention has further excellent casting properties making it possible to cast virtually any size and shape.
[0025] As a result of its spectrum of characteristics properties presented above, the Ti—Si alloy according to this invention are advantageously suitable for the manufacture of diverse components, such as:
[0026] connecting rods, piston crowns, piston pins, inlet and outlet valves and manifolds of exhaust gas mains in internal combustion engines and diesel engines;
[0027] static blades in axial flow compressors and fan blades in jet engines;
[0028] wear resistant parts in textile machines—weaving looms—like shuttles and connecting shafts;
[0029] surgical implants, bone plates, joints;
[0030] hard facings and surface alloys used as coatings in surface engineering for improving wear resistance and to avoid fretting;
[0031] watch cases;
[0032] pump cases and impellers for the chemical and oil industry.
[0033] The Ti—Si alloy according to the invention is particularly suitable for as cast components because of their relatively low melting temperatures of about 1330 to 1380° C. and excellent castability.
[0034] The Ti—Si alloy according to the invention can be produced in conventional way, such as by arc melting in a water cooled copper hearth.
DETAILED DESCRIPTION OF INVENTION
EXAMPLE 1
[0035] A hypoeutectic Ti-6Si-2Al alloy according to the invention was produced by arc melting using a non consumable tungsten electrode. Titanium sponge with a purity of more than 99.8 wt %, metallurgical grade silicon and aluminium granules with a purity of more than 99.8 wt % were used as starting materials. The alloy was kept during arc melting in a water cooled copper hearth by forming a thin solid skull on the copper hearth and was then cast into a copper mould in order to achieve rod like ingots. These were machined by turning and grinding to cylindrical compression and tensile test samples exhibiting a smooth surface finish.
[0036] The Brinell hardness was determined to be about 336±3 HB 187.5/2.5 applying a testing load of 187.5 kp. The flow stress was determined at room temperature in compression test to be about R P 0.2 ≈725 to 750 MPa and the plastic strain exceeds −ε pi 10%. The fracture toughness was measured in a four point bend test. The stress intensity factor K IC varies between 19≦K IC ≦21 MPa √m. At higher temperature of 650° C. the flow stress is still 260 R P O.2 275 MPa and the fracture toughness is about 32≦K IC ≦34 MPa √m. The weight gain in an oxidation test on air at 600° C. was 4.5 mg/cm 2 after 525 hrs.
EXAMPLE 2
[0037] A hypereutectic Ti-10Si alloy containing 0.2 wt % Al was also produced by arc melting technique as described above in Example 1.
[0038] The macrohardness—Brinell—of this alloy was determined to be about 365 HB 187.5/2.5 and the yield stress at room temperature ranges between 930≦R P 0.2 ≦965 MPa depending upon the grain size of the alloy. The plastic strain in compression is about 6 to 8% and the fracture toughness is in between K IC =16 and 19 MPa √m.
[0039] At higher temperature of 650° C. the yield stress is about 330 to 360 MPa. The fracture toughness is in between 25 and 28 MPa √m. The creep strength was determined at 600° C. and exhibits values of 215 to 230 MPa in the coarse-grained state.
[0040] The oxidation on air at 650° C. leads to a weight gain of about 3.8 mg/cm 3 at 500 hrs exposure time.
EXAMPLE 3
[0041] A hypoeutectic (near eutectic) oxide dispersion strengthened Ti-7Si-2Al alloy with addition of 0.07 mass-% Y was also produced by the arc melting technique described in example 1. Metallic Yttrium was added to the melt and formed Y 2 O 3 with the dissolved oxygen of about 1200 ppm. The Brinell hardness was determined to be 347±2 HB 187.5/2.5. The measured yield strength was about 960 to 990 MPa. First creep experiments at 600° C. with the creep rate of {dot over (ε)}=10 −7 s −1 showed a creep strength in between 235 and 255 MPa.
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The present invention relates to high strength, oxidation and wear resistant titanium-silicon base alloy containing: 2.5-12 wt % Si 0-5 wt % Al 0-0.5% B 0-2% Cr 0-1 wt % rare earth metals and/or scandium balance Ti with unavoidable impurities.
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1. FIELD OF THE INVENTION
The present invention is related to a method and a system for image processing.
More specifically, it is related to a method and a system for processing, in real time, source image furnished at a rate C, to produce display images to be visualized on a visualization display unit (wall of images) formed by N columns and M lines of visualization screens.
2. DISCUSSION OF BACKGROUND INFORMATION
Visualization display units are used to visualize large format images of up to several dozen square meters in size. These visualization display units are often placed in very large areas such as, for example, stadiums, airport halls or conference halls, for the benefit of persons who are in these areas.
Currently, display images are visualized on a visualization display unit having N columns and M lines of visualization screens (each screen having Y columns and X lines) from source images formed by a matrix of YO columns and XO lines. A conventional method includes the following steps:
(a) each source image XO YO is divided into MN equal sub-matrix windows. If the ratios XO/M and/or YO/N are not whole numbers, the matrix window corresponding to the last column and/or the last line of the visualization display unit will be smaller than the other matrix windows. In other words, the visualization of the source image will be partial.
(b) The lines and the columns of each matrix window are interpolated by repeating each column N times and each line M times.
(c) Each of the interpolated matrix windows are delivered to the corresponding screen of the visualization display unit.
If M is greater than N, or if N is greater than M, the display image produced will respectively be elongated or broadened with respect to the source image. In order for the display image to completely occupy the visualization surface which has MX lines and NY columns, these lines and columns must respectively be multiples of XO and YO.
There are several limits and disadvantages of the abovedescribed conventional method. Enlargement of the source image, either in width or in height, must be presented as a whole number, because the interpolation coefficients of the lines and the columns ar whole numbers (repetition), and the display images produced are hazy, especially in case of very large enlargements (strobe effect).
There are methods of image processing that can avoid haziness of the produced image by using complicated interpolation functions. These methods are valid only for processing static images or weak resolution images, and cannot be applied on visualization display units having a matrix of screens.
SUMMARY OF THE INVENTION
For these reasons and for others, the present invention proposes a method and a system for processing source images in real time. The system produces display images to be visualized on a visualization display unit comprising N columns and M lines of visualization screens, but avoids the disadvantages mentioned earlier, and overcomes the limitations of the current state of the art.
According to the present invention, any interpolation coefficient of lines or of columns may be used. The screens constituting the visualization display unit may each have a number of lines and a number of columns that are different from those of the source image, without it being necessary to use standard converters. In addition, the display images produced are not hazy, and the display images produced can completely occupy any format of the visualization display unit.
To this end, and according to one arrangement of the present invention, a method is provided for processing, in real time, images provided at a rate C. Each image is formed of a matrix of YO columns and XO lines (XO YO elements). The images are processed in order to produce display images, corresponding to the source images or to a portion of the source images, the display images being visualized on a visualization display unit (wall of images) having N columns and M lines of visualization screens.
The source images (or a desired portion of these source images) are furnished at a rate C and are each divided into matrices having MN image windows. Each matrix generally comprises Y1 columns and X1 lines, thus producing MN image wave windows, each at a rate C. Each matrix window X1 Y1 is processed to produce a visualization matrix of Y4 columns and X4 lines to be visualized on one of the MN visualization screens. The process is characterized in that each image wave window X1 Y1 is processed according to the following steps:
(a) The Y1 columns and the X1 lines of each image window are sub-sampled to produce an intermediate image matrix of Y2 columns and X2 lines (X2 Y2 image elements) in accordance with a column coefficient of sub-sampling K C =Y2/Y1 and a line coefficient of sub-sampling K L =X2/X1. K C and K L are each, independently, one of the values 1, 1/2, 1/3, etc. Each line and each column of the intermediate image respectively replace one or more lines or columns of the image window, and each of the elements of the intermediate image are calculated as the arithmetic mean or the weighted mean of the corresponding image elements of the image window which is being replaced.
(b) The formed intermediate images are stored at the rate C, in printing/reading memories.
(c) The stored intermediate images are read in the same order as they were stored and at a rate C' equal to or different from the rate C.
(d) The columns Y2 and lines X2 of each intermediate image are over-sampled to produce an output image having a matrix of Y3 columns and X3 lines. The over-sampling is performed in accordance with a coefficient of over-sampling of columns E C =Y3/Y2 and with a coefficient of over-sampling of lines E L =X3/X2, where E C and E L are each any value greater than or equal to 1. Each element of the output image X3 Y3 is calculated as a weighted mean on the basis of the corresponding neighboring elements of the columns or of the lines of the intermediate image being over-sampled. Each output image of X3 Y3 elements are registered into a matrix of X4 Y4 elements, where Y3 is less or equal to Y4 and X3 is less or equal to X4.
According to another arrangement of the present invention, a processing system is provided. Matrixing means are provided to matrix (divide into matrices) each of the source images XO YO (or the desired portion of these source images) into MN image windows, each composed of Y1 columns and X1 lines. Processing means transform each image window X1 Y1 into an image having Y4 columns and X4 lines to be visualized on one of the MN visualization screens. The processing means include several devices. Processors are provided for re-sampling images with multiple sequences (PRISM) of a number MN.
Each processor (PRISM) comprises:
(a) a sub-sampling unit receiving data, in a digital form, from the image windows X1 Y1 at a rate C, the sub-sampling unit including:
a first sub-unit for sub-sampling of columns (in accordance with a coefficient of sub-sampling of columns K C =Y2/Y1) the first sub-unit receiving the lines from the image window, each line having Y1 elements, and delivering lines each having Y2 elements;
a second sub-unit for sub-sampling of lines (in accordance with a coefficient of sub-sampling of lines K L =X2/X1), the second sub-unit receiving the lines having Y2 elements per line and delivering, at a rate C, intermediate images X2 Y2;
(b) a transmission control unit for receiving the formed intermediate images X2 Y2 and for delivering them one after another to the two printing/reading memories, each memory receiving an image X2 Y2;
(c) two printing/reading memories constructed by a memory segmented into two zones, the first being used for printing and the second being used for reading, the roles of the two zones being interchanged when the printing of each image is terminated;
(d) a transmission commutator unit for reading, at a rate C', different or equal to C, the memories one after another in the same order as the transmission control unit at the over-sampling unit; and
(e) an over-sampling unit receiving, at a rate C', intermediate images X2 Y2 one after another, the over-sampling unit comprising:
a third sub-unit for over-sampling of columns in accordance with a coefficient of over-sampling of columns E C =X3/X2, the third sub-unit receiving the lines from the intermediate image, each line having Y2 elements, and delivering lines with Y3 elements; and
a fourth sub-unit for over-sampling of lines in accordance with a coefficient of over-sampling of lines E L =X3/X2, the fourth sub-unit receiving the lines from the preceding sub-unit (Y3 elements/line) and delivering output images X3 Y3.
The system further comprises a central processing unit (CPU) for controlling the sub- and over- sampling units and the transmission units of each processor, and further comprises a control unit (PC) linked to the central processing unit, which is used to introduce into the system, among other values, the processing parameters K C , K L , E C and E L .
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood upon reading the detailed description that follows, accompanied by drawings in which:
FIG. 1 is a diagram that presents both sub-sampling and over-sampling into columns and into lines,
FIG. 2 is a diagram that presents the general structure of the processing system,
FIG. 3 is a diagram that presents the structure of a processor and its connection with other elements of the system,
FIG. 4 is a diagram that presents the variations that occur in each image due to processing by a processor,
FIGS. 5a and 5b are two diagrams that present the details of processing by sub-sampling of columns,
FIGS. 6a and 6b are two diagrams that present the details of the processing by sub-sampling of lines,
FIG. 7 is a diagram that presents the details of over-sampling of columns, and
FIG. 8 is a diagram that presents the details of over-sampling of lines.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
FIG. 2 presents the general architecture of the system according to the invention. Referring to FIG. 2, source images are input at an input (1) of a system (3), and they are each divided into MN of matrices (2). Each matrix constitutes a window or a part of a source image, and is, after processing, visualized on one of the MN visualization screens (2) arranged according to N columns and M lines.
The invention differs from prior art by the processing method of each image window that results in an output image to be visualized on one of the screens of a visualization display unit. According to prior art, in the field of large format visualization using several screens, processing consists of repeating each line and each column of the image window a predetermined number of times to have an output image that has the same number of elements as each screen of the display unit. This necessarily means that the enlargement coefficient is a whole number.
As an example, to enlarge a source image 4 times, the lines and the columns of each image window are each repeated once in order to have an output image having twice the number of lines and columns of the image window. In this case, the display image occupies the surface of 4 screens of the same number of elements as the source image. Each element of the source image is represented by 4 elements, having the same value as the display image. The grains of the display image are 4 times coarser than those of the source image.
According to the invention, the restrictions on the enlargement coefficient are eliminated and preservation of the quality of the source image is improved.
According to the method of the present invention, the lines and the columns of each image window first go through a sub-sampling and then an over-sampling, separated by a segmented printing/reading memorization. The use of sub-sampling enables, on the one hand, the use of moderate capacity memories. On the other hand, by cooperating with over-sampling, it enables modulation at will of the characteristics of the output image that forms a part of the display image, especially enlargement, and also the number of elements.
In sub-sampling as in over-sampling the new elements of the intermediate image, or the output image, are a weighted mean of the neighboring elements of the processed image. Sub-sampling of the image window is done serially according to a sub-sampling of columns and then a sub-sampling of lines.
Sub-sampling of the columns of the intermediate image according to which each K C columns of the image window (Y12 columns and X1 lines) are replaced by a single column to form the intermediate image (Y2 columns and X2 lines). Each element of each column of the intermediate image is either the arithmetic mean of the K C elements corresponding to the requisite columns of the image window, or the weighted mean of these corresponding elements.
In FIG. 1, an element P ij of an image window where i=1, 2, . . . , X1 and j=1, 2, . . . , Y1, and an element P i ,n of a produced line, where n=1, 2, . . . , Y2, are shown. The element P i ,n of column n is calculated according to one of the following two formulae: ##EQU1## in which the element P i ,j is the arithmetic mean of the elements
P.sub.i,j, . . . P.sub.i,j +K.sub.C -1, or ##EQU2## in which the element P.sub.i,n is the weighted mean of the elements
P.sub.i,j, . . . , P.sub.i,j +K.sub.C -1,
a=a(0), a(1), . . . , a(K.sub.C -1)
The a coefficients are given.
The choice of these elements is made to give certain effects to the intermediate images produced.
The choice of a(S) as a positive symmetrical function having an approximately sharp single peak leads to the production of intermediate images having an appropriate contrast.
The choice of a(S) as a constant value equal to 1/K C reduces the formula (2) to the formula (1).
Signals representing the three colors of the image arrive in a digital form. Each color is (for example) digitized with 8 bits.
To obtain sub-sampling, referring to FIG. 5a, a sub-unit, for sub-sampling and for producing the arithmetic mean, comprises an adder for storing elements (11) and a divider (12). The adder receives the lines from the image window, one after another, each line comprising Y1 elements, adds each K C element and delivers the sum to the divider. The divider divides the sum by K C thus producing the lines, each having Y2 elements, K C =Y2/Y1.
Referring to FIG. 5b, the sub-unit for sub-sampling and for producing the weighted mean comprises a multiplier (13) and an adder for storing elements (14). The multiplier receives the lines from the image window, one after another, each line comprising Y1 elements, and multiplies the elements one after the other by the coefficients: a(0), a(1), . . . a (K C -1). The multiplier repeats the operation in a cyclic manner according to the cycle K C elements. The adder adds the elements of each cycle and delivers the sum, thus producing intermediate lines, each having Y2 elements. K C =Y2/Y1.
The sub-sampling of lines from the image window is done on the data produced by the sub-sampling of columns.
According to this sub-sampling, the liens given by the sub-sampling unit of columns are replaced. Each of K L lines are replaced by a line forming a part of the intermediate image.
Similarly to the sub-sampling of columns, the sub-sampling of lines is done either according to the principle of arithmetic mean or according to the principle of weighting mean.
Referring to FIG. 6a, the sub-sampling unit for lines, which sub-samples according to the principle of arithmetic mean, comprises an adder for storing lines (15), a line memory (16), and an divider (17). The adder receives the lines output by the unit for sub-sampling of columns, each line having Y2 elements, and adds of each of K L lines together by storing the intermediate results in the line memory, when they arrive, up until the K L th line.
The divider divides each element of the stored line (accumulation of K L lines) by K L , thus producing intermediate images each having X2 lines and Y2 columns. K L =X2/X1.
Referring to FIG. 6b, the unit for sub-sampling of lines comprises, according to the principle of weighting mean, a multiplier (18), and adder for storing lines (19) and a line memory (20). The multiplier receives lines output by the unit for sub-sampling of columns, each line having Y2 elements, and cyclically multiplies the elements of each line by coefficients a'(0), a'(1), . . . , a' (K L -1) furnished previously. The results of these multiplications, for the lines, are added by the line adder; and intermediate results are accumulated in the line memory up until the K L th line which is the weighted mean of the K L lines being considered.
The lines produced thus form intermediate images having X2 lines and Y2 columns of image elements.
The intermediate images formed are stored one after the other in a memory that has two segments, each of which can be printed or read.
It must be noted that the coefficient of sub-sampling of columns and of lines K C and K L can be 1/n where n is an integer greater than or equal to 1. It is preferable that these coefficients independently adopt one of the values (1/2 n ), where n=1, 2, . . . 8.
The transmission control unit (5) delivers the intermediate images formed (X2 Y2) to the two memories (6) at a rate C, and in a sequential manner. Whereas the multiplier (5) writes/prints at one of the two memories (6), the transmission commutator unit (7) reads the other memory containing the preceding image (X2 Y2) at the over-sampling unit (8).
At the end of printing, the roles of the two memories are inverted.
The over-sampling unit (8) first over-samples the intermediate images read (X2 Y2) according to an over-sampling of columns, and then according to an over-sampling of lines, and this is done with the help of two units for over-sampling columns and lines.
Referring to FIG. 7, a sub-unit for over-sampling of columns comprises a subtractor (21), a multiplier (22) and an adder (23). To calculate an element P m ,v, the subtractor reads the elements P m ,n and P m ,n+1 where n is the whole portion of the ratio v/E C and retains the difference between them. The multiplier multiplies this difference by the coefficient W where W is the decimal portion of the ration v/E C . The adder adds the result of this multiplication to the value of the element P m ,n,
P.sub.m,v =W(P.sub.m,n+1 -P.sub.m,n)+P.sub.m,n
where
n=E (v/E C ) and
W=D(v/E C ) .
Referring to FIG. 8, a sub-unit for over-sampling of lines comprises a line memory (24), a subtractor (25), a multiplier (26) and an adder (27). To calculate the point P u ,v, the line memory (24) stores Y3 elements, including element P m ,v where m is the whole portion of the ratio u/E L . The subtractor reads the points P m+1 ,v and P m ,v retains the difference between them. The multiplier multiples this difference by the coefficient Z where Z is the decimal portion of the ratio u/E L . The adder adds the result of this multiplication to the value of the element.
P.sub.m,v
P.sub.u,v =Z(P.sub.m+1,v -P.sub.m,v)+P.sub.m,v
where
m=E/(u/E L ) and
z=D(u/E L )
The over-sampling that has just been described was based, both for columns and for lines, on only two elements of the line being processed. It is clear that this over-sampling may be based on the four or more elements that are closest together, applying the principle of weighting throughout. The image thus produced in a digital form by the disclosed method and system may either be directly used or transformed into analog forms, according to the nature of the screens used. The system is provided with an analog-logic converter (28) and with a logic-analog converter (29).
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A method and system of image processing are disclosed in which a source image is enlarged, the source image being represented by a source matrix of image elements having Y0 columns and X0 lines of image elements. The source image is enlarged and displayed on a visualization screen, comprising a matrix of N by M screens. Adjacent data elements within the source matrix are assigned to respective image windows within an M by N matrix having M N image windows, each image window being divided into X1 lines and Y1 columns of image elements. Each image element is sub-sampled to form an intermediate image matrix having X2 Y2 image elements. The resulting intermediate image matrix is then over-sampled to form an output image having X3 Y3 image elements. The resulting X3 Y3 image element output matrix is then registered to a matrix having Y4 columns and X4 lines of image elements, for subsequent display on the visualization screen.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of International Application No. PCT/US06/62749 filed Dec. 29, 2006 and published Jul. 12, 2007 as International Publication No. WO 2007/079421, designating the United States, and which claims benefit of the filing date of U.S. Provisional Application Ser. No. 60/755,159, filed Dec. 30, 2005, the teachings of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to Stirling cycle engines having a rotary piston mechanism adapted to operate as a Stirling engine wherein a rotating piston, or rotor, captured in a rotating chamber moves eccentrically with respect to an output drive shaft and drives the output shaft and, additionally, to sealing vane arrangements for the rotor.
BACKGROUND OF THE INVENTION
[0003] Modern concerns with the need to reduce chemical and noise pollution of the atmosphere have revived interest in the Stirling engine. This engine was first invented in 1816 by the Rev. Robert Stirling, then a junior Presbyterian minister at Kilmarnock, Scotland. Its early development was hampered by a lack of materials with sufficient strength and corrosion resistance at high temperatures and a lack of suitable materials and techniques for gas sealing. For this reason, it was unable to compete with the steam engine or internal combustion engine, though it may be capable of higher thermal efficiency, may be much quieter and may be designed to produce far less atmospheric pollution.
The Stirling Engine Cycle
[0004] In contrast with the internal combustion engine, in which the fuel is burned inside the main engine cylinders, the Stirling engine receives its heat supply through the cylinder walls or from a heat exchanger in communication with a heat source. The “working gas”, which usually has a fixed volume and remains permanently inside the engine, is made to undergo a continuous series of cycles of heating and cooling, which causes the cyclic expansion and contraction required for performing mechanical work.
[0005] In one popular early Stirling engine arrangement, a displacer piston slides back and forth along a gas filled cylinder which is heated at one end and cooled at the other end. The gas is therefore transferred alternately to the hot and cold spaces at the ends of the cylinder and the resultant cyclic temperature changes cause pressure changes, which are used to drive an output power piston through a connection pipe. Many ingenious mechanisms have been devised for maintaining the correct relationship between the movements of the two pistons. In most cases, the movements of the displacer pistons are arranged to occur in advance of those of the output power piston by about one quarter of the engine cycle.
[0006] In early engines, the working gas was air at about atmospheric pressure, but in most modern engines the pressure is raised (in some cases to several hundred atmospheres), and air may be replaced by helium or hydrogen, since these gases are preferred at the extremes of temperature which occur in the engine cycle. It is therefore advantageous to make the temperature of the hot end of the engine as high as the properties of the construction materials will allow, and most engines may operate in the range of about 850° F. to about 1400° F.
[0007] The Stirling engine has found limited use, however, during the last few years engines with higher efficiency and similar output power for a given weight and size to gasoline and diesel engines have been developed. The main barriers which prevent the adoption of the Stirling principle for high power engines include the well-established position of gasoline and diesel engines in the marketplace and the relatively high cost of the heat exchanger required for passing the large amounts of heat into and out of the engine.
[0008] Another promising potential application of the Stirling principle lies in its “reversibility”. If a Stirling engine is driven by externally applied mechanical power, without the application of a heat source, the engine continues to draw in heat at what would normally be its hot end, thereby cooling it, and rejects heat at what would normally be its cold end, thereby heating it. In this mode of operation it has been demonstrated as a particularly efficient refrigerator for temperatures in the range of about −70° F. to about −292° F. It could also be used as a heat pump, for example, to draw in heat from the outside environment for heating buildings.
[0009] Any form of heat source may be used, for example, the sun's radiation, a wood fire, landfill and digester gas and low grade waste fuels. The cold space could be arranged to be in the shade and, perhaps, be cooled by pumped water.
Hybrid Power for Automobiles
[0010] The hybrid power unit for automobiles has various functions depending on the configuration. In a parallel hybrid, the unit drives the wheels through a transaxle. In a series hybrid, it drives an alternator to produce electricity. The candidates for the hybrid power unit consist of internal combustion engine technologies with fuel cells as an attractive longer term possibility. Fuel use in these engines is another variable, with reformulated gasoline, natural gas, alcohols, and other alternative fuels impacting both emissions and driving performance.
[0011] Important factors in considering hybrid power unit technologies for automobile applications include high energy efficiency, reduced emissions (in relations to current and future standards), and good transient response. The ability to use diverse fuels and specific power and power density equal to or higher than that of conventional engines are also important factors. Other factors to consider include noise and vibration reduction, reliability, durability, maintenance experience, operating costs and safety levels equal to or superior to current levels.
[0012] The Stirling cycle external combustion engine has certain characteristics that make it a potential candidate for an automobile hybrid power unit. Among these are high thermal efficiency, potential for low emissions, and low noise. The principle disadvantage is low power density due to external combustion and large heat rejection requirements. In addition, there is a clear need for much more experience with Stirling engines in automotive applications. Most working knowledge of the technology is in aerospace and cryogenic cooling applications. Previous work has shown that the transient response of the engine is poorly matched to conventional drive train vehicle demands. For a series hybrid, this constraint would be mitigated, thus the engine is potentially attractive in some automobile hybrid power unit applications. Recent technical achievements have overcome some of the past problems so that a Stirling engine may be in contention for future automobiles. As mentioned above, some of the advantages it may offer include very smooth, quiet and continuous operation producing very low emissions, and an ability to run on many types of fuel.
Rotary Piston Internal Combustion Engines
[0013] Rotary piston internal combustion engines exemplified by the Wankel type engine have a generally triangular shaped rotor in an epitrochoidal chamber. The rotor is eccentrically driven in the chamber as it rides eccentrically about a fixed centrally located gear. Thus, the output drive shaft connected to the rotor is driven at the same rotation rate as the rotor. Three points of the rotor are equipped with sliding seals that engage the inner walls of the chamber and divide the chamber into three spaces, each bounded by one of the faces of the rotor. During a complete revolution of the rotor, each of these spaces moves around the chamber increasing and decreasing in size to perform the four functions of intake, compression, power and exhaust as a gasoline/air mixture is drawn into the space, compressed, combined to deliver power as it expands, and then finally, exhausted. These functions are performed in all the moving spaces during each rotation of the rotor in the chamber and the power function is performed consecutively in the spaces, always along the same portion of the walls of the chamber. The other functions are also performed consecutively in each of the spaces along a given portion of the walls of the chamber. Thus, the combustion and exhaust functions, which inflict the greatest wear on the walls of the chamber, occur repeatedly along the same portions of the chamber walls causing the effectiveness of the seals carried at each of the points of the rotor to degrade along these portions of the chamber walls.
[0014] It is intrinsic to the Wankel type engine and to any type rotary piston mechanism that uses a triangular shaped rotor which seals against the chamber walls at the point of the triangle, that the chamber be epitrochoidal with two symmetrical cusps. Hence, with respect to the axis of the chamber, the walls of the chamber are curvilinear and concave at all points except at the two cusps. At that point, the walls are generally convex with respect to the chamber axis. Hence, the seals must follow a concave wall which changes abruptly to convex at two points along a complete cycle of travel of the seal against the wall and the angle the seal subtends with the wall is not constant during the entire travel of the seal along the wall. In fact, that angle becomes exceedingly acute as it moves along the wall from a convex portion of the wall to a concave portion. The effectiveness of the seal where the angle is exceedingly acute is thus diminished and the seals may have a tendency to leak at such points.
[0015] Another rotary piston mechanism in which some of the disadvantages of the Wankel type mechanism are avoided is disclosed in U.S. Pat. No. 4,111,617, entitled “Rotary Piston Mechanism”, issued Sep. 6 , 1978 , in which the inventor herein is a co-inventor and which is included herein by reference in its entirely. This patent discloses an oblong rotary piston or rotor in a generally triangular shaped chamber defined by three equal curved walls that are convex with respect to the chamber axis. Each side of the rotor conforms generally to the chamber wall and the rotor is rotatably mounted so that it rotates about its geometric center and the geometric center moves around the chamber axis over a three cusp epicycloidal path. For each cycle of rotation of the geometric center of the rotor around the chamber axis along the epicycloidal path, the rotor rotates one-half cycle on its geometric center and so the rotor closes exclusively with the three walls of the chamber six times for each full revolution of the rotor. In addition, seals at the ends of the rotor which slide along the walls of the chamber can at all times contact the walls perpendicular thereto. More particularly, a gear train is provided which is carried by at least one of the rotating chamber end plates that carries the rotor for rotating the rotor on the rotor axis (geometric center). Thus, both the position and the attitude of the rotor in the chamber are positively controlled by gears and are independent of forces between the rotor and the side walls of the chamber.
[0016] The '617 patent describes embodiments of a rotary piston mechanism wherein the rotor is of fixed dimension from end to end. In other words, the dimension of the rotor from vane tip to vane tip is fixed. In that case, there are three equal convex chamber side walls that define an equilateral triangle and the span of the chamber along a bisector of any of the angles of the equilateral triangle must be precisely equal to the length of the rotor from vane tip to vane tip. One of the embodiments described in that patent (see FIG. 12 ) may also be used in a rotary piston mechanism in which the length of the rotor from vane to tip to vane tip changes during a cycle of rotation and so the chamber shape need not define an equilateral triangle. For example, the chamber may be circular and the sealing vanes carried by the vane tip to divide the chamber at all times into two sections each sealed from the other.
[0017] Some of the problems that arise for a rotary piston device in a circular chamber include: the need to extend the vanes unequal distances as the rotor rotates; sealing each end of a major diameter of the rotor against the chamber wall; providing a drive mechanism within the rotor to drive seals outward against the chamber wall; and providing a mechanism that holds the seals forcefully against the chamber wall.
[0018] Embodiments of the present invention incorporate mechanical designs that overcome these problems by; locating the pivot points of the rotor with respect to the chamber on a circle of larger diameter than the chamber diameter (outside the chamber) so that the vanes extend equal distances; providing that sealing vanes project from slots at each end of a major diameter of the rotor; locating a cam within the rotor to drive the vanes outward against the chamber wall; and providing springs to hold the vanes forcefully against the chamber wall.
[0019] Heretofore, rotary piston combustion engines like the Wankel type and the engines disclosed in said U.S. Pat. No. 4,111,617 have been limited to internal gas combustion. Thus, adaptation to operation as a Stirling cycle engine promises to improve efficiency by significantly increasing the number of displacements of the rotor per revolution of the driveshaft. With a triangular chamber, the present invention may provide, for instance, 6 displacements per revolution and with a circular chamber, 12 .
SUMMARY OF THE INVENTION
[0020] Accordingly, it is an object of the present invention to provide a Stirling cycle engine wherein at least some of the above-mentioned problems or disadvantages with the engine are avoided or overcome.
[0021] The present invention comprises a rotary piston mechanism having a double eccentric that is caused to rotate by way of a gear train. The mechanism may have a static outer chamber and rotating inner chamber, which contains the piston or rotor, with appropriate porting for both expanding and expended gases. In particular, the present invention provides a Stirling engine with much greater displacement than earlier designs. This then provides the potential to produce greater power (KW/HP) for an equal size (physical outside dimensions) engine.
[0022] In a first exemplary embodiment, a power piston mechanism for a Stirling cycle engine for operation with a Stirling engine regenerator gas system is provided, including an outer body having a cylindrical, that is, circular in cross-section, chamber rotatably carried therein on a chamber axle; a power rotor confined in the chamber, the rotor being generally elongated and having a rotor axle for rotation parallel to the chamber axle; a double eccentric gear train from the rotor to the outer body; a regenerator gas input port in the outer body for feeding gas from a regenerator gas system into the chamber and a regenerator gas exhaust port in the outer body for feeding gas from the chamber to the regenerator gas system. High temperature gas from the regenerator gas system, fed to said chamber, causes rotation of the rotor which drives the chamber in rotation in the outer body producing a shaft output from the chamber axle and spent gas flow from the chamber which is returned to the regenerator gas system.
[0023] In a second exemplary embodiment, the present invention comprises a power piston mechanism for a Stirling cycle engine for operation with a Stirling engine regenerator gas system, including an outer body having a 3-lobed, that is substantially triangular in cross-section, chamber rotatably carried therein on a chamber axle; a power rotor confined in the chamber, the rotor being generally elongated and having a rotor axle for rotation parallel to the chamber axle; a double eccentric gear train from the rotor to the outer body; a regenerator gas input port in the outer body for feeding gas from the regenerator gas system into the chamber and a regenerator gas exhaust port in the outer body for feeding gas from the chamber to the regenerator gas system.
[0024] In a third exemplary embodiment, the present invention comprises a Stirling cycle engine having a rotary power piston for a circular or triangular chamber that rotates with the output drive, the engine containing the heating and cooling systems and not requiring a separate regenerator.
[0025] It is an object of the present invention to provide a Stirling cycle engine having a rotary power piston in a chamber that is driven in a rotating motion, with a drive train from the piston to an output drive shaft that is carried inside the piston and through the chamber wall at a part of the chamber wall that is covered throughout the engine cycle of operation.
[0026] It is a further object that the drive train exposure to the engine driving gas be minimized.
[0027] It is a further object of the invention to provide a Stirling cycle engine that does not require the conventional crankshaft arrangement of piston and piston rod connected to the crankshaft.
[0028] It is a further object to provide such an engine wherein the rotor vanes project an equal amount throughout a power stroke.
[0029] It is a further object to provide such an engine wherein the rotor vanes are driven by a common drive carried by the rotor.
[0030] Accordingly, the entire rotating chamber including the wall and front and back plates that carry the rotating piston (rotor) may be fixedly attached to the output drive shaft that is journalled to the grounded housing. The chamber rotates with the output and the rotor engages the housing at the internal gear of the major eccentric that is fixed to the housing.
[0031] One feature of the present invention is that the pivot point of rotation of the rotor may be located outside of the chamber wall, in other words, the pivot points are equally spaced on a circle of greater diameter than the diameter of the circular rotating chamber. The combined result of moving the pivot point outside of the cylinder wall and having equal vane travel provides for a smoother rotating/sweeping action of the rotor within the chamber as opposed to an interrupted movement caused by a pivotal action at the chamber wall.
[0032] One other embodiment of the present invention provides for a chamber which is circular in cross-section with rotor sealing vanes, the vanes being of equal length and extending equal distances from slots at each end of the rotor and having their maximum extension halfway through the rotor stroke. With vanes which extend equally at all times, it is possible to simplify the drive in the rotor that extends the vanes and permit the use of a single cam to drive both vanes. These features with their attendant advantages are achieved by increasing the diameter of the pinion gear of the minor eccentric gear train to greater than the diameter of the pinion gear of the major eccentric gear train causing the pivot point to move outward of the cylinder wall and resulting in equal vane extension from each and of the rotor. This design also may cause the major diameter of the rotor to move lower into the chamber such that the minor diameter of the rotor decreases, resulting in a smaller (shorter and thinner) rotor and providing a greater available working volume. Moving the chamber walls inward from the pivot points may have the same effect, that is, shorter vane travel, a smaller rotor and a greater available working volume as well as a smaller cylinder diameter. In addition, by changing the gearing, multiple displacements per revolution of the rotor may be provided, up to, for instance, 12/1.
[0033] In another exemplary embodiment, with a triangular chamber, spring-loaded static vanes may be provided which extend from the rotor to seal against the chamber wall and simplify the construction of the rotor.
[0034] Other objects, features and advantages of the present invention and various embodiments thereof will be apparent from the following description of these features and embodiments taken in conjunction with the drawings.
DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 is a cross-sectional view taken through the output drive shaft, the housing, the chamber and the rotor that illustrates a basic embodiment of the present invention of a rotary power piston Stirling cycle engine.
[0036] FIG. 2 is a cross-sectional view taken at 2 - 2 of FIG. 1 of the rotary power piston Stirling cycle engine of the present invention.
[0037] FIG. 3 is another cross-sectional view taken at 3 - 3 of FIG. 1 of the rotary power piston Stirling cycle engine of the present invention.
[0038] FIG. 4 is an enlarged cross-sectional view of the sliding vanes in the rotor of FIG. 2 that ride against the cylinder wall, taken along line 4 - 4 of FIG. 1 .
[0039] FIG. 5 is an enlarged cross sectional view taken at 3 - 3 of FIG. 1 illustrating an alternative spring-loaded static vane seal in a rotating power piston in a rotating chamber having a 3-lobed inner wall, according to the present invention.
[0040] FIG. 6 is a cross-sectional view taken through the output drive shaft, the housing, the chamber and the rotor that illustrates a third (self-contained) embodiment of the present invention, a rotary power piston Stirling cycle engine.
DETAILED DESCRIPTION OF THE INVENTION
Rotating Power Piston Stirling Cycle Engine
[0041] FIGS. 1 and 2 are cross-sectional views of a rotary piston mechanism 1 , such as described in above-referenced U.S. Pat. No. 4,111,617, that has been adapted to perform as a Stirling cycle engine. As shown in FIG. 1 , the entire chamber 13 including chamber inner cylindrical wall 20 and front and back plates 51 and 52 that carry the rotating piston (rotor) 15 may be fixedly attached to the output drive shaft 55 / 56 that may be journalled ( 73 ) to the grounded housing 53 / 54 . The chamber 13 may rotate with the output and the rotor 15 may engage the housing 53 at the internal gear 34 of the major eccentric that may be fixed to the housing. An input gas passage 131 may be provided in the housing 54 to deliver expanding gas through the annular space 14 to the input port 95 in the cylindrical wall 20 of the chamber 13 from a Stirling cycle regenerator system (or heat exchanger). Similarly, an exhaust gas passage 132 may be provided in the housing 53 to deliver expended gas from the exhaust port 96 in the chamber wall 20 to the Stirling cycle regenerator system (not shown). The ports 95 , 96 (shown as circled numerals to indicate that they are not in the plane of the section) may be offset around the periphery of the chamber 13 , preferably at 120° from one another. In other words, port 96 is shown as a dotted line to illustrate its position on the inner wall that has been cut away by the section. Port 95 is shown partially as a solid line and partially as a dotted line since in the sectional view a portion of the port would be visible on the inner wall 20 of the chamber. A peripheral seal 93 may separate the expanding, G 1 , and expended, G 2, gases in the annular chamber 14 . The seal 93 may be spring-loaded, or labyrinth, etc. and function to separate the heating and cooling sections of the engine 1 .
[0042] A regenerator gas system such as would be known to those skilled in the art and including one or more heat exchangers and/or regenerators may be used to heat and cool the working gas. This system is not described in more detail here as it is not part of the present invention.
Rotor Position and Attitude Control Mechanisms
[0043] FIGS. 1 and 2 illustrate the mechanical action of one embodiment of the present invention for carrying the rotor 15 in a chamber 13 and controlling the position and attitude of the rotor 15 over its cycle of rotation in the chamber 13 to perform as a Stirling cycle engine. FIG. 1 illustrates an embodiment wherein the inner chamber wall 20 and end plates 51 , 52 may be a rigid structure journalled to the housing 53 , 54 and carrying the rotor 15 and a double eccentric axle drive 31 / 32 at an end thereof which may engage an internal gear fixed to the housing. The chamber may be fed power gas from a Stirling cycle engine gas regenerator system, so that the rotor may drive the output.
[0044] FIG. 2 is a cross-sectional view of FIG. 1 taken along 2 - 2 and illustrates the principal parts of the rotor or piston 15 , the circular chamber 13 and successive positions of the piston and the piston vanes 7 , 8 to allow equal vane extensions at all positions of the rotor and three or more power strokes of the rotor per revolution. This may be achieved by positioning the successive pivot points of the rotor outside of the chamber, for instance at point A.
[0045] As shown in FIG. 1 , the rotor 15 may be journalled centrally to the eccentric axle 31 so that the axis of the axle 31 and the central axis 12 of the rotor 15 (at the geometric center of the rotor 15 ) coincide. Axle 31 may be fixed to axle 32 which may be carried by the rotating chamber end plate 51 which may be journalled to the mechanism housing 53 , 54 that may attach to the outer chamber cylinder wall 20 so that the entire chamber end plates 51 and 52 may rotate on the chamber axis 10 . Thus, the entire chamber 13 may rotate to deliver an output to shaft 55 / 56 when the mechanism is used as a Stirling cycle engine.
[0046] The two axles 31 and 32 of the rotor may be fixedly attached and are referred to herein as the double eccentric axle because the axle 32 is mounted to the plate 51 eccentrically with respect to the axis of rotation 10 of the plate 51 and axle 31 is eccentric with respect to axle 32 . Thus, as the plate rotates about axis 10 , both axles 31 and 32 may orbit around axis 10 . In other words, the double eccentric axle 31 / 32 may be carried by the chamber in orbit around the chamber axis 10 .
[0047] As mentioned, axle 32 may be journalled to the chamber 13 at plate 51 . The axle may extend through the plate and through the pinion gear 33 . The pinion gear may mesh with an internal gear 34 concentric with the axis 10 and fixed to the housing 53 . The ratio of internal gear 34 to pinion gear 33 is preferably 2:1. Thus, from the initial position of the double eccentric axle 31 / 32 and rotor 15 represented by the solid lines in FIG. 2 , the end plate 51 may rotate counterclockwise (ccw) causing the pinion gear 33 to rotate to successive positions around internal gear 34 , which, in turn, positions the rotor axle 31 at the corresponding successive positions. Note that the side 9 of the rotor 15 in FIG. 2 is displayed as a solid line which becomes 9 ″ in a successive position, displayed as a dotted line. The gear combination of internal gear 34 and pinion gear 33 is referred to as the major eccentric and the combination of internal gear 36 and pinion gear 35 is referred to as the minor eccentric.
[0048] In operation, the rotor 15 may rotate counterclockwise relative to the rotor axle 31 so that the rotor will, in effect, rotate successively about the pivot points that are outside the chamber and fall on a circle 120 of greater diameter than the chamber 13 diameter. The first pivot point on circle 120 is denoted A, the second is denoted B, and the third denoted C. The successive points are spaced apart equally, but do not necessarily fall at the same position with respect to the housing for each revolution of the rotor. Reference numerals 122 , 124 and 126 represent the position of one end of the rotor 15 as it pivots around point A, as vane seal 8 becomes 8 ′ and 8 ″. Correspondingly, the opposite end of the rotor 15 moves from 121 to 123 to 125 and vane seal 7 becomes 7 ′ and 7 ″, respectively.
[0049] The minor eccentric gear train may include a pinion gear 35 , concentric with axle 32 and rotatably received in the plate 51 meshing with an internal gear 36 concentric with axle 31 and to the rotor 15 . The ratio of gears 36 to 35 is preferably 2:1. Clearly, as the chamber 13 rotates counterclockwise, gear 35 moves to the successive position 35 ″ shown in FIG. 2 and since it is fixed to chamber plate 51 , it orbits around chamber axis 10 and rotates ccw about the axis of axle 32 . Meanwhile, the rotor axle 31 may move along a hypocycloidal path and rotate clockwise on axis 12 .
[0050] Thus, the rotor position is precisely determined by the major eccentric and the rotor attitude is precisely determined by the minor eccentric gear train. Both rotor position and attitude are independent of any forces exerted at the rotor vane tips 7 and 8 where they contact the chamber side wall 20 ( FIG. 2 ). The vanes are driven by cam 31 (See FIG. 4 ) to extend equally at all times to seal against the cylindrical side wall 20 of the chamber dividing the chamber into the two parts bounded by the faces 9 and 11 of the rotor. In FIG. 2 , face 9 of rotor 15 bounds the compression volume and face 11 bounds the expansion volume.
Two Cycle Operation of Exhaust/Intake Ports
[0051] Referring again to FIG. 1 , intake is through housing port 131 and port 95 in chamber wall 20 and exhaust is through port 96 in chamber wall 20 and the exhaust port 132 in housing 54 . A peripheral seal 93 separates the annular space 14 outside the cylindrical wall 20 into intake and exhaust portions. Note that the intake port 95 and the exhaust port 96 in chamber wall 20 are offset, out of phase, with each other so that the exhaust port registers during the cycle just before the intake ports registers. It is preferred that exhaust be complete before intake starts although some overlaps may be tolerated. As the intake portion approaches full expansion, exhaust occurs, then the exhaust port closes and then intake occurs before compression begins. Thus, the arrangement of ports for both intake and exhaust may be the same, but staggered, so that exhaust and intake occur in the desired sequence as well as at the desired position of the rotor. Intake or exhaust openings into the chamber may also be provided axially. For example, either intake or exhaust or both may be through central axial openings in the end plates 51 , 52 concentric with the chamber axis 10 and the main shaft 55 / 56 . Where such a central opening is provided in a rotating end plate, the shaft on the outside of the plate may be hollow and so provide a connecting passage to the plate opening. A control valve (not shown) in the hollow shaft or in a conduit to the hollow shaft may control the timing of the fluid flow therethrough. Where intake is provided by this technique and exhaust is through the rotating exhaust plate holes as they align with exhaust ports in the exhaust housing, exhaust occurs first and then intake. So the intake would be delayed with respect to the exhaust to insure that they do not both occur simultaneously. This may be implemented by adding a control valve before the intake opening in the drive shaft, which delays input until the holes in the rotating exhaust plate move just out of registration with the exhaust ports.
[0052] Seals 67 , 68 may bridge the space between the sides of the rotor 15 and the end plates 51 , 52 of the chamber 13 . These seals may be spring-loaded strip seals as are known to those skilled in the art.
Cam Driven Sealing Vanes
[0053] In one embodiment of the present invention, the mechanisms for controlling rotor position and attitude may be independent of rotor contact with the side walls of the chamber. The rotor 15 may be equipped with variable vanes 7 , 8 that seal against the cylindrical side wall 20 of the chamber. The vanes may be driven to slide in and out at the end of the rotor 15 so that the vane tip to vane tip dimension of the rotor may change as the rotor rotates. Where the basic rotor action in the chamber is as described herein with respect to FIGS. 1 and 2 , variation of the vane tip to vane tip dimension of the rotor as it rotates is required. FIG. 3 is a cross-sectional view of FIG. 1 taken along line 3 - 3 that illustrates the principal parts of the rotor 15 , the circular chamber 13 and successive positions of the piston 15 and the piston vanes 7 , 8 for equal vane extension at all positions of the rotor and three or more power strokes of the rotor per revolution. This is achieved by positioning the successive pivot points of the rotor outside of the chamber (circle 120 ). This cross-sectional view is taken through the gas exhaust port 132 in the housing 53 and through the exhaust port 96 in the chamber inner wall 20 . As shown in FIGS. 1 and 2 , a cam slot 91 is provided in the eccentric rotor axle 31 providing a generally oval shaped cam surface 92 that is preferably an integral part of the total double eccentric axle 31 / 32 .
[0054] As shown in FIG. 4 , which is an enlarged cross-sectional view taken through the center of the rotor 15 along lines 4 - 4 of FIG. 1 , vane plungers 193 and 194 may slide in plunger bores 195 and 196 to move vanes 7 and 8 as urged by cam rollers 197 and 198 , respectively, at their inside ends acted upon by the cam. These plungers contact springs 199 and 200 in the bores and the springs contact the sliding vanes 7 and 8 at the ends of the rotor 15 . The sliding vanes extend the full width of the rotor and slide in accommodating slots 209 and 210 , respectively. Each of the plunger springs may be loaded at all times between the plunger and sliding vane so the vane may be forced against the chamber side walls by a steady force over the full extension of the vanes 7 , 8 .
[0055] In operation, the rotor 15 may be carried by the end plates 51 and 52 on the double eccentric axle 31 / 32 , and the two gear trains, the position gear train including gears 33 and 34 and the attitude gear train including gears 35 and 36 . These precisely determine the position and attitude of the rotor in the chamber independent of any contact between the rotor vanes and the chamber side wall 20 . As the rotor 15 rotates on rotor axle 31 , cam 92 rotates with respect to the vane plunger 193 and 194 positioning the vanes 7 , 8 under spring force precisely as required to seal against the circular chamber side wall 20 . Thus, the rotor action is the same as already described above with reference to FIGS. 1 , 2 and 3 , and the end plate and housing is substantially the same. Furthermore, intake and exhaust may be accomplished using any of the techniques already described herein. The use of variable or sliding vanes permits use of a simpler circular chamber construction.
[0056] The vane seals of the present invention may include a flattened end which may articulate as the rotor moves from position to position to seal against the inner wall of the chamber.
Spring-Loaded Static Sealing Vanes
[0057] In another embodiment, an oblong rotary piston or rotor may be provided in a generally triangular shaped (3-lobed) chamber defined by three equal curved inner side walls that are convex with respect to the chamber axis. Each side of the rotor may conform generally to the chamber end walls and the rotor may be rotatably mounted so that it may rotate about its geometric center and the geometric center may move around the chamber axis over a three cusp epicycloidal path. (See FIG. 5 ). For each cycle of rotation of the geometric center of the rotor 15 A around the chamber axis along the epicycloidal path, the rotor may rotate one-half cycle on its geometric center and so the rotor may close exclusively with the three inner walls 20 A of the chamber 13 A six times for each full revolution of the rotor. In addition, seals 107 , 108 at the ends of the rotor 15 A which slide along the walls of the chamber 20 A may at all times contact the walls perpendicular thereto. More particularly, a gear train 31 / 32 / 33 / 34 / 35 / 36 is provided which may be carried by at least one of the rotating chamber end plates, for instance 51 A, that carries the rotor for rotating the rotor on the rotor axis (geometric center). Thus, both the position and the attitude of the rotor in the chamber may be positively controlled by gears and are independent of forces between the rotor and the side walls of the chamber.
[0058] FIG. 5 illustrates a further embodiment wherein the cam actuated sliding vanes 7 , 8 of FIG. 4 have been replaced by static vanes 107 , 108 in a chamber having a triangular inner wall. The static vanes provide improved sealing at higher operating temperatures, may reduce the possibility of leakage and do not require any lubrication, as do the sliding vanes. The use of static vanes may provide a less expensive rotor construction as fewer components are required and maintenance is reduced as there are no moving parts.
[0059] The fixed vanes 107 , 108 preferably comprise a material which has good high temperature resistance which has been inserted into an opening having a corresponding shape in the ends of the rotor 15 A. The vanes may be securely fit into the openings and may protrude a sufficient amount to maintain contact with the triangular inner wall 20 A of the chamber as the rotor rotates. Springs 299 and 300 may provide pressure on the vanes 107 , 108 to insure contact with the triangular inner wall 20 A. In this embodiment, the chamber 13 A has a triangular, or 3-lobed, rather than circular inner cross-section so that the vanes do not need to vary in the amount that they project into the chamber from the ends of the rotor 15 A. The use of a chamber having a triangular rather than circular cross-section as shown in FIG. 1 , may provide slightly less available working space for the gas (displacement) but a simpler and potentially more durable sealing vane arrangement which may not require lubrication.
[0060] The details of operation of an engine 1 A with a triangular or 3-lobed inner wall 20 A in chamber 13 A as a Stirling cycle engine, as shown in FIG. 5 , are quite similar to those described above, for the circular chamber 13 . While a 3-lobed construction has been illustrated herein, a different number of lobes may be used as long as the rotor can be designed to match the lobe shape.
[0061] With the present invention, a cylindrical chamber about 5 inches in diameter with a rotor about 2.5 inches high by 2.5 inches thick provides sufficient displacement to develop about 65 horsepower or about 48 kilowatts. Gearing may be changed to provide multiple displacement strokes per revolution of the rotor. A similar size engine with a triangular chamber may provide about 54 horsepower or 40 kilowatts.
Self-Contained Rotating Power Piston Stirling Cycle Engine
[0062] In a third embodiment, the engine of the present invention has been adapted to be self-contained, that is, it does not require a separate heating and cooling source, such as a regenerator. As shown in FIG. 6 , a self-contained engine 1 ′ including heating and cooling systems may be provided. While shown here with a cylindrical inner wall (circular in cross-section) 20 ′ for the chamber 13 ′, the chamber may be of a 3-lobed or triangular inner shape (as shown in FIG. 5 ). Rather than having a through output shaft 55 , the engine includes a heating source or head 90 at one (hot) end. On the other (cold) side, the engine 1 ′ includes a cooler 97 comprising a plurality of tubes which conform to the general shape of the engine and which cooperate with a heat exchanger or regenerator 98 to extract heat from the expended gas G 2 . Heated gas G 1 then flows from the heater 90 , into intake port 95 , out of exhaust port 96 (as G 2 ) and across tubes 97 .
[0063] While the present invention is shown as a singular rotating chamber with rotor therein, one may chose to add multiple chambers side by side of the shapes shown in FIGS. 1 and 5 , and have pairs of chambers heating and cooling the gas. Likewise, FIG. 6 may be configured with another chamber and hot end arranged on the opposite side of the cold side to share the common cold side and provide greater output.
[0064] The embodiments of the present invention illustrate a novel adaptation of a rotary piston mechanism to a Stirling cycle engine. The embodiments also allow the control of the position and attitude of the rotary piston for a circular cross-section chamber, as described. It will be apparent to those skilled in the art that additional mechanisms may be required to provide a complete useful two cycle Stirling cycle engine operation. The operation of these and other additional mechanisms will be apparent to those skilled in the art as are various changes, modifications and other uses of the present invention that can be made without departing from the spirit and scope of the invention as set forth in the appended claims.
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A power piston mechanism for a Stirling cycle engine for operation with a Stirling engine regenerator gas system, including an outer body having a chamber rotatably carried therein on a chamber axle; a power rotor confined in the chamber, the rotor being generally elongated, and having a rotor axle for rotation parallel to the chamber axle; a double eccentric gear train from the rotor to the outer body; a regenerator gas input port in the outer body for feeding gas from the regenerator gas system into the chamber and a regenerator gas exhaust port in said outer body for feeding gas from said chamber to the regenerator gas system, whereby high temperature gas from the regenerator gas system, fed to the chamber, causes rotation of the rotor which drives the chamber in rotation in the outer body producing a shaft output from the chamber axle and spent gas flow from the chamber which is returned to the regenerator gas system. In another embodiment the heating and cooling sources are contained in the outer body.
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BACKGROUND OF THE INVENTION
Uranium metal is conventionally produced by reducing uranium tetraflouride (UF 4 ) with magnesium, often with magnesium fluoride slag liners. This reduction of the uranium provides a product commonly referred to as a regulus or derby of uranium metal which has a crust of magnesium fluoride adhering to the derby surface. The derbies from the reduction operation are remelted into ingots by induction casting. Prior to the induction casting of a derby the crust or slag including the magnesium fluoride was supposedly removed from the derby surface by mechanical means such as chipping, thermal shocking, grit blasting, and the like.
The casting operation was previously achieved by melting the derby in a graphite crucible. A reaction occurs between the molten uranium and the graphite that introduces considerable carbon in the ingot. Therefor, since in many instances carbon concentrations greater than about 100 ppm were found to be undesirable, the graphite crucibles used in the casting operation were provided with a surface coating of yttria or zirconia which are essentially non-wettable by molten uranium. With such an yttria or zirconia coating uranium derbies which have a carbon content of about 25 ppm could be cast into ingots with the carbon content increasing to only about 75 ppm carbon which is well within the 100 ppm limitation.
During the course of analyzing ingots from casting procedures utilizing yttria or zirconia coated graphite crucibles, it was discovered that several ingots contained carbon in concentrations considerably greater than 100 ppm. It was determined that residual magnesium fluoride on the surface of the uranium derbies reacted with the coatings on the graphite crucible resulting in a breakdown of the coating so as to expose the underlying graphite to molten uranium. This exposure of the graphite resulted in reactions with the molten uranium so as to contaminate the uranium with carbon concentrations greater than 100 ppm. A suitable solution or technique was needed for removing the magnesium fluoride from the uranium derbies prior to the induction casting of the ingots to inhibit the breakdown of the crucible coatings. Several techniques previously used for removing the magnesium fluoride from the uranium derbies suffered shortcomings or drawbacks. For example, the forming of an oxide layer on the uranium surface by heating the derbies in air and then water quenching the derbies so as to remove both the oxide and the magnesium fluoride layers by thermal shocking was found to result in excess oxidation of the uranium. As pointed out above, other techniques for cleaning the surface of the uranium derbies such as chipping and grit blasting left sufficient residual magnesium fluoride on the derby to react with the crucible coatings. Also, the use of a warm nitric acid bath did not remove the residual magnesium fluoride from the surface of the uranium derbies.
BRIEF SUMMARY OF THE INVENTION
Accordingly, it is the primary objective or goal of the present invention to substantially minimize or obviate the above and other problems associated with the casting of bomb-reduced uranium metal. The objective of the invention is to provide a method for removing residual magnesium fluoride from the surfaces of the uranium derbies prior to the casting operation so as to minimize or inhibit the destruction of the yttria or zirconia coatings on the graphite crucibles used in the casting operation. The method of the present invention for achieving this objective comprises the immersing of the uranium derby after excess slag has been removed by conventional chipping and blasting procedures into an alkali metal salt bath at a temperature greater than about 500° C. This molten salt bath effectively decomposes the magnesium fluoride on a surface of the uranium derby. After a sufficient duration the derby is removed from the bath and quenched in a water bath so as to remove the salt and the decomposition products from the surface of the article by thermal shocking. The derby is then washed in a warm solution of nitric acid to remove any residual salt from the surface of the articles. As in previous practices the uranium article may then be rinsed with water to remove the nitric acid. The uranium derby after being so treated is essentially free of surface impurities which would be reactive with the yttria or zirconia coatings on the induction casting crucibles.
Other and further objects of the invention will be obvious upon an understanding of the illustrative method about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph illustrating and comparing the carbon contents of several 800-kilogram ingots of uranium which were induction cast in yttria-coated graphite crucibles from derbies cleaned by practicing the subject method and derbies which possessed excess residual magnesium fluoride on the surfaces thereof, and
FIG. 2 is a graph similar to that of FIG. 1 but relating to 2200-kilogram ingots of uranium prepared from induction casting of derbies cleaned by the subject method and unclean derbies.
The graphs have been chosen for the purpose of illustration and description. The graphs illustrated are not intended to be exhaustive or to limit the invention to the precise carbon levels disclosed. They are chosen and described in order to best explain the principles of the invention and their application in practical use to thereby enable others skilled in the art to best utilize the invention in various method steps and modifications thereof as are best adapted to the particular use contemplated.
DETAILED DESCRIPTION OF THE INVENTION
As briefly pointed out above, uranium metal derbies prepared by the bomb reduction of uranium tetrafluoride and magnesium (often in the presence of magnesium fluoride slag liners) resulted in the presence of some residual magnesium fluoride on the surface of the derbies even after practicing conventional techniques for removing such impurities from the surface of the derbies. The presence of this excess of residual magnesium fluoride has been found to be deleterious to the production of vacuum-cast uranium ingots with a carbon content less than 100 ppm. The reaction between the magnesium fluoride and the yttria or zirconia coating on the graphite crucible utilized in the vacuum-casting operations results in a coating breakdown to expose the underlying carbon to the molten uranium. The reaction between the molten uranium and the graphite causes carbon to be induced into the uranium melt at a level considerably greater than desired for many applications.
The method of the present invention is practiced on bomb-reduced uranium derbies which contain residual uranium on the surfaces thereof prior to casting ingots from the derbies. To practice the present invention the uranium derby is immersed in a liquid alkali metal salt bath for a sufficient duration to allow the salt to react with and decompose the magnesium fluoride. The alkali metal salt bath utilized in the present invention is preferably a bath having a melting point less than 600° C. such as provided by a eutectic composition of 35 wt.% lithium carbonate (Li 2 CO 3 ) and 65 wt.% potassium carbonate (K 2 CO 3 ). The bath temperature is preferably maintained as low as practical for safety purposes, e.g., inhibiting explosion, during the water quenching of the derbies and also to inhibit oxidation of the hot derbies. The dissolving of the fluoride in a bath results in a chemical reaction between the salt and the magnesium fluoride as follows:
MgF.sub.2 +Li.sub.2 CO.sub.3 →MgO+CO.sub.2 ↑+2LiF
The reaction produces a white froth on the surface of the salt bath which is believed to be magnesium oxide and CO 2 .
While it is desirable to use a eutectic composition±about 5 wt.% as the bath because of its lower melting temperature, in instances where higher temperatures are permissible, a bath of potassium carbonate and/or lithium carbonate in concentrations of 0 to 100 percent may be used. In a 50/50 molar ratio bath at about 600° to 650° C. of potassium carbonate and lithium fluoride it was found that the lithium fluoride was not necessary in the bath for decomposing the magnesium fluoride. This reaction with the potassium carbonate-lithium fluoride bath from X-ray analysis appeared to be
3MgF.sub.2 +K.sub.2 CO.sub.3 →2KMgF.sub.3 +MgO+CO.sub.2 ↑
After soaking the uranium derbies in the alkali salt baths for a duration sufficient to decompose essentially all of the residual magnesium fluoride on the surface of the derby, the derby is subjected to an immediate water quench to effect the removal of the salt and the decomposition products from the surface of the article. Normally, the time duration sufficient for decomposing the magnesium fluoride depends upon the quantity of magnesium fluoride present on the surface and also upon the particular bath composition being employed. With the eutectic lithium carbonate-potassium carbonate bath at a temperature of about 630° C. an immersion period of about one hour is normally sufficient for decomposing excess residual potassium magnesium fluoride on the surface of the uranium derby without effecting excessive waste of the uranium metal. The water bath, or quenching step, is achieved immediately after the soaking of the uranium derby in the salt bath. This quenching operation normally requires only a sufficient time to remove the reaction products from the surface of the derbies. After finishing the quenching step, the uranium derbies are preferably immersed in a warm solution (about 82° F.) of nitric acid, e.g., a 35-50 wt.% HNO 3 solution, to remove any remaining residual salt and reaction products from the surface of the article. Again after completing the acid rinsing step the uranium derbies are rinsed in water to remove the acid to provide a uranium derby virtually free of all impurities on the surface thereof with the coatings on the casting crucibles.
By practicing the present invention, weight loss of the uranium is only very minimal. In fact such weight losses are considerably less than that encountered by the thermal shocking step previously utilized to remove the impurities from the uranium derbies prior to the uranium casting. Upon completion of practicing the present invention, the uranium derbies can be vacuum cast into graphite crucibles coated with yttria or zirconia without encountering the deleterious coating breakdown heretofore caused by the presence of magnesium fluoride on the derbies.
In order to provide a more facile understanding of the present invention examples are set forth below relating to the melting of uranium derbies cleaned of residual magnesium fluoride by the present method and compared with the carbon content of ingots prepared from derbies which were not adequately cleaned of residual magnesium fluoride.
EXAMPLE I
Sixteen uranium ingots cast in yttria-coated graphite crucibles from derbies having residual magnesium fluoride on the surface thereof are shown in FIG. 1 and contain a mean of 101.1 ppm carbon. Nine similar castings were prepared from derbies subjected to the surface cleansing method of the present invention. Each of these nine derbies was soaked in a eutectic salt bath containing 35 wt.% lithium carbonate and 65 wt.% potassium carbonate at 630° C. for one hour. The nine derbies were then water quenched to remove a large portion of the salt and reaction products from the surface of the derbies. Any residual salt remaining on the derbies was then etched therefrom in a warm solution (82° C.) of 50% nitric acid for 15 minutes. The nitric acid was rinsed from the derby with demineralized water. As shown in FIG. 1, the nine cleaned derbies when induction cast had a mean carbon content of only 76.7 ppm.
EXAMPLE II
In another demonstration of the present invention eight derbies having residual magnesium fluoride impurities on the surface thereof were selected for comparison. Five of these derbies were vacuum cast with the residual magnesium fluoride thereon. These five castings had a mean carbon content of 66 ppm. The remaining three of the derbies were treated or cleaned as set forth in Example I. The melts had a mean carbon content of 38.3 ppm.
It will be seen that the high level of carbon induction cast ingots of uranium in uranium alloys produced from bomb-reduced derbies containing residual magnesium fluoride on the surface thereof is essentially eliminated by practicing the derby cleaning method of the present invention.
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The concentration of carbon in uranium metal ingots induction cast from derbies prepared by the bomb-reduction of uranium tetrafluoride in the presence of magnesium is effectively reduced to less than 100 ppm by removing residual magnesium fluoride from the surface of the derbies prior to casting. This magnesium fluoride is removed from the derbies by immersing them in an alkali metal salt bath which reacts with and decomposes the magnesium fluoride. A water quenching operation followed by a warm nitric acid bath and a water rinse removes the residual salt and reaction products from the derbies.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a technique for recording information onto an optical disk by using a laser beam.
[0002] In a rewritable optical disk such as DVD-RAM, DVD-RW, CD-RW and a write once disk such as DVD-R and CD-R, information is recorded by applying a laser beam onto the disk recording surface. As the laser beam application method for forming a recording mark on the recording surface of the optical disk, there is a CD-R method for forming a recording mark by applying a recording pulse having time width according to the length of the recording mark, a DVD-RAM method for making the recording mark forming pulse comb-shape so as to control head accumulation and to form an optimal recording mark, and the like. The waveform of the recording pulse to obtain the optimal recording mark is called write strategy.
[0003] FIG. 1 schematically shows a write strategy of 4.7 GB-capacity DVD-RAM (hereinafter, referred to simply as DVD-RAM) which is one of the rewritable optical disks. FIG. 1 shows the write strategy when recording 11T (T is a recording clock cycle) mark. As shown in the figure, the DVD-RAM write strategy consists of a first pulse defined by TSFP, TEFP, TFP, a repeated pulse (multi pulse) defined by TMP, and a last pulse defined by TSLP, TELP, TLP. It should be noted that the laser power level may be binary and tertiary. Here, for simplification, the binary case is shown.
[0004] The first pulse of this write strategy may be defined by “a method for defining the waveform rise and fall end absolute time by the TSFP and FEFP” or “a method for defining the rise edge absolute time and the pulse time width by the TSFP and TFP.
[0005] Moreover, the last pulse also may be defined by two methods: “a method for defining the edge absolute time by the TSLP and TELP” or “a method for defining the fall edge absolute time and the pulse time width by the TELP and TLP”.
[0006] The TSFP which is a value deciding the time position of the front edge of the first pulse and the TELP which decides the time position of the rear edge of the last pulse are varied according to the recording mark length and the preceding and the following space length. This is because affect of the heat accumulation and heat diffusion by the laser beam when recording a mark varies depending on the recording mark length and the preceding and following space length.
[0007] FIG. 2 shows an example of adjustment table of TSFP and TELP. The 3T, 4T, 5T, ≧6T (6T or more) arranged in the longitudinal direction of the TSFP table represent the space length immediately before the recording mark while the 3T, 4T, 5T, ≧6T (6T or more) in the lateral direction represent mark length. Similarly, in the TELP table, the 3T, 4T, 5T, ≧6T (6T or more) arranged in the longitudinal direction represent the space length immediately after the recording mark while the 3T, 4T, 5T, ≧6T (6T or more) in the lateral direction represent mark length to be recorded. Since the values in the adjustment table shift the edge of the write strategy decided by TSFT and TELP, hereinafter these tables will be referred to as shift tables. Moreover, values deciding the edge timing of the recording waveform such as TSFP described in FIG. 1 and the aforementioned shift tables will be referred to as recording parameters (parameter group).
[0008] The method of modifying the write strategy by the relationship between the recording mark and the space length is used not only in the DVD-RAM but also in the other rewritable phase-change type medium DVD-RW, CD-RW and in the write once type pigment type medium DVD-R, CD-R, and the like.
[0009] Conventionally, for the recording parameters, the value which a medium manufacturer considers optimal under the condition of the constant linear velocity is recorded on the medium and provided. Since the write strategy form including the power level and the timing and the optimal values of the recording parameters such as shift tables significantly vary depending on the recording medium composition and material, it has been considered preferable that the medium manufacturer suggest the write strategy. For example, in the DVD-RAM, the aforementioned recording parameters are recorded in the physical format information (PFI) area in the control data zone arranged in the lead in area. It should be noted that the aforementioned conventional technique is disclosed in JP-A-2003-085753 and JP-A-2002-260226.
SUMMARY OF THE INVENTION
[0010] In the same as the recording medium has irregularities in the composition and material, an optical disk recording apparatus (hereinafter, referred to as “drive”) also has irregularities in the laser output power and circuit characteristics. Accordingly, the optimal recording parameter in a particular drive may not be the optimal recording parameter in another drive. Especially the recording parameter recorded on the medium is an optimal parameter when recording is performed at a particular linear velocity. When recording information onto the recording medium at a linear velocity other than the particular linear velocity, the recording parameter recorded on the medium in advance is not optimal. Accordingly, when performing recording at a linear velocity other than the linear velocity corresponding to the optimal parameter recorded in advance, it is preferable that the drive decide the optimal parameter at the linear velocity.
[0011] However, in the drive for recording information on a recording medium where an optimal recording parameter at a particular linear velocity is described, conventionally, no consideration has been taken on the method to obtain an optimal recording parameter at a linear velocity other than the particular linear velocity at the drive side.
[0012] It is therefore an object of the present invention to provide a method for preferably deciding a recording parameter provided by a medium manufacturer and a method to obtain, by using this recording parameter, a recording parameter at a linear velocity other than the linear velocity estimated by the medium manufacturer.
[0013] Next, explanation will be given on the variable velocity writing method which switches the write strategy when a predetermined linear velocity is reached.
[0014] In general, the heat diffusion amount at the front edge of the recording mark is proportional to the recording linear velocity while the heat accumulation amount at the rear edge is proportional to the square root of the recording linear velocity. Moreover, an energy amount given to the recording medium by the laser beam irradiation of a predetermined power level such as a recording power and an erase power is proportional to the laser beam irradiation power level per unit area and substantially proportional to the recording velocity.
[0015] However, if the write strategy is different, the aforementioned proportional relationship between the heat diffusion amount, heat accumulation amount, recording laser power and the recording velocity is broken. Accordingly, a recording parameter at an arbitrary linear velocity obtained by simple interpolation method (interpolation method, extrapolation method) of an optimal recording parameter at a plurality of linear velocities recorded in the recording medium in advance, generally, cannot be an optimal recording parameter. For this, in the writing method in which the recording linear velocity is successively changed like CAV (constant angular velocity) recording, it is difficult to realize a preferable variable speed recording by successively calculating the optimal recording parameter at the respective recording linear velocities.
[0016] During the CAV recording, it is possible to use a writing method for switching the write strategy each time a predetermined linear velocity is reached. However, when such a writing method is employed, the write strategy is abruptly switched at a predetermined position and as has been described above, the aforementioned proportional relationship becomes discontinuous. Accordingly, the same mark (for example, 3T mark) changes its shape before and after the strategy switching. Thus, when reproducing data immediately after the write strategy switching position, the equalizer, group delay and other reproduction parameter characteristic switching cannot follow the recording mark characteristic switching and there arises a problem of deterioration of the reproduction quality when the areas before and after the write strategy switching are reproduced continuously.
[0017] A second object of the present invention is to assure continuity of recording parameters, assure continuity of the recording mark shape, and improve the reproduction quality.
[0018] In order to achieve this object, there is provided a recording medium on which information is recorded by applying a laser pulse to form a mark on a recording layer, wherein identification information is recorded to indicate that a plurality of control parameter groups are recorded which have the laser pulse power level changing timing substantially proportional to the recording velocity for recording a mark of length not smaller than the laser spot diameter in the recording layer.
[0019] According to another aspect of the invention, there is provided a recording medium on which information is recorded by applying a laser pulse to form a mark on a recording layer, the recording medium containing control parameters recorded for respective linear velocities decided by: a step of recording a first mark having a length not smaller than the laser spot diameter in the recording layer at a first linear velocity, a step of recording a second mark having a length equivalent to the first mark at a second linear velocity, a step of calculating a voltage value change amount at two points at a distance Ts (Ts<Tm/2) in the time axis direction before and after the time position reference Tm/2 from the front edge of an electric signal waveform obtained by reproducing the first or the second mark at a predetermined linear velocity and having a time width Tm, and a step of deciding a control parameter of the laser pulse power level change timing so that the aforementioned change amount is substantially constant during recording at any of the linear velocities.
[0020] According to still another aspect of the present invention, there is provided an optical disk apparatus comprising a laser for applying a laser beam onto an optical disk, laser control means for controlling the laser, and rotation drive means for driving the optical disk to rotate, so that a laser pulse is applied onto a recording layer of the optical disk to form a mark, thereby recording information on the optical disk, wherein the laser control means changes recording linear velocity successively or stepwise for continuous recording by using such a control parameter that a change timing of the power level of the laser pulse for recording a mark having a length not smaller than the laser spot diameter in the recording layer is substantially proportional to the recording linear velocity.
[0021] According to yet another aspect of the present invention, there is provided an optical disk apparatus comprising a laser for applying a laser beam onto an optical disk, laser control means for controlling the laser, and rotation drive means for driving the optical disk to rotate, so that a laser pulse is applied onto a recording layer of the optical disk to form a mark, thereby recording information on the optical disk, wherein continuous recording in which the recording linear velocity changes successively or stepwise is performed by using control parameters for respective linear velocities decided by: a step of recording a first mark having a length not smaller than the laser spot diameter in the recording layer at a first linear velocity, a step of recording a second mark having a length equivalent to the first mark at a second linear velocity, a step of calculating a voltage value change amount at two points at a distance Ts (Ts<Tm/2) in the time axis direction before and after the time position reference Tm/2 from the front edge of an electric signal waveform obtained by reproducing the first or the second mark at a predetermined linear velocity and having a time width Tm, and a step of deciding a control parameter of the laser pulse power level change timing so that the aforementioned change amount is substantially constant during recording at any of the linear velocities.
[0022] According to yet still another aspect of the present invention, there is provided a writing method for recording information on an optical disk by applying a laser pulse on a recording layer of the optical disk so as to form a mark, wherein recording linear velocity is changed successively or stepwise for continuous recording by using such a control parameter that a change timing of the power level of the laser pulse for recording a mark having a length not smaller than the laser spot diameter in the recording layer is substantially proportional to the recording linear velocity.
[0023] The present invention assures continuity of the shape of a reproduction waveform, thereby enabling stable reproduction. Moreover, it is possible to easily calculate a recording parameter at a recording velocity other than the recording velocity where the recording parameters provided by a medium manufacturer are defined, from the recording parameters provided by the medium manufacturer. Accordingly, when performing CAV recording, it is possible to calculate a preferable recording parameter.
[0024] Moreover, for a drive manufacturer, it is possible to simplify the write strategy setting method when realizing a high velocity recording by the CAV recording, reduce the drive development time, and reduce the learning time when adjusting the write strategy in the drive.
[0025] Moreover, by using the procedures of the present invention in the drive, it is possible to calculate the write strategy and the recording parameter coping with the variable velocity recording so as to realize a variable velocity recording such as CAV recording in a medium not having any recording parameters provided by a medium manufacturer coping with the variable velocity recording. Furthermore, by referencing the variable velocity recording flag, it is possible to easily identify a medium supporting the variable velocity recording and reduce the write strategy learning time when performing the variable velocity recording.
[0026] Other objects, features and advantages of the invention will become apparent from the following description of the embodiments of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 schematically shows 11T mark recording waveform of a 4.7 GB DVD-RAM.
[0028] FIG. 2A and FIG. 2B show an example of recording parameter control table.
[0029] FIG. 3A and FIG. 3B are an example of a 10T mark reproduction waveform and its schematic diagram.
[0030] FIG. 4 schematically shows an example of relationship between the recording velocity and recording parameter.
[0031] FIG. 5A and FIG. 5B are an example of a 10T space reproduction waveform and its schematic diagram.
[0032] FIG. 6 shows a waveform of a 4.7 GB DVD-RAM reserved area.
[0033] FIG. 7A and FIG. 7B are an example of a 10T mark reproduction waveform and its schematic diagram.
[0034] FIG. 8 schematically shows an example of 14T mark reproduction waveform and sample pulse.
[0035] FIG. 9 schematically shows an example of 14T mark reproduction waveform and sample system.
[0036] FIG. 10 is a flowchart showing a drive operation sequence.
[0037] FIG. 11 is a block diagram of a drive according to the present invention.
[0038] FIG. 12 schematically shows an example of relationship between the recording velocity and the normalization recording parameter.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Embodiment 1
[0039] Explanation will be given on the first embodiment by using the DVD-RAM as an example. As has been described above, in the DVD-RAM, the recording parameter is selected by a medium manufacturer and shipped.
[0040] Currently, as the DVD-RAM standard, double speed (hereinafter, referred to as “2×”) recording standard and triple speed (hereinafter, referred to as “3×”) recording standard are released. Release of five-times speed (hereinafter, referred to as “5×”) recording standard is expected. That is, the 5× recording disk (hereinafter, referred to as DVD-RAM 5×) is probably provided with the 2× recording and 3× recording parameter, considering the compatibility with a lower apparatus. Moreover, by using the recording parameters of the respective recording velocities, in the 5× recording drive, it is possible to perform CAV recording with recording velocity of 2× at the innermost circumference and 5× at the outermost circumference. An example of recording parameter decision procedure in the respective recording velocitys for recording onto the DVD-RAM will be explained below.
[0041] Procedure 1. Recording Parameter Estimation
[0042] In the procedure 1, firstly, recording parameters at the respective recording velocities provided, i.e., 2×, 3×, 5× are tentatively set in the linear value of the recording velocity. This is because in order to cope with the variable speed recording such as CAV recording, linearity is required between the recording parameters provided and the recording velocity.
[0043] Procedure 2. Long Mark Reproduction Waveform Adjustment and Basic Recording Parameter Linearity Check
[0044] In the procedure 2, by using the tentative recording parameters set in the procedure 1, a long mark of 6T or more is recorded at each recording velocity and reproduction waveforms obtained when reproduction is performed at a constant speed are compared.
[0045] In general, in optical disk reproduction, when reproducing a mark almost equal to or greater than a spot diameter, the reproduction signal amplitude level is saturated and the waveform shift difference generated by the spot shape difference is small. In the case of the DVD-RAM of the present embodiment, the diameter of beam for reproduction is 0.86 μm and the amplitude value of the 6T signal or above equivalent to the 0.84 μm length which is almost identical to the beam diameter is almost constant. Accordingly, the recording parameter initial adjustment is performed by using a waveform of a long mark of the 6T or above as a reference and after this, the recording parameter for forming a short mark is adjusted. This reproduction velocity may be the lowest reproduction velocity defined by the medium.
[0046] FIG. 3 shows a reproduction waveform 301 of a long mark (10T) recorded at a certain recording velocity in the DVD-RAM. FIG. 3 is an example of the 10T waveform and the low portion of the waveform indicates a dark portion (mark portion). Moreover, the reproduction velocity is 2×, and the reproduction system parameter is the standard parameter described in the DVD-RAM specification. FIG. 3B shows a waveform schematically extracted from the waveform of FIG. 3A . Here, the waveform is separated to the front part and the rear part with respect to the center of the recording mark waveform, i.e., the 5T position 302 in this case. The minimum value 303 of the front part and the minimum value 304 of the rear part are extracted and the inclination A2× of the straight line 305 connecting the both waveform positions is calculated.
[0047] The inclinations at 3× and 5× are also calculate to obtain A3× and A5×. A medium manufacturer decides the recording parameters provided as follows. That is, the recording parameters at the respective velocities are adjusted so that the values of A2×, A3×, A5× are almost identical (preferably within a range of ±10%).
[0048] It should be noted that here, adjustment has been made according to the inclination of the minimum value of the front part and the minimum value of the rear part. However, the present invention is not to be limited to this. it is also possible to calculate an inclination between two points positioned at a predetermined distance from the mark center and make adjustment according to the inclination.
[0049] During this adjustment, linearity for the recording velocity is checked for the recording parameter which is advised not to be adjusted in the drive in the medium specification (hereinafter, referred to as basic recording parameter). In the DVD-RAM of the present embodiment, “TFP, TMP, TLP, TCL, TEFP, TSLP” in FIG. 1 and “TSFP ( 201 in FIG. 2 ) when a mark of 6T or above follows the space of 6T or above, TELP ( 202 in FIG. 2 ) when space of 6T or above follows a mark of 6T or above” are the basic recording parameters.
[0050] As has been described above, the aforementioned basic recording parameters can all be set so that they have a logically linear relationship with respect to the recording velocity. However, a slight error may be generated in each recording parameter value by the recording parameter decision procedure and the value rounding.
[0051] For this, as shown in FIG. 4 , from the recording parameter value 401 obtained by the highest recording velocity (5× recording in this case) and the recording parameter value 402 obtained by the lowest recording velocity (2× recording in this case), between them, the recording parameter value 404 of the velocity (3× recording in this case) at which a medium manufacturer provides a recording parameter is calculated. A difference ΔPt 406 between the value thus obtained and the aforementioned velocity obtained in the procedure 1 and procedure 2, i.e., 3× recording parameter value 403 in this case is calculated.
[0052] This ΔPt is compared to an error allowance value defined for each recording parameter. If the ΔPt is not greater than the error allowance value, the adjustment is completed. If the ΔPt is greater than the error allowance value, the recording parameter is again adjusted by the mark reproduction waveform. After this adjustment, if the inclination at each recording velocity of reproduction waveform of the long mark defined above and the linearity of the basic recording parameter do not satisfy a predetermined condition, the recording medium is improved by considering the recording medium composition and material.
[0053] It should be noted that the recording parameter condition extraction in the above is performed by simultaneously comparing to the data to clock jitter (hereinafter, referred to simply as jitter) during reproduction of the recording waveform, reproduction waveform asymmetry, and other specification values.
[0054] Procedure 3. Shift Table, Power Level Adjustment
[0055] In the procedure 3, after adjustment of the recording parameter, adjustment of recording parameters other than the basic recording parameters adjusted in the procedure 2 at each recording velocity is performed. In this embodiment, the area other than 201 and 202 of the shift table in FIG. 2 and the recording power level adjustment correspond to this adjustment. As the adjustment method, it is possible to employ a method to minimize the reproduction jitter. For example, it is possible to employ the technique defined in the medium specification such as the DVD-RAM.
[0056] It should be noted that the basic recording parameters adjusted in the procedure 2 are not modified in the procedure 3. This is for maintaining the shape of the long mark reproduction waveform and the recording parameter linearity for the recording velocity in the procedure 2.
[0057] Procedure 4. Recording Parameter Linearity Check
[0058] In the procedure 4, linearity for the recording velocity is checked for the recording parameter at each recording velocity extracted in the procedure 3. In the DVD-RAM of the present embodiment, linearity for the recording velocity is checked for the recording parameters shown in FIG. 1 and the TSFP and TELP shift tables shown in FIG. 2 .
[0059] When the linearity of basic recording parameters is guaranteed in the procedure 2, these recording parameters can all be set so that they have theoretically linear relationship with the recording velocity. However, similarly as in the procedure 2, an error may be involved by rounding the recording parameter values and accordingly, in the same way as the procedure 2, an allowable error value is set for each recording parameter so as to check the linearity.
[0060] Procedure 5. Setting Flag for Variable Velocity Recording
[0061] Depending on the recording medium film composition and material, there is a case that an appropriate parameter cannot be selected by the adjustments of the procedures 1 to 4. Such a medium cannot cope with the variable velocity recording such as the CAV recording and should be distinguished from those which satisfy the adjustments of the procedures 1 to 4. The procedure 5 sets a judgment flag indicating presence/absence of a recording parameter adjusted by the procedures 1-4 so as to distinguish it.
[0062] For example, in the DVD-RAM standard, bit 613 and after in the RFIL sector where the recording parameters provided by a medium manufacturer are recorded are reserved (empty bits). Here, the 1-bit judgment flag can be set for distinguishing.
[0063] In the drive, when inserting a medium, it is checked whether the judgment flag is present. When the bit is 1, the medium is recognized as a variable velocity recording medium and at a recording velocity between the medium lowest recording velocity and the highest recording velocity, recording is performed by using a recording parameter obtained by linear interpolation or the recording parameters provided by a medium manufacturer for the lowest recording velocity and the highest recording velocity. In the case of the DVD-RAM 5× recording medium of the present example, from the recording parameters provided by the medium manufacturer for the 2× recording and 5× recording, it is possible to calculate the recording parameters at the recording velocities between them such as 2.5×, 3×, and 4×.
[0064] By using the procedures 1-4 shown in this embodiment, it is possible to easily calculate recording parameters of recording velocities other than those corresponding to the recording parameters provided by a medium manufacturer from the recording parameters provided by the medium manufacturer. When performing continuous recording in the CAV recording where the recording velocity is successively changing, it is possible to always calculate an optimal recording parameter. Moreover, a high quality CAV recording is guaranteed by the optical disk of the present embodiment and a user can perform data recording of a high quality.
[0065] Moreover, by providing a flag indicating the employment of the procedures 1-4, it is possible to know whether the recording medium can cope with the CAV recording and an appropriate recording control can be performed. That is when the recording medium is judged to cope with the CAV recording, CAV recording is performed and when the recording medium is judged not to cope with the CAV recording, CAV recording is not performed. Moreover, for a drive manufacturer, it is possible to simplify the write strategy setting method when realizing a high velocity recording by CAV recording, which reduces the drive development time and the learning time during the write strategy adjustment.
[0066] It should be noted that when employment of the procedures 1-4 is guaranteed by the medium standard, there is no need of checking the recording medium whether it can cope with the CAV recording and no flag is required.
[0067] Furthermore, even when areas recorded with different recording velocities are adjacent to each other, the reproduction waveform shapes match and accordingly, it is possible to perform stable reproduction.
Embodiment 2
[0068] Next, explanation will be given on a second embodiment. The second embodiment also sets recording parameters in the same way as the first embodiment. However, the procedure 2 is different from that of the first embodiment. Hereinafter, explanation will be given on the procedure 2.
[0069] In the procedure 2 of the first embodiment, by monitoring the reproduction waveform of the long mark of 6T or above recorded by using the recording parameters of different velocities, the inclination of the mark portion is substantially matched between the recording velocities. In the present embodiment, the inclination of the reproduction waveform of the long mark of 6T or above is compared to the long space portion of 6T or above or the inclination of the reproduction waveform of a reserved area, thereby deciding an optimal recording parameter.
[0070] For example, in the case of the space portion, as shown in FIG. 5 , the center of the space portion waveform 501 , i.e., in the case of 10T space, for the areas before and after the 5T portion, the straight line 504 connecting peaks 502 and 503 of the each area is made a reference value Asp. Alternatively, an average potential between arbitrary two areas within one track of a reserved area is calculated and from the difference, a waveform inclination reference value Anw of the reserved area is calculated. For example, in the DVD-RAM, as shown in FIG. 6 , the inclination 601 is calculated from the average potentials V 61 and V 62 of n sectors of m sectors (m and n are arbitrary numbers) before and after the PID (physical ID) area so as to serve as the reference value Anw.
[0071] Next, as has been calculated in the first embodiment, the inclinations A×2, A×3, A×5 at the mark portion are calculated. In this embodiment, the recording parameters are set so that A×2, A×3, A×5 at the mark portion are substantially matched with the inclinations at the space portion Asp and Anw. FIG. 7 shows the reproduction waveform of the mark portion after the actual adjustment. In the same way as in the first embodiment, the inclination of the mark portion of the long mark reproduction waveform is obtained by the center point 701 and the left and the right peaks 702 and 703 . When the obtained inclination 704 is defined for each velocity as A×2, A×3, A×5, the recording parameters are adjusted so that differences between these inclination values A×2, A×3, A×5 and Asp, Anw are substantially zero as shown by 704 in FIG. 7 .
[0072] By adjusting the recording parameters by the procedure of this embodiment, the mark shape approaches a uniform ellipse as compared to the long mark of the first embodiment and it is possible to improve the erase characteristic and cross talk characteristic during overwrite and disk resistance against the rewrite.
Embodiment 3
[0073] Next, explanation will be given on a third embodiment. In this embodiment, the recording parameter setting method and variable velocity recording bit are identical to the first embodiment. However, the method for checking the recording parameter linearity in the procedures 2 and 4 is different. Hereinafter, explanation will be given on the procedures 2 and 4.
[0074] In the procedure 2 of the first embodiment, a difference between the recording parameter obtained by the linear interpolation and the recording parameter obtained by a condition of the waveform inclination defined for the long mark reproduction waveform of 6T or above is compared to a predetermined error allowance value to judge the linearity of the recording parameter.
[0075] The procedure 2 of the present embodiment calculates only a basic recording parameter (which is made basic recording parameter A) at the medium maximum recording velocity (5× recording in this embodiment) and a basic recording parameter (which is made basic recording parameter B) at the medium minimum recording velocity (2× recording in this embodiment). A basic recording parameter (which is made basic parameter C) provided by a medium manufacturer at the recording velocity between them is calculated by linear interpolation of the basic recording parameters A and B.
[0076] When this is applied to FIG. 4, 401 is the basic recording parameter A, 402 is the basic recording parameter B, and 404 is the basic recording parameter C. Next, the area recorded by using the basic parameter C at an adaptive recording velocity of the basic parameter C is reproduced at a predetermined reproduction velocity, for example 2× if DVD-RAM, to obtain the reproduction jitter. If the jitter value σ is smaller than a predetermined allowance jitter value σr, i.e., c the adjustment is terminated. If σ>σr, in the same way as in the first embodiment, “the recording parameter is re-adjusted by the long mark reproduction waveform” and “the recording medium is improved by considering the recording medium composition and material”.
[0077] In the procedure 4, in the same way as in the procedure 2, from the recording parameter obtained by the medium maximum recording velocity and the minimum recording velocity, the recording parameter provided by the medium manufacturer is interpolated at the recording velocity between them. The reproduction jitter σs as a result of recording by the recording parameter is compared to a predetermined allowance jitter value σrs so as to check the linearity of the recording parameter.
[0078] In the procedure of the present embodiment, there is no need of extracting basic recording parameters other than at the maximum recording velocity and the minimum recording velocity or other recording parameters. Accordingly, it is possible to reduce the basic recording parameters and the time required for deciding the basic recording parameters.
[0079] Moreover, in this embodiment, for interpolating the basic recording parameters and other recording parameters, the basic recording parameters at the maximum recording velocity and the minimum recording velocity specified in the medium and other recording parameters are calculated. However, it is also possible to perform interpolation by interpolation and extrapolation of basic recording parameters at two or more arbitrary different velocities provided by the medium manufacturer and other recording parameters.
Embodiment 4
[0080] Next, explanation will be given on a drive according to the present invention as a fourth embodiment of the present invention. FIG. 10 shows an example of processing procedure of the drive performing variable velocity recording on a disk having description of advised recording parameters for a plurality of recording velocity.
[0081] FIG. 11 shows configuration of the drive according to the present embodiment. In the drive of the present embodiment, a laser diode 111 is driven by a laser driver (LDD) 1121 mounted on a pickup 110 and a laser beam is emitted from an objective lens 113 . The laser emission timing is controlled by a waveform parameter controller in a DSP 105 . It should be noted that in this embodiment the waveform controller is built in the DSP but it may also be a separate chip or mounted on the LDD.
[0082] The reproduction signal is introduced from the pickup through RF F/E LSI 104 into the waveform acquisition section in the DSP and a waveform analyzer so as to be subjected to waveform processing. In the waveform acquisition section, acquired waveform data is A/D converted to obtain digital data, which is sent to the waveform analyzer. Moreover, a part of data is acquired directly by a microcomputer 106 , which performs waveform analysis. Furthermore, in the DSP, a variable velocity recording flag detection function is provided to judge presence/absence of the flag. It should be noted that presence/absence of the flag can also be judged by the microcomputer and the flag detection function need not necessarily be provided in the DSP.
[0083] Procedure 1. Checking the Variable Velocity Recording
[0084] Firstly, check is made to determine whether the variable velocity recording flag shown in procedure 5 of the first embodiment is recorded on the medium to be reproduced (step 1003 ). When the variable velocity recording flag is ON in the medium (medium which can cope with variable velocity recording), according to the recording parameter at a particular linear velocity recorded on the medium, a recording parameter value at a linear velocity other than that is calculated by linear calculation so as to perform variable velocity recording (steps 1004 - 1008 ).
[0085] Procedure 2. Checking the Linearity of the Recording Parameter Advised by the Medium Manufacturer
[0086] When the variable velocity recording flag is OFF or the variable velocity recording flag is not set, linearity is checked between the basic recording parameter advised by the medium manufacturer and advised not to be modified in the drive and the recording velocity (step 1009 ). It should be noted that the check method may be, for example, the method shown in the procedure 2 of the first embodiment of the present invention in which a predetermined recording parameter error value is defined or the method shown in the procedure 2 of the third embodiment of the present invention in which a predetermined jitter allowance value is defined.
[0087] When the linearity can be confirmed, variable velocity recording such as CAV recording is performed while interpolating the recording parameter at each linear velocity from the recording parameters read out from the medium (steps 1004 - 1008 ).
[0088] When the linearity cannot be confirmed, by using a part of the recording parameters recorded on the medium, the basic recording parameters and other recording parameters are extracted (step 1010 ).
[0089] Procedure 3. Extracting the Basic Recording Parameter by the Long Mark Waveform and Checking the Linearity
[0090] By using recording parameters at a plurality of recording velocities provided by the medium manufacturer, long mark recording and long space recording of 6T or above are performed at each recording velocity. In the area where they are recorded, a reproduction waveform of a long mark of 6T or above is extracted and in the same way as is defined in the first embodiment, the inclination of the long mark reproduction waveform when reproduction is performed at a constant velocity is measured. The recording parameters for the long mark and long space of 6T or above are adjusted so that the inclinations of the long mark reproduction waveform at the respective recording velocity are substantially matched. This recording parameter corresponds to the basic recording parameter in the first embodiment.
[0091] As for the measurement method for measuring the long mark reproduction waveform inclination, for example, in the case of DVD-RAM, there is a method for extracting the sync pattern 14T in the drive and generating the sample pulses shown in 802 and 803 for the 14T mark reproduction waveform 801 as shown in FIG. 8 . Since the sync pattern repeatedly appears at the same timing, it is possible to generate such a sample pulse. This sample pulse generates a window at identical positions at the both sides of the center of the 14T mark reproduction waveform with an identical width. By calculating a difference V between voltage values V 1 and V 2 of the hold signals 804 and 805 held only during the window period of the sample pulses 802 and 803 , the value obtained is defined as the inclination of the long mark reproduction waveform.
[0092] Moreover, there is another method for measuring the inclination. As shown in FIG. 9 , the reproduction waveform 901 is AD converted by a reproduction clock cycle, for example. From the sampling sequence obtained, a predetermined long mark reproduction waveform, i.e., 14T reproduction waveform in this case, is extracted. At the positions at an identical distance of time width from the time center of the long mark waveform, average values of the sample values 902 , 903 of the identical number of samples are calculated. A difference between the obtained average values is defined as the inclination of the long mark reproduction waveform. By using one of these methods, a linearity parameter is decided.
[0093] Furthermore, for confirmation of the basic recording parameters obtained in the respective recording velocities, recording is actually performed to check the linearity (step 1011 ). The check can be performed by using the method of the procedure 3 described in the first and the second embodiment. If the linearity of the basic recording parameters cannot be confirmed by this procedure, return to the procedure 2 and modify the inclination of the long mark reproduction waveform. If the linearity of the basic parameters cannot be confirmed even by this, only the constant velocity recording such as CLV is performed (step 1013 ).
[0094] The extraction of the basic recording parameters and linearity check are preferably performed while performing comparison to the data to clock jitter (hereinafter, referred to simply jitter) during reproduction of the recording waveform and the standard value of the reproduction waveform asymmetry.
[0095] Procedure 4. Shift Table, Power Level Adjustment
[0096] After adjustment of the basic recording parameters, adjustment of recording parameters other than the basic recording parameters adjusted in the respective velocities in the procedure 2 is performed.
[0097] Here, in the same way as in the first embodiment, the basic recording parameters adjusted in the procedure 2 are not modified. As the adjustment method, various techniques can be suggested. It is also possible to use the method defined in the medium standard such as the DVD-RAM.
[0098] Procedure 5. Checking the Recording Parameter Linearity
[0099] For the recording parameters at the respective recording velocities extracted in the procedure 3, linearity for the recording velocity is checked. In this case also, in the same way as in the procedure 2 of the first embodiment, the respective recording parameter values may have errors caused by rounding. Accordingly, in the same way as the procedure 2, an allowance error value is set for each of the recording parameters to check the linearity.
[0100] The drive having the aforementioned procedures have the following advantages.
[0101] 1. By referencing the variable velocity recording flag, it is possible to easily identify the medium supporting the variable velocity recording.
[0102] 2. When a medium supporting variable velocity recording is identified, the write strategy setting becomes easy when performing the variable velocity recording such as CAV and it becomes possible to reduce the write strategy learning time.
[0103] 3. By referencing the variable velocity recording flag, in a medium not supporting variable velocity recording, it is possible to prevent recording failure when performing the variable velocity recording by using the recording parameter provided by a medium manufacturer.
[0104] 4. Even in a medium not provided with a recording parameter corresponding to variable velocity recording from a medium manufacturer, by using the aforementioned procedures, it is possible to obtain the write strategy and a recording parameter corresponding to the variable velocity recording and realize variable velocity recording such as CAV recording.
[0105] It should be noted that by holding the recording parameters obtained by the present procedures in the drive such as in the EEPROM, it is possible to rapidly set the recording parameters when the same medium is inserted into the drive, thereby reducing the recording parameter learning time.
[0106] Moreover, in the above, instead of performing variable velocity recording according to the recording parameters provided by the medium manufacturer, it is possible to perform variable velocity recording by using the learning result of recording parameter optimal for the drive by using the method defined by the medium standard according to the recording parameters provided by the medium manufacturer instead of the recording parameters provided by the medium manufacturer.
Embodiment 5
[0107] Next, explanation will be given on a fifth embodiment. In this embodiment, the recording parameter setting method and the variable velocity recording bit are identical to the first embodiment, but the recording parameter linearity check in the procedures 2 and 4 are different. Hereinafter, explanation will be given on the procedures 2 and 4 of this embodiment.
[0108] This embodiment is characterized in that when checking the linearity of the parameter defining the time-axis direction information of the recording pulse with respect to the recording velocity in the procedure 2 and 4 of the first embodiment, a value of the parameter normalized by the recording clock cycle is used. For example, in the case of DVD-RAM, the recording parameters to be processed are TFP, TMP, TLP, TCL, TEFP, TSLP, TSFP, and TELP.
[0109] Explanation will be given by making these parameters Tpr and using FIG. 12 . The recording parameter value (Tpr5×) obtained at the maximum recording velocity (in this case, 5× recording) and the recording parameter value (Tpr2×) obtained at the minimum recording velocity (in this case, 2× recording) are normalized by the recording clock cycle of the respective recording velocities to obtain the normalized recording parameters Tpr5×s and Tpr2×s. The normalization is performed by an equation (1) as follows.
Tpr[n]xs=Tpr[n]x/Tw[n] (1)
[0110] In Equation (1), [n] represents times of speed (recording speed) and Tw[n] represents a recording clock cycle at the n times of speed. The Tpr5×s is shown by 1201 in FIG. 12 . Similarly, Tpr2×s is shown by 1202 in FIG. 12 .
[0111] These are used to calculate the normalized recording parameter value 1204 (Tpr3×s_I) of the speed (3× recording in this case) at which recording parameter is provided by the medium manufacturer. By calculating a difference ΔTpr3×s 1206 between the Tpr3×s_I and the aforementioned speed obtained by the procedures 1 and 2 shown in the first embodiment, i.e., the 3× recording parameter value (Tpr3×) in this case which is normalized into a normalized recording parameter value Tpr3×s ( 1203 in FIG. 12 ) by Equation (1), the difference is compared to an error allowance value for the predefined normalized recording parameter, thereby judging the adjustment end.
[0112] Thus, it is possible to check the linearity with the recording pulse time-axis direction information not depending on the recording velocity, thereby facilitating to assure the linearity.
[0113] It should be noted that in this embodiment, comparison with the error allowance value is performed by using the difference of the normalized recording parameter values but it is also possible to return the Tpr3×s_I obtained above to the previous time information Tpr3×_I by Equation (2) as follows, calculate the difference ΔTpr3× with the aforementioned Tpr3× not normalized, and compare the error allowance value for the predefined recording parameter, thereby judging the adjustment end.
Tpr 3 x — 1 =Tpr 3 xs — 1 ×Tw[ 3] (2)
Embodiment 6
[0114] Next, explanation will be given on a sixth embodiment. In this embodiment, the recording parameter setting method and the variable velocity recording bit are identical to the third embodiment but the recording parameter linearity check method in the procedures 2 and 4 is different. Hereinafter, explanation will be given on the procedures 2 and 4 of the present embodiment.
[0115] This embodiment is characterized in that when checking the linearity for the recording velocity of the parameter defining the recording pulse time-axis direction information in the procedures 2 and 4 of the third embodiment, the value of the parameter normalized by the recording clock cycle is used. The method explained in the fifth embodiment is used to obtain the normalized recording parameter Tpr3×s_I from the normalized recording parameters Tpr5×s, Tpr2×s and the aforementioned Equation (2) is used to calculate the time information Tpr3×_I. The reproduction jitter us as a result of recording performed with the recording parameter Tpr3×_I thus obtained is compared to a predetermined allowance jitter value urs to check the linearity of the recording parameter.
[0116] Thus, it is possible to check the linearity with the recording pulse time-axis direction information not depending on the recording velocity, thereby facilitating to assure the linearity.
Embodiment 7
[0117] Next, explanation will be given on a seventh embodiment. This embodiment is characterized in that when calculating the recording parameter for performing variable velocity recording in the procedure 1 of the fourth embodiment of the present invention, linearity calculation is performed by using the parameter normalized by the recording clock cycle using the method shown in the fifth embodiment of the present invention.
[0118] Moreover, in the recording parameter linearity checks in the procedures 2 to 4 in the fourth embodiment of the present invention, check of the recording parameter linearity indicating the time information is performed by using the parameter normalized by the recording clock cycle using the method shown in the fifth embodiment of the present invention.
[0119] Thus, it is possible to check the linearity with the recording pulse time-axis information not depending on the recording velocity and facilitate to assure the linearity.
[0120] It should be noted that the long mark and long space of 6T or above in the aforementioned embodiments intend for mark length and space length in which voltage of the waveform mark portion and space portion during reproduction is not affected by the preceding and following marks and spaces. This can also be defined as a mark and space of one or more times of the laser spot diameter focused on the recording medium. For example, when the laser spot diameter is 1 μm in the DVD-RAM recording apparatus, this is equivalent to the length of 7.14T. That is, it is also possible to perform the aforementioned procedures by using a long mark and a long space of 8T or above.
[0121] It should be further understood by those skilled in the art that although the foregoing description has been made on embodiments of the invention, the invention is not limited thereto and various changes and modifications may be made without departing from the spirit of the invention and the scope of the appended claims.
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Recording parameters are decided so that the time control information on at least the front edge and the rear edge of a parameter forming a mark of twice size or above of the laser spot diameter focused on the recording medium is substantially proportional to the recording linear velocity. The mark is recorded and reproduced at a predetermined linear velocity to obtain an electric signal waveform having a time width Tm. A parameter is decided so as to control the laser pulse for recording information so that a voltage value change amount at two points at a distance Ts (Ts<Tm/2) in the time axis direction before and after the time position Tm/2 from the front edge of the waveform is substantially constant for the recording linear velocity change. Identification information indicating the parameter is described on the recording medium.
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RELATED APPLICATION
[0001] This application claims the benefit of the European patent application EP14305776.8 filed May 23, 2014, the entirety of which is incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a thermal-acoustic protection sheet assembly for an exhaust duct of a rotary machine or boiler associated with the machine.
[0003] Rotary machines, such as industrial gas turbines, and boilers discharge exhaust gases that require exhaust ducts. The exhaust gases typically leave the rotary machines at high velocities and high temperatures such as in excess of 600° C. (degrees Celsius). Exhaust ducts, such as diffusers, include passages that direct the exhaust gases from the rotary machines or boilers to heat recovery steam generators (HRSG) or other systems that receive the exhaust gases.
[0004] Exhaust ducts tend to be relatively large structures that provide a gas passage for large volumes of exhaust gases. A typical exhaust duct may have a cross-sectional dimension of 100 to 900 square feet (9 to 100 square meters). The cross-sectional area of the exhaust duct may increase as the exhaust gas flows from the rotary machine to the HRSG. The exhaust duct may have a generally square, circular or conical cross section. The exhaust duct may be connected to the discharge end of the rotary machine or boiler by an expansion joint.
[0005] The walls of an exhaust duct are typically formed by insulated sheet assemblies. These assemblies are arranged side-by-side and supported by a framework of ribs to form the wall of a passage for the exhaust gases. Each sheet assembly includes an internal stainless steel sheet, an external steel sheet and an intermediate layer (or layers) of insulation between the internal and external sheets. Insulation in the walls suppresses the transmission of heat and acoustic noise from the hot gases to the environment surrounding the exhaust duct.
[0006] The insulation in the intermediate layer is typically formed of mineral fibers, glass fibers, bio-soluble fibers or rock wool. The insulation is arranged in layers or may be packed as a cushioning material between the interior and external sheets. The materials and thicknesses of the intermediate layer(s) of the exhaust duct is typically selected to attain a certain low heat transfer coefficient through the intermediate layer. The insulation is generally configured to prevent the material from disintegrating over time and facilitate the handling of the insulation during installation of the insulation into the sheet assemblies.
[0007] The sheet assembly includes support plates also referred to as separators that extend through the intermediate layer to support the internal and external sheets and provide spacing for the intermediate layer.
[0008] The support plates are typically perpendicular to the internal and external sheets. An edge of each support plate is fixed or welded to an internal surface of the external sheet. An opposite edge of each support plate is attached to a bolt that extends through the internal sheet. A nut and washer are fastened to the bolt to secure the internal sheet to the support plate. The assembly of nuts, washers and support plates form a framework that holds together the internal sheet, the intermediate layer and the external sheet.
[0009] The bolts and support plates tend to conduct heat through the sheet assembly. Heat is conducted because the bolts and support plates form a metal path through the intermediate layer. The bolts are fasten to the hot internal sheet and may be directly exposed to the hot exhaust gases if they extend through the internal sheet. The bolts conduct heat to the support plates. If an edge of the support plate is in contact with the internal sheet, heat from the internal sheet may be conducted directly to the support plate. The metal material of the bolts and support plates conducts heat to a much greater extent than does the insulation of the intermediate layer. The metal paths of the bolts and support plates form thermal bridges through the insulation of the intermediate layer of the sheet assembly.
BRIEF DESCRIPTION OF THE INVENTION
[0010] There is a long felt need for a thermal acoustic sheet assembly for a wall of an exhaust duct that effectively suppresses the transmission of heat and acoustic noise and lacks thermal bridges that conduct heat through the sheet assembly. A thermal acoustic insulating sheet assembly has been conceived and is disclosed here for a hot gas exhaust duct of a rotary machine, a boiler or other source of a large volume of hot gases. The conceived thermal acoustic insulating sheet assembly avoids the heat conductive paths formed by bolts and support plates of a conventional sheet assembly.
[0011] The thermal acoustic insulating sheet assembly may comprise an internal sheet, an external sheet parallel to the internal sheet and a thermally insulating layer or layers between the sheets. The internal sheet may be formed of stainless steel or other metal, the external sheet may be steel or another metal and the insulation in the intermediate layer includes insulation formed of layers or cushioning material formed of, for example, of mineral fibers, glass fibers, bio-soluble fibers or rock wool.
[0012] The thermal acoustic insulating sheet assembly also includes bars and thermally insulating support brackets for connecting the bars to the external sheet. The bars and support brackets replace the bolts and support plates of a conventional insulting sheet assembly. The support brackets may include insulated washers and non-conductive layers that thermally isolate the bar from the support bracket.
[0013] A thermal acoustic insulation structure has been conceived and is disclosed here that includes including: a metal internal sheet having an exposed surface configured to be exposed to a hot gas, an external sheet and an insulation sandwiched between the internal and external sheets; a bar secured to the metal internal sheet and extending through at least a portion of the insulation; a bracket connected to the external sheet or to a support plate extending from the external sheet, wherein the bracket includes an opening configured to receive an end of the bar; a fastener securing the end of the bar to the bracket, and an insulating washer separating the bracket from the bar and the fastener.
[0014] An exhaust gas duct has been conceived and is disclosed here that includes: a gas passage, and a wall of the gas passage, wherein the wall forms a closed perimeter of a cross section of the gas passage, and the wall includes: a metal internal sheet having an exposed surface configured to be exposed to a hot gas, an external sheet and an insulation layer sandwiched between the internal and external sheets; a bar secured to the metal internal sheet and extending through at least a portion of the insulation; a bracket fixed to the external sheet, wherein the bracket includes an opening configured to receive an end of the bar; a fastener securing the end of the bar to the bracket, and an insulating washer separating the bracket from the bar and the fastener.
[0015] A method to assembly a thermal acoustic wall structure has been conceived and is disclosed here that includes: sandwiching an insulation layer between a metal internal sheet having an exposed surface configured to be exposed to a hot gas and an external sheet and an insulation sandwiched between the internal and external sheets; fastening a bar to the metal internal sheet and extending the bar through at least a portion of the insulation; fastening the bar to a bracket fixed to the external sheet or to a support plate extending from the external sheet, wherein the bracket includes an opening configured to receive an end of the bar; securing the end of the bar to the bracket, and installing an insulating washer to separate the bracket from the bar and the fastener.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a side view of a cross section of a conventional acoustic thermal sheet assembly;
[0017] FIG. 2 is a side view of the conventional acoustic thermal sheet assembly;
[0018] FIG. 3 is a side view of a bar fitted on a novel support element in an acoustic thermal sheet assembly;
[0019] FIG. 4 is a side view of a second embodiment of a bar fitted on a novel support element arranged in a thermal acoustic sheet assembly; and
[0020] FIG. 5 is a side view of bars fitted to the support element in a thermal acoustic sheet assembly, wherein the view is along a line parallel to the support element.
DETAILED DESCRIPTION OF THE INVENTION
[0021] FIG. 1 illustrates a conventional thermal acoustic sheet assembly 10 for an exhaust duct of a rotary machine. The insulation structure 10 comprises an internal sheet 1 and an external sheet 2 . An insulation layer 3 is between the internal 1 and external sheet 2 . A bar 4 extends through the insulation layer. A first end 4 a of each bar is welded to an internal surface (insulation side) of the external sheet 2 such that the bar is perpendicular to the external sheet. The opposite end 4 b of the bar extends through a hole in the internal sheet 1 . The opposite end 4 b is threaded and receives a nut 6 that with a washer 7 secures the internal sheet to the bar. Several bars, nuts and washers are arranged in the insulation structure and hold together the assembly of the internal sheet, insulation layer and external sheet.
[0022] FIG. 2 illustrates the conventional thermal acoustic sheet assembly 10 with an internal sheet 1 and an external sheet 2 . An insulation layer 3 is between the sheets 1 , 2 . Bars 4 extend partially through the insulation layer and are fitted to a support plate 5 between the sheets. The support plate 5 may be a flat plate extending through the insulation layer and oriental perpendicularly to the internal and external sheets. The support plate 5 is parallel to other support plates in the sheet assembly. The support plates are at regular intervals across the width of the insulation structure. The support plate has a straight edge 5 a adjacent the internal sheet. The opposite edge of the support plate includes V-shaped cuts and feet 5 b between the cuts. The feet 5 b are welded to an internal surface (insulation side) of the external sheet 2 .
[0023] One end 4 a of each bar 4 is welded to one of the plates 5 above the V-shaped cuts in the plate. The opposite end 4 b of each bar is aligned with and extends through a hole in the internal sheet 1 . Nuts 6 engage threads on the end 4 b. Annular washers 7 are fitted on the end 4 b on opposite sides of the internal sheet. The washers and nut secure the bar and the plate to the internal sheet. The nuts and washers engage the threaded end 4 b of the each bar such that the internal sheet compresses the insulation layer 3 .
[0024] The side of the internal sheet 1 opposite to the insulation layer is exposed to hot gases discharged from the rotary machine. Because the threaded ends 4 b of the bars 4 extend through the internal sheet, the ends of the bars are exposed to the hot gases. Heat from the hot gases conducts through the internal sheet, the bars and into the metal support plates 5 . The conducted heat through the bars and support plates allows heat to flow past the insulation layer 3 and conduct heat into the external sheet. The conduction of heat through the support plate forms a thermal bridge through the insulation layer that reduces the effectiveness of the insulation layer in suppressing the transfer of heat from the hot exhaust gas to the external sheet and to the ambient air environment beyond the insulation structure 10 .
[0025] FIG. 3 illustrates a first embodiment a thermal-acoustic sheet assembly 20 for ducting exhaust gas from a rotary machine to a HRSG or other system. The elements of the structure 20 that are similar to elements of the conventional insulation structure bear the same reference numbers.
[0026] The thermal-acoustic sheet assembly 20 includes one or more internal sheets 1 each having a surface exposed to the hot gases discharged from the rotary machine and one or more external sheets 2 each having a side exposed to ambient air. An insulating layer(s) 3 , such as an insulating mattress, is sandwiched between the internal and external sheets 1 and 2 . The internal and external sheets may be substantially parallel to each other, such as within five degrees of parallel. The materials and structure of the insulation layer 3 may be conventional and are not show so that the details of the connecting bars may be illustrated.
[0027] Bars 22 may be arranged in a regular pattern and at regular distances in the thermal acoustic sheet assembly 20 . The bars 22 provide structural support for the thermal acoustic structure, such as providing the separation between the internal and external sheets and a compression of the insulation layer. The bars may be metal rods and formed steel or stainless steel for example. The bars may be threaded along their entire length or threaded just at their ends. FIG. 3 shows the end sections 22 a and 22 b of the bar but does not show the middle section of the bar as the middle section is not necessary for the description of the invention. The entire length (L) of the bar extends from one end 22 a to the other end 22 b of the rod.
[0028] The bars may extend the thickness of the thermal acoustic structure 20 and extend entirely through the insulation layer 3 . The bars 22 may be oriented substantially perpendicular to the internal and external sheets, such as within ten degrees of perpendicular.
[0029] The bars 22 are separated from the external sheet 2 by an insulated support element 24 . The insulated support element supports the end 22 a of the bar 22 . The insulated support element 24 is fixed to the external sheet. The insulated support element 24 provides the junction between the bar 22 and the external sheet 2 .
[0030] The bar 22 is not in direct contact with the external sheet 2 . The lack of direct contact and the insulation in the insulated support element 24 prevents thermal conduction heat transfer from the bar 22 to the external sheet 2 . Because there is only minimal thermal conduction at the junction between the junction between the bar and support element, the amount of heat transferred from the bars to the external sheet is substantially reduced, such as by 70 to 90 percent or more, as compared to the heat transfer if the bar was directly connected to the external sheet or a support plate.
[0031] An insulated support element 24 is at the end 22 a of each bar 22 . The insulated support element may include a U-shaped bracket 26 that extends the length of the thermal acoustic structure 20 along a direction parallel to the exhaust gas flow. The U-shaped bracket 26 may also be configured as a platform for a single bar 22 . The U-shape of the bracket 26 refers to a cross sectional shape of the bracket which appears as an upside down U. The cross section shape may have other shapes, such as an O, L or C shape.
[0032] The U-shaped bracket 26 is fixed to the insulation side of the external sheet 2 . The U-shaped bracket 26 has legs 28 that are welded to the external sheet 2 , such as by a fillet weld 30 . The legs may or may not directly contact the surface of the external sheet. A slight separation between the legs and the external sheet assists in suppressing heat transfer. The fillet weld 30 may create the separation between the legs and external sheet.
[0033] A bridge portion 32 of the U-shaped bracket 26 is spaced by the length of the legs 28 from the external sheet 2 . The bridge portion 32 may be welded to the legs 28 to form the U-shaped bracket 26 . The bracket may also be formed by bending a band of metal to form the legs with the bridge on either side of the legs. The bracket may also be formed from a metal piece having a U-shape cross section. The legs 28 may form a ninety degree angle with respect to the bridge. The angle between the legs and bridge may be greater or smaller than 90 degrees such that the legs splay outward of the bridge or are canted inward of the bridge. The angle between the leg and bridge may be between 45 to 135 degrees.
[0034] The bridge portion includes a circular opening 34 sized to receive an insulated washer 36 . The washer 36 is annular and has a center aperture to receive the bar 22 . The washer is an annular disc positioned on one side of the bridge 32 and may include a rim covering the perimeter of the opening 34 . A second washer 38 covers an opposite side of the bridge. Both washers 36 , 38 are centered on the opening 34 in the bridge. Alternatively, the washers 36 , 38 is on an opposite side of the bridge. The washers 36 , 38 separate the metal nut or nuts 40 , 41 on the end 22 a of the bar from the metal of the bridge 32 .
[0035] The washers 36 , 38 provide a thermal barrier to prevent heat conduction between the nuts and the bridge. An inner insulating cylindrical rim of the washer 36 prevents heat conduction between the bar 22 and the bridge. The washers 36 , 38 are formed of a material having a low heat transfer coefficient material such as non-metal material. The washers may be formed of a ceramic, fiber glass reinforced composite or Polytetrafluoroethylene (PTFE). The washers may also be formed of a metal coated with an insulation layer. The washers provide a thermal barrier between the metal of the bar 22 and nuts 40 and the metal of the bracket 26 . The washers 36 , 38 may also be embodied as a brushing that seats in the opening 34 .
[0036] The nuts 40 , 41 such as hex nuts, engage the threads of the end 22 a of the bar 22 . The nuts fasten the bar 22 to the U-shaped bracket. The nuts 40 , 41 are on opposite sides of the bridge portion 32 of the U-shaped bracket such that the bridge is clamped between the nuts. The torque applied to the nuts is sufficient to secure the nuts and bars to the U-shaped bracket without damaging the insulation of the washer 36 . The washer may be held under compression by the nuts. The upper nut 40 may be welded 42 to the bar 22 after a desired amount of torque is applied to the nut. The lower nut 41 may be secured against rotation on the bar by an annular plate or stub 44 that receives the nut and is welded 46 to one or both of the legs 28 . The weld 42 to the upper nut may be applied after the lower nut is secured against rotation.
[0037] Exemplary dimensions of the insulated support element 24 include a diameter of the washers 36 , 38 being 20 millimeters (20 mm) and in a range of 15 mm to 25 mm. A gap 48 between the lower end of the bar 22 a or lower surface of the nut 40 is in a range of 3 mm to 15 mm. The gap 48 provides insulation due to the air gap between the lower surface of the nut or bar and the external sheet or support plate. The gap may also allow for expansion and contraction of the length of the bar 22 and prevent the bar from expanding into contact with the external sheet.
[0038] The opposite end 22 b of the bar is secured to the internal sheet 1 . The end 22 b extends through an opening 50 in the internal sheet 1 . The opening 50 may have a diameter of 5 to 50 mm, and have sufficient clearance from the bar to permit variations in the thermal expansion and contraction of the sheet and bar. A washer 52 is welded to the bar and forms a flange that engages an insulation side surface of the internal sheet. The threads of the end 22 b engage a nut 54 that secures the bolt 22 to the gas exposed surface of the internal sheet.
[0039] There is no support plate shown in the embodiment shown in FIG. 3 . A support plate may be included in another embodiment of the thermal acoustic sheet assembly. The support plate may be connected along one edge to the internal sheet and along an opposite edge to bars. The bars would connect the U-shaped bracket fixed to the external sheet.
[0040] FIG. 4 is a side view of an alternative embodiment of a thermal acoustic sheet assembly 60 that includes an internal sheet(s) 1 , an external sheet(s) 2 and an insulation layer 3 . The same reference numbers have been used to identify the components of the thermal acoustic structure 60 that are similar to the components of the other thermal acoustic structure 20 .
[0041] The thermal acoustic structure 60 includes a second nut 62 that engages the end 22 b of the bar 22 and the internal sheet 1 . The second nut 62 is used in place of the washer welded to the bar shown in FIG. 3 . A washer 52 may be between either or both of the nuts 54 , 62 and the internal sheet. The two nuts 54 , 62 secure the bar 22 to the internal sheet such that the sheet may not slide with respect to the bar. The two nuts also provide a means to adjust the distance between the internal and external sheets. This adjustment also is used to set a compression on the insulation layer.
[0042] The U-shaped bracket 26 is seated on an insulation layer 64 on the external sheet 2 . The insulation layer may be formed of a material have a low heat transfer coefficient such as a ceramic, fiber glass reinforced composite or Polytetrafluoroethylene (PTFE). The insulation layer 64 may also be positioned in the gap between the end of the nut 41 and the external sheet 2 . The insulation layer may be relatively thin, e.g., 2 mm to 4 mm between the legs 28 and the external sheet, and be relatively thick, e.g., 3 mm to 5 mm, between the nut 41 and the external sheet.
[0043] A signal nut 41 may secure the end 22 a of the bar to the U-shaped bracket 26 . The single nut is below the bridge 32 and is held in place by the bridge, threaded end 22 a and insulation layer 64 . The nut 41 is prevented from rotation by the plate or stub 44 welded to the U-shaped bracket. A washer 66 separates the nut 41 from the U-shaped bracket to prevent conduction of heat between the nut and the bracket. The washer has a low heat transfer coefficient and may be formed of materials such as a ceramic, fiber glass reinforced composite or Polytetrafluoroethylene (PTFE). The washer 66 may also include an annular rim that covers the inner perimeter of the opening 34 in the bridge and separates the bridge from the bar.
[0044] FIG. 5 is a side view of the thermal acoustic structure 60 show from a view parallel to the length of the U-shaped bracket 26 . In this embodiment, the U-shaped bracket 26 extends the length of the thermal acoustic structure 60 . The bars 22 are arranged at regular intervals along the length of the U-shaped bracket 26 . The brackets 26 may be arranged parallel to each other across the width of the structure 60 and in a direction parallel to the exhaust gas flow.
[0045] The insulation layer 3 is sandwiched between the internal and external sheets 1 and 2 . The insulation layer covers the external sheet 2 except where the U-shaped bracket covers the sheet. The insulation layer fits around the U-shaped bracket but need not be within the bracket.
[0046] Unlike the embodiment shown in FIG. 4 , the embodiment shown in FIG. 5 does not have an insulation layer that extends the length of the U-shaped bracket and fits between the legs of the bracket and external sheet. In the embodiment shown in FIG. 5 , an insulation pad 68 is between the nut 62 and the external sheet 2 . The insulation pad may be inserted through a slot 70 in one or both of the legs 28 of the U-shaped bracket. The slot is adjacent the end 22 b of the bar. The insulation pad has a low heat transfer coefficient and may be formed of mineral fibers, glass fibers, bio-soluble fibers, PTFE or rock wool.
[0047] The thermal acoustic structure 60 may be connected at one end to an expansion joint 80 which is connected to a gas discharge 82 of a rotary machine such as a stationary gas turbine. The thermal acoustic structure may be assembled with other similar structures to form an exhaust duct defining a gas passage 84 through which flows the exhaust gas from the rotary machine. The gas passage may have a cross section that is circular, oval, rectangular or other entirely curved, curvilinear or straight sided shape.
[0048] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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A thermal acoustic insulation structure including: a metal internal sheet having an exposed surface configured to be exposed to a hot gas, an external sheet and an insulation sandwiched between the internal and external sheets; a bar secured to the metal internal sheet and extending through at least a portion of the insulation; a bracket connected to the external sheet or to a support plate extending from the external sheet, wherein the bracket includes an opening configured to receive an end of the bar; a fastener securing the end of the bar to the bracket, and an insulating washer separating the bracket from the bar and the fastener.
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TECHNICAL FIELD
[0001] The present disclosure in one or more embodiments relates to an intelligent heating cable providing smart heating and a method of manufacturing the same. More particularly, the present disclosure relates to an intelligent heating cable providing smart heating, wherein an optical cable sensor is embedded in a heating cable of a heat tracing system such that the heating cable has a function of sensing the temperature of the system to minutely measure the temperature of a portion difficult to sense temperature in the system and thus to properly control the output of the heating cable, thereby reducing unnecessary energy consumption or preventing damage to the heating system due to insufficient supply of heat, and a method of manufacturing the same.
BACKGROUND
[0002] In general, a heat tracing system is used to compensate for heat loss caused from a facility or an object, such as a pipe or a tank, or to supply a uniform amount of heat to the object, thereby preventing the object from being frozen to burst or uniformly maintaining the temperature of the object. In addition, the heat tracing system prevents frost from forming on a concrete slab or to remove snow from a road or is installed as an indoor floor heating system.
[0003] In the heat tracing system, a heating cable serves to supply heat necessary for the object having the system installed. The heating cable is constructed to have a multi-layer structure including a heating element for generating heat, insulation for protecting the heat element, and an outer jacket. In the heat tracing system, the heating cable is operated based on a temperature measured from the system or the object. For example, in order to prevent a pipe or a tank from being frozen to burst, the heat tracing system is powered on to supply heat to the pipe or the tank through the heating cable when the measured temperature of the system is lower than a reference temperature used as the critical temperature at which the pipe or the tank is prevented from being frozen to burst.
[0004] When the measured temperature exceeds the reference temperature, the heat tracing system is powered off to interrupt the operation of the heating cable, thereby reducing unnecessary energy consumption. In case the heating cable is installed to maintain the temperature of the pipe or the tank, if the measured temperature exceeds the upper limit of a predetermined temperature range to maintain, the heating cable is powered off to interrupt the supply of heat. On the other hand, if the measured temperature goes below the lower limit of the temperature range, the heating cable is powered on to supply heat to the object. This operating principle of the heating cable also applies to a heating cable used to prevent frost or freezing or to heat a room.
[0005] In order to efficiently and properly operate the heating cable in the heat tracing system, the heating cable need to be suitably designed considering the heating capacity and the temperature of the system need to be accurately measured in timely manner.
[0006] A conventional heating cable includes a heating element, insulation for protecting the heating element, and an outer jacket. Power supplied to the heating cable is controlled based on changes in temperature sensed by an external temperature sensor to properly adjust the output of the heating cable. Since the temperature necessary to control the power supplied to the heating cable is measured by a temperature sensor mounted at an object, such as a tank or a pipe, the position of the sensor is critical.
[0007] In a conventional heat tracing system, a sensor for measuring the temperature of the system is usually mounted at a point representing the temperature of the system or a point where the system is exposed to the harsh conditions. The measured temperature is a reference used to control the operation of the heating cable or basic data used to check the condition of the system. For this reason, measurement of the temperature of the system is critical in efficient operation of the system and, therefore, it is reasonable and appropriate to measure temperatures of the system at various points of the system and to operate the system based thereupon.
[0008] Since, in most cases, the temperature sensor is mounted at one point, such as a point representing the temperature of an object or a point exposed to harsh conditions, the temperature sensor is unable to present the overall temperature of the object.
[0009] Although the described conventional method may provide a simple construction of the system, it does not contemplate to measure the temperature of the entire object but a single selected point which is then assumed to be the overall temperature as a basis for controlling the systems. By doing this, a simple and convenient measurement of temperature can be achieved, while the overall temperatures of the object cannot be provided. In case, however, it is necessary to control the heat supply based upon a precise measurement of the temperature of an object, conventional methods are ineffective in providing such proper control.
[0010] In case the object has an uneven temperature profile, sensors cannot be deployed at all points to measure the temperatures of the object. Consequently, it may be inefficient and improper to adjust thermal capacity of the heating cable based on the temperatures measured at limited number of points.
[0011] It costs a great deal to deploy sensors at multiple points of the heat tracing system and to measure temperatures at the points of the heat tracing system. In addition, it is highly costly for the temperature of the entire system to be accurately measured.
DISCLOSURE
Technical Problem
[0012] Therefore, the present disclosure has been made in an effort to effectively resolving the above-described limitations and provides a heating cable combined with an optical cable sensor. The heating cable is capable of measuring the temperature of the heating cable itself, which cannot be achieved by a conventional heating cable. Consequently, the present disclosure provides an intelligent heating cable providing smart heating and self diagnosis of a system in addition to efficient supply of heat and a method of manufacturing the same.
SUMMARY
[0013] In accordance with some embodiments of the present disclosure, an intelligent heating cable, for use in a heat tracing system, comprises a heating element and an insulating layer formed at an outer surface of the heating element. The heating cable has a hybrid construction in which an optical cable as a sensor is combined with the heating cable.
[0014] The heating element may be any one selected from among a polymeric heating element exhibiting positive temperature coefficient of resistance (PTC) characteristics, the polymeric heating element generating heat using electrical energy, a metallic resistance alloy conductor and a copper conductor.
[0015] The polymeric heating element may contain, in a polymeric material constituting the heating element, any one selected from carbon black, metal powder, and carbon fiber, as a conductive material to exhibit electrical conductivity.
[0016] The metallic resistance alloy conductor may contain any one selected from among copper-nickel, nickel-chrome, and iron-nickel as a main ingredient.
[0017] The copper conductor may comprise any one selected from among unplated copper, tin-plated copper, silver-plated copper and nickel-plated copper.
[0018] The optical cable may be made of optical fiber, such as glass optic fiber or plastic optic fiber.
[0019] In accordance with some embodiments of the present disclosure, a method for manufacturing an intelligent heating cable comprises forming by using extrusion molding, on an outer surface of a heating element of a heating cable, insulation constructed to protect the heating cable; combining an optical cable sensor functioning as a temperature sensor on the insulated heating element; fixing the optical cable sensor to the insulated heating element through copper wire braiding or cotton braiding, and extruding an outer jacket and performing a post-treatment process.
Advantageous Effects
[0020] According to the present disclosure as described above, an intelligent heating cable providing a smart heating is used to thereby considerably improve the energy efficiency of a heat tracing system. In addition, an unexpected serious danger, such as fire or explosion, which may be caused to the system by the heating cable during use of the heating cable, is monitored. Furthermore, change in performance of the heat tracing system, which may occur in the heating cable installed in the heat tracing system, is monitored in real time, thereby improving and guaranteeing stability of the heat tracing system.
[0021] According to the present disclosure as described above, an optical cable is used as a sensor to measure change in temperature of the heating cable and the surroundings using the optical cable in real time and to accurately monitor the change in temperature and temperature distribution over the entire area, in which the heating cable is placed. Due to such smart heating, the temperature of a portion where temperature sensing is not easy in the heat tracing system may be minutely checked to thereby efficiently supply an amount of heat necessary for a facility and reduce energy consumption.
[0022] Since change in temperature of the entire area of the heating cable is monitored in real time, the present disclosure as described above provides convenient check of the operation of the heating cable at any time. Abnormality which may occur in the system in which the heating cable is placed due to unexpected internal and external situations or a degradation phenomenon which may gradually occur over time may be observed and resolved based on change in temperature over time. Furthermore, an abnormal point is accurately checked and repaired to thereby achieve easy repair and further reduce repair costs.
[0023] The intelligent heating cable having such a self temperature measurement function according to the present disclosure has the following effects, which cannot be provided by a conventional heating cable.
[0024] 1. Change in temperature and temperature distribution of the entire system can be accurately checked in real time;
[0025] 2. Efficient energy saving can be achieved;
[0026] 3. An abnormal point caused due to an excessive amount of heat or an insufficient amount of heat can be accurately observed; and
[0027] 4. Such an abnormal point can be easily found, thereby reducing repair costs.
[0028] Meanwhile, according to the present disclosure as described above, the temperatures of a facility and the entire heating cable can be measured in real time in addition to the smart heating, thereby optimizing energy efficiency of the heat tracing system. In addition, the present disclosure as described above has the advantageous effect of monitoring whether the heat tracing system is abnormal in real time by tracing the change in temperature of the heating cable.
DESCRIPTION OF DRAWINGS
[0029] FIG. 1 is a schematic diagram showing a construction of a heat tracing system having an intelligent heating cable providing smart heating according to at least one embodiment of the present disclosure mounted therein;
[0030] FIG. 2 is diagram showing a construction of a heating cable providing smart heating according to at least one embodiment of the present disclosure;
[0031] FIG. 3 is diagram showing the measurement results of temperature over the entire length of a heating cable using an intelligent heating cable providing smart heating according to at least one embodiment of the present disclosure;
[0032] FIGS. 4 to 6 are diagrams illustrating types of an intelligent heating cable providing smart heating according to at least one embodiment of the present disclosure; and
[0033] FIGS. 7 and 8 are schematic diagrams of measurement apparatuses used in at least one embodiment of the present disclosure.
DESCRIPTION OF REFERENCE NUMERALS
[0034]
[0000]
10, 20, 30, 40, 70: Heating cables
21, 32, 41: Heating elements
23, 33, 43: Optical cable sensors
50: Temperature controlled unit
60: Water bath
80: Temperature controlled chamber
DETAILED DESCRIPTION
[0035] The present disclosure provides a new heating cable having a hybrid construction in which an optical cable sensor is combined in the heating cable to measure the temperature of a system having the heating cable mounted therein using the optical cable sensor as well as to generate heat, thereby performing efficient and proper operation based on the measured temperature.
[0036] FIG. 1 is a schematic diagram showing a construction of a heat tracing system having an intelligent heating cable providing smart heating according to at least one embodiment of the present disclosure mounted therein. FIG. 1( b ) is a diagram showing a construction of a heat tracing system according to at least one embodiment of the present disclosure and FIG. 1( a ) is a diagram showing a construction of a conventional heat tracing system to compare with the heat tracing system according to the embodiment of the present disclosure.
[0037] As shown in FIG. 1 , in a new heat tracing system, in which a heating cable according to at least one embodiment of the present disclosure is installed, the heating cable 10 itself functions as a temperature sensor. Consequently, the temperature sensor can be mounted and temperature can be measured at any point of the heating cable 10 , thereby accurately locating a weak portion in the system.
[0038] Consequently, the operation of the heating cable can be controlled based on the weak portion in the system to achieve both the efficient operation and the energy saving of the system.
[0039] In FIG. 1( b ), reference symbol A indicates a temperature measurement area and B indicates a weak portion in the system.
[0040] In an example of a conventional heat tracing system, as shown in FIG. 1( a ), temperature is measured at a point 5 where a temperature sensor is mounted. However, this point 5 may be different from a weak portion 3 . In a case in which the point 5 , where the temperature sensor is mounted, is different from the weak portion 3 , it is difficult to efficiently operate a heating cable 1 . Reference numeral 7 indicates a temperature measurement area.
[0041] FIG. 2 is diagram showing a construction of a heating cable providing smart heating according to at least one embodiment of the present disclosure.
[0042] As shown in FIG. 2 , the heating cable 10 providing smart heating according to the embodiment of the present disclosure has a function as a sensor for measuring temperature using change in optical signals transmitted via an optical cable 10 b which is combined with a heating cable 10 a. Consequently, the temperature of the entire system having the heating cable 10 a embedded therein can be continuously measured in real time. A typical example of such a temperature measurement function is shown in FIG. 3 .
[0043] FIG. 3 is a graph showing distribution of temperature measured using a heating cable providing smart heating according to at least one embodiment of the present disclosure.
[0044] As can be seen from FIG. 3 , temperature can be measured at all points of the heating cable and thus an accurate temperature distribution profile can be obtained. Consequently, the operation of the heating cable can be properly controlled using the temperature distribution profile.
[0045] Meanwhile, FIGS. 4 to 6 are diagrams illustrating types of a heating cable providing smart heating according to at least one embodiment of the present disclosure.
[0046] FIG. 4 is a diagram illustrating intelligent heating cables using a polymeric heating element exhibiting positive temperature coefficient of resistance (PTC) characteristics.
[0047] FIG. 5 is a diagram showing intelligent heating cables using a heating element made of a metallic resistance alloy conductor.
[0048] FIG. 6 is a diagram showing an intelligent heating cable using an alloy conductor or a copper conductor as a heating element.
[0049] In the heating cables 20 and 20 ′ providing smart heating of FIG. 4 , reference numeral 21 indicates a polymeric heating element exhibiting PTC characteristics and reference numeral 23 indicates an optical cable sensor.
[0050] In the heating cables 30 and 30 ′ providing smart heating of FIG. 5 , reference numeral 31 indicates a heating element made of a metallic resistance alloy conductor and reference numeral 33 indicates an optical cable sensor.
[0051] In the heating cable 40 providing smart heating of FIG. 6 , reference numeral 41 indicates a heating element made of a metallic resistance alloy conductor or a copper conductor and reference numeral 43 indicates an optical cable sensor.
[0052] As illustrated in the above drawings, the heating cable providing smart heating according to the embodiment of the present disclosure can be formed using various heating elements, such as a polymeric heating element, a heating element made of a metallic resistance alloy conductor, and a heating element made of a copper conductor.
[0053] Hereinafter, a process of manufacturing an intelligent heating cable providing smart heating according to at least one embodiment of the present disclosure will be described.
[0054] The heating cable is manufactured through the following processes.
[0055] An insulation is formed on an outer surface of a heating element of a heating cable for protecting the heating cable by extrusion molding. The heating element used herein may include any one selected from among heating elements designed for special purposes, such as a polymeric heating element exhibiting PTC characteristics, a heating element made of a metallic resistance alloy conductor, and heating element made of a copper conductor, as illustrated above.
[0056] An optical cable is combined on the insulated heating element, the optical cable functioning as a temperature sensor. Then, the optical cable sensor is fixed to the insulated heating element through copper wire braiding or cotton braiding.
[0057] An outer jacket is extruded upon completion of the braiding and post-treatment is performed to obtain a heating cable with smart heating feature.
[0058] Examples of temperature measurement on the heating cable using the heating cable having the polymeric heating element and the metallic resistance alloy conductor as mentioned above will now be described.
EXAMPLE 1
[0059] First, insulation was formed on a polymeric heating element exhibiting PTC characteristics by extrusion, an optical cable sensor was combined on the insulated heating element, the optical cable sensor was fixed through copper wire braiding, and an outer jacket was extruded to manufacture a test specimen of a heating cable.
[0060] The manufactured test specimen was placed in experiment facilities having different temperature zones as shown in FIG. 7 and the temperatures of the optical cable sensor were measured while changing temperatures at various portions of the test specimen and the output of the heating cable. The results are shown in Table 1 below.
[0000]
TABLE 1
Changes in temperature of heating cable having polymeric heating element
exhibiting PTC characteristics
Output (W/m)
18.6
Temperature
Atmospheric
Water bath
Atmospheric
controlled unit
conditioning
temperature
Reference
10.0
CH#1
CH#3
CH#6
CH#4
CH#5
temperature
(° C.)
Optical cable sensor
29.5
38.5
37.3
20.6
19.5
Thermocouple
29.4
38.2
37.9
13.6
18.9
Output (W/m)
16.4
Temperature
Atmospheric
Water bath
Atmospheric
controlled unit
conditioning
temperature
Reference
20.0
CH#1
CH#3
CH#6
CH#4
CH#5
temperature
(° C.)
Optical cable sensor
36.3
39.6
39.2
25.1
19.9
Thermocouple
34.7
38.1
38.6
17.8
20.7
Output (W/m)
15.3
Temperature
Atmospheric
Water bath
Atmospheric
controlled unit
conditioning
temperature
Reference
30.0
CH#1
CH#3
CH#6
CH#4
CH#5
temperature
(° C.)
Optical cable sensor
40.3
40.7
38.9
25.6
21.6
Thermocouple
39.8
39.8
38.5
18.5
21.5
Output (W/m)
14.8
Temperature
Atmospheric
Water bath
Atmospheric
controlled unit
conditioning
temperature
Reference
40.0
CH#1
CH#3
CH#6
CH#4
CH#5
temperature
(° C.)
Optical cable sensor
44.2
39.8
38.4
24.7
21.9
Thermocouple
45.5
39.3
38.1
18.1
21.3
Output (W/m)
13.6
Temperature
Atmospheric
Water bath
Atmospheric
controlled unit
conditioning
temperature
Reference
50.0
CH#1
CH#3
CH#6
CH#4
CH#5
temperature
(° C.)
Optical cable sensor
52.0
39.3
39.7
25.1
22.2
Thermocouple
52.0
38.6
39.6
18.3
21.9
EXAMPLE 2
[0061] Insulation was formed on a heating element made of a metallic resistance alloy conductor by extrusion, an optical cable sensor was combined on the insulated heating element, the optical cable sensor was fixed through copper wire braiding, and an outer jacket was extruded to manufacture a test specimen of a heating cable.
[0062] The manufactured test specimen was placed in a temperature controlled chamber having uniform air speed under a temperature atmosphere as shown in FIG. 8 and the temperatures of the optical cable sensor were measured while changing the temperature and output of the test specimen. The results are shown in Table 2 below.
[0000]
TABLE 2
Changes in temperature of heating cable using metallic resistance alloy
conductor as heating element
Reference
10.0
temperature (° C.)
Output (W/m)
0
20
25
30
35
40
45
50
55
60
70
Optical cable
10.6
23.7
27.1
31.5
34.1
37.3
41.2
46.9
48.3
53.3
59.1
sensor #1
Optical cable
10.5
23.9
27.0
31.7
34.2
37.5
41.5
46.8
48.2
53.4
59.2
sensor #2
Thermocouple #1
10.4
22.8
26.4
31.0
33.4
36.3
40.4
45.8
47.2
52.1
58.1
Thermocouple #2
10.4
22.6
26.4
30.9
33.3
36.3
40.3
45.2
47.0
50.9
57.3
Reference
5.0
temperature (° C.)
Output (W/m)
0
20
25
30
35
40
45
50
55
60
70
Optical cable
5.5
19.5
22.8
26.3
29.8
33.0
39.0
41.2
44.4
49.1
55.1
sensor #1
Optical cable
5.7
20.2
23.9
27.5
31.3
33.9
40.1
42.3
45.3
50.4
56.2
sensor #2
Thermocouple #1
5.4
18.4
22.0
25.4
29.2
32.1
38.1
40.8
43.9
48.3
54.0
Thermocouple #2
5.5
19.6
23.1
26.9
30.6
33.2
39.4
41.6
44.5
49.6
55.3
COMPARATIVE EXAMPLE 1
[0063] A thermocouple was attached to the surface of the test specimen of the heating cable of <Example 1> per temperature zone and temperature was measured in the same manner as in <Example 1>.
COMPARATIVE EXAMPLE 2
[0064] A thermocouple was attached to the surface of the test specimen of the heating cable of <Example 2> and temperature was measured in the same manner as in <Example 2>.
[0065] The test specimens of the heating cables mentioned in the examples and the comparative examples were placed in a test apparatus and the temperature of the system and the output of the heating cable were measured to evaluate performance of the respective test specimens.
[0066] FIGS. 7 and 8 are schematic diagrams of measurement apparatuses used for <Example 1> and <Example 2>.
[0067] For <Example 1> and <Comparative example 1>, as shown in FIG. 7 , the test apparatus has three zones having different temperature conditions, such as a temperature controlled unit 50 , a zone exposed to atmosphere, and a water bath 60 containing a predetermined amount of water. The temperature controlled unit 50 is an apparatus that circulates fluid at a uniform flow speed to maintain the temperature designed for testing. In the three zones of the test apparatus, the temperature of the optical cable sensor and the temperature of the thermocouple attached to the surface of the heating cable were measured in accordance with various conditions and they were compared.
[0068] For <Example 2> and <Comparative example 2>, as shown in FIG. 8 , a heating cable 70 was attached to a shelf in a zigzag pattern, the heating cable 70 was placed in a temperature controlled chamber 80 in which air is circulated at a uniform air speed, and the temperatures of the thermocouples attached to the surface 70 of the heating cable and temperatures measured by the optical cable sensor in the heating cable were compared under various conditions.
[0069] The output of the heating cable was calculated by changing voltage applied to the heating cable by using a transformer and measuring the current flowing through the heating cable.
[0070] [Measurement Results According to <Example 1>]
[0071] It can be seen that there is no difference between the measured temperature of the thermocouple mounted at the test specimen and the temperature measured by the optical cable sensor. Moreover, it is obvious that, when the temperatures of various portions of the test specimen are changed, the change in temperature of each portion is sensed with high precision by the optical cable sensor. It can be seen that distribution of change in temperature over the heating cable and the temperature of each point of the heating cable are measured with high precision by the optical cable sensor and displayed.
[0072] It can be seen that the temperature of the portion immersed in the water bath measured by the optical cable sensor is higher than that measured by the thermocouple. This is because the thermocouple measures the temperature of water in the water bath, whereas the optical cable sensor measures the temperature of the heating cable alone. This difference shows that, in actual temperature measurement, the optical cable sensor can more directly and minutely measure the temperature, and that temperatures measured depending upon the position of the sensor may be different from the actual temperatures.
[0073] [Measurement Results of <Example 2>]
[0074] It can be seen that, when comparing the measured values of the thermocouple and the optical cable sensor, changes in temperature of the heating cable caused in accordance with the change in output of the heating cable are equal to each other. In an actual situation, continuous temperature distribution appearing in the longitudinal direction of the heating cable can be seen in detail based on the measured value of the optical cable sensor. This continuous temperature distribution cannot be obtained using thermocouples.
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According to the present disclosure, a heating cable has a hybrid construction in which an optical cable sensor is coupled to the heating cable to achieve the function of a sensor for sensing the temperatures of both an object and the heating cable so as to provide an active heating supply source capable of adjusting the output of the heating cable in accordance with temperature variations. To this end, an intelligent heating cable of the present disclosure provides smart heating for use with a heat tracing system. The cable comprises a heating element and an insulating layer formed on an outer surface of the heating element and features an optical cable combined as a temperature sensor.
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This invention relates to the calibration of electronic devices. It is particularly suitable for, but by no means limited to, fast calibration of transceiver devices.
RELATED APPLICATION
This application claims priority under 35 U.S.C. §119 or 365 to European Application No. 14306760.1, filed Nov. 4, 2014. The entire teachings of the above application are incorporated herein by reference.
BACKGROUND
Most analog and RF transceivers ICs suffer from tolerances and part-to-part performance variation that require calibration of each device. Product calibration generally entails adjusting one or more tuning parameters whilst observing a particular performance metric and finding the tuning parameters values that yield device performance within the desired range.
Product calibration is typically performed as part of a wider product test implementation. The general setup for such a product test is shown in FIG. 1 .
The device under test (DUT) 10 receives test signals 11 from test equipment 12 or transmits signals 13 to test equipment 12 . Both DUT 10 and test equipment 12 are typically controlled 15 (including test setup) by a controller PC 14 or other controlling device such as a dedicated processing system which also collects 16 the measured data provided by the test equipment 12 and/or the DUT 10 .
In some cases a device being calibrated (DUT 10 ) comprises a controlling element. Furthermore, it is possible that the device being calibrated comprises one or more separate sub-systems that can mutually act as tested and testing sub-systems. For example, the receiver part of a transceiver IC may test the transmitter and vice-versa. In such cases auto-calibration may be possible and no explicit controller PC 14 or test equipment 12 may be needed. However, conceptually separate parts of the system may be associated as controlling element (e.g. PC 14 ), test equipment 12 and tested sub-system. All following discussions therefore include such architectures, however they may not all be present.
As is understood, testing and calibration, especially when reliant on external test equipment, adds to the overall product cost. The shorter the overall test and calibration time, the smaller the associated cost.
Typically, all calibration methods follow some kind of successive approximation scheme where starting from a single measurement or a series of measurements, the range of candidate tuning parameters is gradually reduced until the search converges on a set of tuning parameters that meet performance requirements.
In a successive approximation scheme, the controlling PC 14 first instructs the DUT 10 to execute a test using an initial set of tuning parameters and it also instruct the test equipment 12 to collect results based on this initial parameter set. Once measurements have been carried out, the results are returned to the controlling unit 14 . The controlling unit then checks if the pre-determined desired performance has been met or selects a new set of tuning parameters for a second measurement cycle if the desired performance has not been met. The new set of tuning parameters is chosen based on the previously obtained measurement values. They are not known a priori.
Such iterative schemes normally converge after a few steps. An example can be found in U.S. Pat. No. 7,369,813. Here, an algorithm is described using an example of the calibration of carrier leakage of a wireless transmitter. Carrier leakage describes an unwanted spectral component at the centre of the transmit channel associated with direct-conversion transmitters. In nearly all implementations, carrier leakage is observed due to small mismatches in the analog and RF circuits performing the up-conversion from baseband signal onto the carrier wave signal. The calibration is conceptually simple. Two tuning parameters (referred to as x and y in the following), are added into the signal path, one to the in-phase signal component and one to the quadrature component as would be understood. One particular combination of the two parameters leads to cancellation with the component originating from circuit imperfections and hence a desired performance.
U.S. Pat. No. 7,369,813 proposes a way to quickly converge on the optimum set of tuning parameters. However, the method is iterative: the parameters chosen in a measurement depend on the choice of previous parameters and the measured carrier leakage.
The disadvantage of such iterative schemes is that the communication between controlling PC 14 , test equipment 12 and DUT 10 can dominate the overall calibration time. While the actual measurement of a spectral component can be very fast (e.g. one millisecond), the overall turn-around time between setting up a test, triggering the measurement, collecting the results and processing it can often be much longer (e.g. 100 milliseconds).
A major contributor to calibration time is typically the time taken to setup 15 both test equipment 12 and DUT 10 and to collect results 16 . Minimizing the number of setup and data collection cycles reduces calibration time and reduces overall cost.
There is therefore a need to minimise the setup and data collection times.
SUMMARY
According to a first aspect there is provided a computer implemented method of calibrating a device as defined in claim 1 of the appended claims. Thus there is provided a method comprising the steps of deriving an analytic expression for a variable to be optimised of the device in terms of at least one parameter of the device, transforming the analytic expression into polynomial form of the at least one parameter of the device, the polynomial form comprising N coefficients, capturing at least N samples of a value of the variable from the device under calibration, each sample being a result of a different independent pre-determined value of the at least one parameter, applying the captured variable values and the corresponding at least one parameter values to the polynomial form, obtaining optimal values of the at least one parameter from the applying step to calibrate the device.
Optionally, the method wherein the pre-determined parameter values are derived from a sub-region of the normal operating region of the parameter values of the device to be calibrated.
Optionally, the method wherein the sub-region is based on characteristics and/or a desired performance of the device to be calibrated.
Optionally, the method wherein the number of samples to be captured is more than the number of coefficients in the polynomial expression.
Optionally, the method wherein pre-determined parameter values are chosen so that noise intrinsic to the individual samples is averaged such that the polynomial form provides a curve fit when more than N samples are captured.
Optionally, the method wherein the capturing step is performed in one scan of the parameter values.
Optionally, the method wherein the capturing step comprises:
instructing the device to operate with the at the least one parameter set at a pre-determined value; capturing a sample of a value of the variable from the device as a result of the instructing step; and repeating the instructing and capturing steps until N samples have been captured, each sample being a result of a different independent pre-determined value of the at least one parameter;
Optionally, the method wherein the instructing, capturing and repeating steps are performed in one scan of the parameter values.
Optionally, the method wherein the pre-determined values of the at least one parameter provide independent data points.
According to a second aspect there is provided a computer readable medium as defined in claim 10 . The computer readable medium comprising instructions that when executed by a processor cause the processor to carry out any of the methods described herein.
According to a third aspect there is provided a processor as defined in claim 11 . The processor being arranged to carry out any of the methods described herein.
According to a fourth aspect there is provided a computer program. The computer program comprising instructions that when executed by a processor cause the processor to carry out any of the methods described herein.
According to a fifth aspect there is provided an apparatus. The apparatus comprises at least one processor and at least one memory, wherein the at least one memory stores computer-executable instructions which, when executed by the at least one processor, cause the apparatus to perform any of the methods described herein.
With all the aspects, preferable and optional features are defined in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments will now be described, by way of example only, and with reference to the drawings in which:
FIG. 1 illustrates a general setup for product calibration according to known systems;
FIG. 2 illustrates a parameter space spanned by x and y parameters and a sub-region where measurements are taken according to an embodiment;
FIG. 3 illustrates communication flow between controlling unit 14 , DUT 10 and test equipment 12 when a test sequence is run on the DUT; and
FIG. 4 illustrates a method of calibrating a device according to an embodiment.
In the figures, like elements are indicated by like reference numerals throughout.
Overview
The method of calibration discussed herein exploits the fact that the functional dependency between the measured performance value (e.g. carrier leakage) and the tuning parameters (e.g. x and y) is often known. The example of transmitter (the device to be calibrated) carrier leakage calibration falls into a class of calibration routines where the measured quantity (carrier leakage, P unwanted ) has a simple square-law relationship with the tuning parameters:
P unwanted =α·[( x−x opt ) 2 +( y−y opt ) 2 ]+P n , (1)
where x and y represent the tuning parameters (I and Q DC offsets as would be understood for transmitter carrier leakage), x opt , y opt the optimum settings that minimize P unwanted . In the example, P unwanted is the power at the carrier. P n denotes random measurement noise or a measurement floor caused by unrelated effects (e.g. second-order distortion).
Other examples that follow this particular square-law include transmitter IQ imbalance calibration, receiver IP 2 calibration (2 nd order calibration) but also many measurements where the unwanted power is measured in terms of Error Vector Magnitude (EVM, generalized noise power over signal power). For example, in envelope tracking systems, it is essential to calibrate both the relative time delay between transmit signal and power amplifier (PA) supply signal as well as the relative gain. As delay (x) and gain (y) are swept, the EVM at the PA output is measured. At the optimum delay and gain settings the EVM is minimized, and around the optimum setting EVM exhibits a parabolic profile in both delay and relative gain parameters in the same way as described in equation (1).
In overview, and as illustrated in FIG. 4 , the method of calibration comprises capturing a problem to be solved (calibration to be carried out) in an analytic expression which in effect, relates the variable to be optimised (minimised or maximized), e.g. unwanted power, to independent tuning parameter(s) of a device. The method may be implemented on a computer or other processing device. At step 40 , an analytic expression is derived that relates the variable to be optimised to tuning parameter(s) of the device. This expression is often known as it describes the intended effect the tuning parameters have on the functionality of the device.
At step 41 , the analytic expression is transformed to take a polynomial form of the (independent) tuning parameter(s). This may involve a non-linear mapping of the quantity to be optimized or of a tuning parameter. For example, the unwanted power measured by test equipment may be in returned in units of dbm (a logarithmic scale) to the controlling unit but a polynomial form may only be obtained by converting the power to Watts (a linear scale). The resulting polynomial is expressed as having N number of independent coefficients.
The number of coefficients present in the polynomial is the minimum number of samples, N, of the variable to be measured that are needed to construct the polynomial and deduce the optimum values of the tuning parameters to provide the desired calibration of the device. Each sample y i , i=1 . . . N, of the variable to be calibrated is sampled at different tuning parameter values. As will be explained later, the N mutually different tuning parameter values used are preferably arranged to probe the variable to be optimised in all dimensions. Hence, at step 42 , at least N samples of the variable to be optimised are captured from the device under calibration, each sample being produced by different tuning parameter values. The tuning parameter values may be pre-determined. The N number of samples may be captured in one scan of the tuning parameter values i.e. without any iteration and without any dependency of subsequent tuning parameters on previously obtained measurements. The capturing of the samples may comprise instructing the device to operate with the at the least one parameter set at a pre-determined value, capturing a sample of a value of the variable from the device as a result of the operating step, and repeating the instructing and capturing steps until N samples have been captured, each sample being a result of an independent pre-determined value of the at least one parameter.
The N samples are preferably captured using tuning parameter values pre-determined from within a sub-region of the overall operating space of the device to be calibrated (explained further later). Hence, at an optional step, a sub-region of parameter values to be used may be derived based on characteristics and/or a pre-determined desired performance of the device to be calibrated. The set of pre-determined tuning parameters preferably span a region of the parameter space wide enough for the measurements to be sufficiently different from one another to be robust against measurement noise. The parameter set preferably explores all dimensions of the parameter space.
At step 43 , subsequent to the capture of the samples of the variable to be measured, the values of the measured variable and the corresponding tuning parameter(s) used are applied to the re-arranged polynomial form from step 41 . Optionally, one or more of the polynomial's coefficients may be computed.
At step 44 , the optimal values of the tuning parameter(s) are derived from the polynomial form. Iteration is not required.
The optimal values of the tuning parameter(s) derived at step 44 may be used to form the basis of calibrating the device and all similar devices. The calibration process can be completed with only one scan of the tuning parameters which reduces time to calibrate by way of reducing the number and frequency of setup instructions that must be sent to the controller 14 , test equipment 12 and DUT 10 during the taking of measurements in order to calibrate the DUT.
The method also can be used if the functional dependence of the undesired component has a different form i.e. does not exhibit a square-law relationship with tuning parameters. The method may be applied to any other polynomial law with any number of tuning parameters (multi-dimensional parameter space). Furthermore, exponential, logarithmic and power-law relationships can often be mapped to polynomial form and can also benefit from the method described herein. For example, where the relationship between tuning parameters and measurement to be optimised is an exponential relationship, the log of the raw measurements obtained from the N samples of tuning parameters may be used as input variables to the polynomial to be solved, in other words the raw measurements may be manipulated and/or transformed before being used as input variables to the polynomial expression.
If more than the minimum of N samples of the variable to be calibrated are sampled, then increased noise rejection is obtained as would be understood resulting in a more accurate derivation of optimal tuning parameter values.
Mathematically speaking, the polynomial form can be obtained from N samples by means of polynomial interpolation. In that case the polynomial will follow the measured data points including any noise exactly. If more than N measurements are used, the polynomial will not necessarily follow all data points but provide the best curve fit to the data samples. The technique of finding the polynomial that best approximates the data points is known as polynomial regression. Polynomial interpolation may be viewed as a special case of polynomial regression. The advantage of polynomial regression is that measurement noise can be suppressed by using all measurements in the estimation procedure. In some cases this may allow use of simpler test setup or lower cost test equipment.
Therefore, if an efficient way is found to locate the two-dimensional (or higher-dimensional) minimum from a single, fixed, set of tuning parameters, all calibration routines can be carried out in the same manner. The disclosed method involves taking measurements (for example of independent pairs, x i , y i ) located across the part of the parameter space in which the minimum is expected.
The method is able to find the optimum tuning setting based on a single parameter scan only. No iterations are needed which reduces overheads of both calibration time (the taking of measurements and the setting up to take those measurement) and hence cost.
DETAILED DESCRIPTION
The following discussion in relation to FIG. 2 uses an example of tuning parameter pairs as present in previous equation (1). However, the same approach could be applied to tuning parameters of other dimensions in order to solve polynomial expressions of any other dimensions or in any other number of independent parameters.
Turing to FIG. 2 , a parameter space 20 spanned by x and y parameters is illustrated with a sub-region 22 of parameter space area where optimum parameter setting is expected. A grid of four-by-four points where measurements are taken 24 is also shown together with an optimum parameter setting 26 (in this embodiment a parameter pair (x opt ,y opt )). The grid may comprise other numbers of measurement points.
As would be understood, it is unlikely that the entire parameter space 20 must be searched, a sub-region 22 can usually be identified during product characterization that will contain the optimum setting 26 for all devices of the same type under test (calibration). Typically, the total parameter range 20 is much wider than needed. Device designers typically provide margin to account for unexpected effects (mismatches between simulated and actual performance). When the first samples of the device are evaluated, the search range can typically be reduced to a sub-region 22 . The sub-region is then the range in which the optimum parameter set 26 is expected based on additional knowledge. For example, evaluation of a large number of devices may have proved that the optimum tuning setting can always be found within a certain sub-region, therefore the parameter space can be reduced to this sub-region.
We assume that the power measurements follow a parabolic profile as follows:
P i =P ( x i ,y i )=α·[( x i −x opt ) 2 +( y i −y opt ) 2 ]+P n +ε i , (2)
where P n corresponds to the average added noise power present in the measurements and ε i is a random noise contribution to the i-th measurement with zero mean value: <ε i >=0, < . . . > denoting the arithmetic average.
The optimum parameters x opt and y opt as well as the overall factor α can be found by a method known as polynomial regression. The above equation may be re-written as follows.
P i =P ( x i ,y i )=α·( x i 2 +y i 2 )−(2α· x opt )· x i −(2α· y opt )· y i +(α· x opt 2 +α·y opt 2 +P n )+ε i =½· C 1 ·( x i 2 +y i 2 )+ C 2 ·x i +C 3 ·y i +C 4 +ε i (3)
The constants C 1 . . . C 4 may be written as vector C. The factor ½ is chosen to simplify the final expressions as will be seen. Assuming now that N points (x i , y i ) have been collected (i=1 . . . N). The minimum number of independent data points needed for polynomial regression equals the number of fitting parameters, in this embodiment the minimum number N=4 (to find coefficients C 1 . . . C 4 ). Whether the selected parameter locations are independent can be seen from the determinant of the square matrix (Z T Z). Generally, the determinant is non-zero and the matrix can be inverted. For special patterns of parameter locations, the determinant of the matrix becomes zero and the coefficients C 1 . . . C 4 cannot be evaluated. For example, all test points lying on a straight line or on a circle are two such special cases where the determinant vanishes. One can understand this as follows: For certain patterns it is not possible to evaluate the shape of the parabolic profile. For example, when all parameter pairs (x i , y i ) have the same y i (y 1 =y 2 = . . . =y N ), then there is no way of working out how the unwanted power depends on parameter y.
Further, the tuning parameters may be arranged in a matrix Z made up of four columns and N rows corresponding to the N measurements. The i-th row is formed as follows
Z i,1 . . . 4 =(½( x i 2 +y i 2 ), x i ,y i ,1). (4)
Then all measurements may be expressed in the following vector form
P=Z·C+ε, (5)
where P is the N×1 vector of all measured power values, Z a N×4 matrix capturing the tuning parameter settings, the 4×1 vector C contains the coefficients of the above polynomial and N×1 vector ε the deltas between measured powers and quadratic curve fit. The best curve fit is achieved if scalar |ε| 2 is minimized.
|ε| 2 =ε T ε=( P−Z·C ) T ·( P−Z·C )= P T P−C T Z T P−P T ZC+C T Z T ZC=P T P− 2· C T Z T P+C T ( Z T Z ) C (6)
The derivative with respect to the fitting parameters C is zero at the point where |E| 2 is minimized:
∂/∂ C|ε| 2 =0=−2· Z T P +( Z T Z +( Z T Z ) T ) C=− 2· Z T P+ 2· Z T ZC (7)
Therefore the best polynomial fit is achieved for the following C as would be understood:
C =( Z T Z ) −1 Z T ·P=M·P. (8)
Note that because the pattern of (x i , y i ) is constant the 4×N matrix M=(Z T Z) −1 Z T is independent of the measurement results and can be pre-calculated and stored as a fixed table. The final multiplication with vector P is then straight-forward.
Having found vector C, the optimum set of tuning parameters can be computed. Considering equation (3), the unwanted power is minimized when ∂P/∂x=∂P/∂y=0. This is the case for the following pair of x and y parameters:
x opt =−C 2 /C 1 , and (9)
y opt =−C 3 /C 1 . (10)
In this example, constant C 4 is not strictly needed for finding the optimum tuning setting. It merely reflects the amount of unwanted power at x=y=0. It is therefore possible to simplify the equations slightly and just multiply the first three rows of the matrix M=(Z T Z) −1 Z T with the vector P. In other words, the coefficients C 1 , C 2 and C 3 are simply given by multiplying three fixed row vectors with the column vector of the measured power figures:
C k =Σ i=1 . . . N ( M k,i ·P i ). (11)
There are 3·N matrix elements that are independent of measurements. These coefficients can be calculated once and applied to each DUT 10 being calibrated. This means that during calibration, the matrix manipulations described above do not actually have to be carried out. It is sufficient to calculate the three sums described in equation (11) based on constant coefficients M k,i . This means the controlling PC only has to store 3·N constants and perform simple multiplication and addition for each DUT. No matrix manipulations would be required.
The same approach as for the example of transmitter carrier leakage calibration can be used for any multi-dimensional polynomial by way of polynomial re-arrangement and regression to provide optimal tuning parameter values in order to optimise a desired variable of the device.
FIG. 3 illustrates communication flow between controlling unit 14 , DUT 10 and test equipment 12 when a test sequence (for example of FIG. 4 ) is run on the DUT. The sequence of tuning parameter pairs to be used to collect measurement data is pre-determined before the start of the routine and does not depend on previous measurements. Similarly, the test equipment collects a fixed number of measurements corresponding to the tuning parameter pairs. The communication flow of FIG. 3 may be implemented on a system as shown in FIG. 1 .
At step 30 , controlling unit 14 initialises, or prepares the test equipment 12 for the collection of N measurements from DUT 10 . The controlling unit also initialises, or prepares DUT 10 to run with each of a set of N tuning parameter values (step 31 ). At step 32 , the controlling unit triggers the test equipment and DUT, and the DUT runs N tests with the pre-determined tuning parameter values (step 33 ), and the test equipment collects the N measurement results (step 34 ). Steps 32 - 34 are akin to step 42 of FIG. 4 .
The final calculations (step 35 ) are performed within the controlling unit. They are based on multiplication and summation only, no matrix manipulations are required at this stage—this allows a reduced processor burden to deduce the optimum tuning parameter values. Step 35 is akin to steps 43 and 44 of FIG. 4 .
The controller 14 , test equipment 12 and DUT 10 may communicate with one another in any manner shown in FIG. 1 , for example, controller 14 may receive measurements directly from DUT 10 or test equipment 12 , and may initialise, or prepare DUT 10 directly.
The N parameter pairs discussed in relation to FIG. 3 could be parameter triplets or any other number based on the polynomial expression to be solved as explained herein, and also applies to the discussion of parameters in relation to FIG. 4 . Therefore FIG. 3 may apply to any calibration exercise where the described method is carried out. The fixed number of measurements, N, may be the minimum required to solve the re-arranged polynomial expression as discussed herein, or could be a higher number based on desired noise rejection, or additional time for allowed for testing.
The method described removes any need for time-consuming iteration. In experiments, the disclosed method allowed certain tests (calibrations) to be speeded up by a factor of one hundred because it eliminates frequent communication between controlling unit 14 , DUT 10 and test equipment 12 . The number of measurements taken need not be larger than with any iterative scheme. In fact, if the measurement noise is low, the number of measurement points can be as low as the number of fitting parameters. In the described embodiment, that number is four (C 1 , C 2 , C 3 , C 4 ). The polynomial regression then becomes an interpolation between the data points.
Apart from the time advantage as discussed above, there is a second advantage provided by the method. The polynomial regression effectively averages out measurement noise that is present in the individual measurement points. While the accuracy of a successive iteration scheme is limited by the noise in the single most recent set of measurements obtained, here, all measurements are considered equally. In some cases this may allow use of lower cost test equipment because each measurement may exhibit noise that need not be filtered out. Pre-determined parameter values used to obtain the samples may be chosen so that noise intrinsic to the individual sample measurements is averaged such that the polynomial form provides a curve fit when more than N samples are captured.
It is difficult to derive an exact relationship between the noise in an individual measurement (quantified by the variance of the noise power, Var(ε)=σ 2 ) and the error of the final estimation for the optimum tuning parameter (quantified by Var(x opt ) and Var(y opt )). For the described embodiment, the tuning parameters are preferably arranged so that the curvature of the quadratic profile leads to changes in measured power much larger than the measurement noise. In that case the tolerance of the estimation for x opt and y out are dominated by Var(C 2 ) and Var(C 3 ) rather than Var(C 1 ). In other words, the estimation of the curvature of the parabolic profile which is captured by the coefficient C 1 will be more robust against measurement noise if the spacing between the parameters used is large enough to see the effect of the quadratic term.
In general, the estimation improves with the number of measurement points according to Var(x opt )=Var(y opt )˜σ 2 /N. A four-fold increase in measurement points will half the error of the estimation for the optimum tuning setting. Whether this relation holds for the particular calibration task at hand can be established through a series of trial runs.
Benefits of the method have been shown, including a reduced time being needed for product calibration time and therefore reduced calibration cost.
A secondary advantage is that all measurements collected during the calibration are directly included in the calculation of the optimum tuning setting which maximally suppresses the effect of measurement noise.
The method is useful for what is generally called production test or production test and calibration. For example, after fabrication of a device, nearly every device goes through a process of testing. Sometimes there are several stages of testing. First, an initial screening is performed at silicon wafer level, then after the device is packaged, and finally, when the device is integrated with the rest of the system.
Further ‘auto calibration’ may take place when the product is already in the field, later in the lifetime.
The method could be implemented at any of those stages.
In a fabrication plant, production tests rely on expensive equipment and the time each device is being probed by the test equipment adds a significant cost to the overall product cost. In a production environment where thousands of units are tested per hour, parallel production and/or test lines are often used to achieve the required factory throughput. If the time of test and calibration is reduced as with the disclosed method, the number of parallel lines can be reduced, which has a direct impact on cost.
If the calibration is performed when the product is already being used because performance has drifted, for example, due to temperature or simply aging, this method allows the time to recalibrate to be kept as short as possible which provides a more efficient recalibration.
The various methods described above may be implemented by a computer program product. This also applies to any or all individual method steps. The computer program product may include computer code arranged to instruct a computer to perform the functions of one or more of the various methods described above. The computer program and/or the code for performing such methods may be provided to an apparatus, such as a computer or processor, on a computer readable medium or computer program product. The computer readable medium may be transitory or non-transitory. The computer readable medium could be, for example, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, or a propagation medium for data transmission, for example for downloading the code over the Internet. Alternatively, the computer readable medium could take the form of a physical computer readable medium such as semiconductor or solid state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), a rigid magnetic disc, and an optical disk, such as a CD-ROM, CD-R/W or DVD, any physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, NVRAM, any other memory chip or cartridge.
An apparatus such as a computer or processor may be configured in accordance with such code to perform one or more processes in accordance with the various methods discussed herein. Such an apparatus may take the form of a data processing system. Such a data processing system may be a distributed system. For example, such a data processing system may be distributed across a network. Any method as disclosed herein may be implemented on a system as shown in FIG. 1 .
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A computer implemented method of calibrating a device comprising the steps of: deriving an analytic expression for a variable to be optimized of the device in terms of at least one parameter of the device, transforming the analytic expression into polynomial form of the at least one parameter of the device, the polynomial form comprising N coefficients, capturing at least N samples of a value of the variable from the device under calibration, each sample being a result of a different independent pre-determined value of the at least one parameter, applying the captured variable values and the corresponding at least one parameter values to the polynomial form, obtaining optimal values of the at least one parameter from the applying step to calibrate the device.
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BACKGROUND OF THE INVENTION
This invention has to do with a measuring tool for use in the construction profession with particular applicability to finish carpentry, framing carpentry, wall layout, drywall installation, fitting countertops, piping layouts, floor and ceiling installations and cabinetry. It also has direct applications in the graphic arts field, the engineering and drafting fields and other manufacturing situations where angle measurements are performed. This invention has direct applications in virtually every situation requiring an angle measurement, and it has a multitude of professional and household applications, providing precise angle readings for any carpentry project and any other project that requires angle measurement, angle copying, angle transferring, and/or angle projection. Such projection of an angle may be accomplished with a laser, scope or other means of projecting or sighting to a distant point, line, plane or planes.
This invention is used in the fitting of trim and decorative pieces, or any material, to the surface of wall surfaces, or any surfaces, which meet at an angular junction. This angular junction is commonly referred to as a miter joint. A miter saw/miter box is used to cut the trim and decorative pieces, or any material, in a precise manner so that a clean and accurate miter joint is established.
The invention is also used for fitting single pieces of trim, or any material, into any angle that is encountered. A miter saw/miter box is used to cut the material in a precise manner so that a clean and accurate fit is established between the freshly cut piece and the work surface(s).
In addition to the above-mentioned functions, which are specific to the angle scale that is virtually universal to the miter saw/miter box, this invention also has scales for determining the actual angle, or any interpretation of the actual angle, throughout an entire revolution (zero degrees through 360 degrees).
This invention has additional scales for determining, transferring and laying out the angles for common roof pitches. In the preferred embodiment, these scales are laid out in the standard “inches of rise per lineal foot.” The indicated roof pitch is simultaneously converted to a protractor or miter saw/miter box setting.
This invention also has scales for determining, transferring and laying out gradients. In the preferred embodiment, the slopes (grades) are presented for reading in percentages wherein 0% slope is horizontal and 100% slope is a 45° angle with respect to horizontal.
While a miter saw/miter box is the preferred and generally most accurate way to achieve the angled cuts determined by the invention, other means such as a hand saw, hand-held circular saw, radial arm saw, table saw, jig saw and any other means for achieving the determined cuts are contemplated by the inventor.
This invention has a laser/scope accessory and provision is made for said laser/scope accessory to be attached to the invention. The union of this invention with the laser/scope accessory provides a means for projecting any angle setting from a chosen point of origin along the angle chosen and out to a distance limited only by the power of the laser/scope. Such a laser/scope projection is useful in the layout of walls and construction angles, regardless of what plane they are in. Such a laser/scope projection is also useful in the electrical, plumbing, drywall and landscaping fields, as well as any trade or endeavor that requires the accurate determination, and/or projection, of any angle. It should be understood that a laser/scope, or lasers/scopes, might also be incorporated in the body of the tool as a permanent fixture(s). All such alternative means for employing a laser(s), scope(s) or other means of projecting or sighting on the measuring tool are contemplated by the inventor.
BRIEF SUMMARY OF THE INVENTION
It is an object of this invention to provide an easy to use tool to transfer angle readings from a work place surface(s) to a miter saw/miter box, to any other cutting device, or directly to any work piece, in a one-step operation.
It is a further object of this invention to measure and/or project with a laser, scope or other means, an angle, its complementary angle, its supplementary angle, common roof pitch angles, gradients and/or any angle measurement to which the several scales might be adapted. In the preferred embodiment all of these angle measurements are measured and projected simultaneously.
In the preferred embodiment of the invention an angle measurement tool is provided that in its final form has two interacting legs and a plurality of interacting gears. The first of the two legs has a fixed gear assembly at the axis of the two interacting legs. The second leg has one or more gears which are driven by the aforementioned fixed gear assembly on the first leg. One or more of these gears serve as dials for the purpose of displaying and reading a variety of angle measurements. Both of the legs and those gears employed as dials have a plurality of scale measurements scribed upon them. The tool is so constructed that the movement of the two legs relative to each other will result in an angle being formed there between that will be measured by referring to a setting on the scales so provided for the gears and the legs.
The tool can be utilized to measure the miter joint angle, bevel and miter settings for compound angles, the actual angle made by the legs of the tool, the complementary angle of the actual angle, the supplementary angle of the actual angle, the common roof pitch angle, gradients, and/or any angle measurement to which the several scales might be adapted. In the preferred embodiment, all of these angle measurements are measured simultaneously. The tool can also be utilized with its laser/scope accessory (or integral laser[s] and/or scope[s]) to measure, layout and project wall angles, construction angles and any angle encountered or required. This improvement is accomplished by attaching the twin-beamed laser/scope to the invention and projecting/sighting a line along a chosen angle from a known point to any other point along the laser beam(s) or sighted line(s). Said point, or points, along the projected laser beam(s), or sighted line(s), must be located in order to achieve a proper rendition of the angle required, and the laser/scope accessory achieves that purpose in a one-step operation. It should be understood by those practiced in the art that many additional deployments of lasers or scopes might be employed for a variety of angle projections that are calculated by the measuring tool. The laser, or lasers, can be used to project planes as well as points along a line. These lasers can be deployed in many useful layouts that are directly related to any of the many angle functions to which the tool can be calibrated. It should be further understood that said laser(s), or scope(s), might also be integrated into the measuring tool, in addition to, or as an alternative to the laser (or scope) accessory.
A first alternate embodiment is presented in which both legs are provided with a fixed gear assembly at the axis of the two interacting legs. Both legs are similarly fit with one or more gears which are driven by the aforementioned fixed gear of the respective opposite leg. This improvement provides the ability to have additional indicia bearing gears and thus the ability to provide additional angle measurements.
In addition, a second alternate embodiment is presented which improves on the gear trains in both the preferred embodiment and the first alternate embodiment. As will be evident in the descriptions and drawings to follow, this second alternate embodiment employs compound gears on either or both legs of the tool to provide angle measurements to a still greater degree of precision as compared to those measurements provided by a non-compound gear train.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of all of the components of tool 10 as assembled with the legs forming an acute angle.
FIGS. 2A , 2 B, and 2 C are orthographic views of bottom leg 18 .
FIGS. 3A , 3 B, 3 C and 3 D are orthographic views of top leg 14 .
FIG. 4 is a section view of top leg 14 .
FIG. 5 is a section view of top leg 14 .
FIGS. 6A , 6 B and 6 C are orthographic views of gear cover 22 .
FIGS. 7A , 7 B, 7 C and 7 D are orthographic views of gears 26 , 30 , 34 , 38 and 42 .
FIGS. 8A , 8 B and 8 C are orthographic views of ‘O’ ring 46 .
FIGS. 9A , 9 B and 9 C are orthographic views of bolt 50 .
FIG. 10 is an exploded view of tool 10 .
FIG. 11 is a plan view of tool 10 as assembled in a closed position. Direction of movement is shown by arrows. Gear cover 22 is not shown.
FIG. 12 is a section view of tool 10 as assembled in a closed position.
FIGS. 13A , 13 B, 13 C and 13 D are orthographic views of the laser device 54 .
FIG. 14 is a perspective view of laser device 54 .
FIG. 15 is a perspective view of laser device 54 .
FIG. 16 is a perspective view of all of the components of tool 11 as assembled with the legs forming an acute angle.
FIGS. 17A , 17 B, 17 C and 17 D are orthographic views of bottom leg 19 .
FIG. 18 is a section view of bottom leg 19 .
FIG. 19 is a section view of bottom leg 19 .
FIGS. 20A , 20 B, 20 C and 20 D are orthographic views of top leg 15 .
FIG. 21 is a section view of top leg 15 .
FIG. 22 is a section view of top leg 15 .
FIGS. 23A , 23 B and 23 C are orthographic views of gear cover 22 of tool 11 .
FIGS. 24A , 24 B, 24 C and 24 D are orthographic views of fixed gear assembly 78 .
FIGS. 25A and 25B are, respectively, elevation and plan views of assembly washer 70 .
FIGS. 26A , 26 B, 26 C and 26 D are orthographic views of gears 86 , 90 , 94 , 98 and 102 .
FIGS. 27A , 27 B and 27 C are orthographic views of ‘O’ ring 47 .
FIGS. 28A , 28 B and 28 C are orthographic views of bolt 51 .
FIG. 29 is an exploded view of tool 11 .
FIG. 30 is a plan view of tool 11 as assembled in a closed position. Direction of movement is shown by arrows. Gear cover 22 is not shown.
FIG. 31 is a section view of tool 11 as assembled in a closed position.
FIG. 32 is a plan view of tool 10 as assembled in a closed position. Direction of movement is shown by arrows. Gear cover 22 is not shown.
FIG. 33 is an exploded view of the components shown in section view 34 . Gear cover 22 is not shown.
FIG. 34 is a section view which applies universally to leg 14 of tool 10 and to legs 15 and 19 of tool 11 .
DETAILED DESCRIPTION OF THE INVENTION
As can be seen in the FIGS. 1-12 the preferred embodiment of angle measurement tool 10 is constructed from several components including top leg 14 , bottom leg 18 , bolt 50 and a plurality of interacting gears. Legs 14 and 18 are the same width and both have a circular shaped end 20 . It should be understood that circular shaped end 20 of both leg 14 and leg 18 is a semicircle of a circle having a diameter equal to the width of leg 14 and leg 18 . It should be further understood that leg 14 and leg 18 might be wider or narrower than circular shaped end 20 where the legs extend beyond the circle described by circular shaped end 20 . It should also be understood that leg 14 and leg 18 might have non-parallel edges and tool 10 will still function as intended. Leg 14 is provided with projected axis spindle 12 at the center of the circle of which circular shaped end 20 is a part. Axis spindle socket 16 of bottom leg 18 is provided at the center of the fixed gear assembly 24 which is at the center of the circle of which circular shaped end 20 is a part. In the preferred embodiment, projected axis spindle 12 is circular in shape and has a diameter equal to or less than the diameter of axis spindle socket 16 , as shown in the figures. It should be understood that projected axis spindle 12 has a diameter equal to or less than the diameter of the axis spindle socket 16 as a function of the assembly of tool 10 and thus to facilitate precisely pivoting legs 14 and 18 secured by bolt 50 . It should be further understood that projected axis spindle 12 does not have to be in the shape of a circle in order for tool 10 to operate in the fashion described. Variable friction adjustment for the pivoting legs 14 and 18 is provided when ‘O’ ring 46 is compressed by projected axis spindle 12 into axis spindle socket 16 when bolt 50 is tightened through bolt hole 32 in leg 18 and into threaded bolt hole 36 in leg 14 , as shown in the figures. Bolt hole 32 and threaded bolt hole 36 are at the center of the circle of which circular shaped end 20 is a part. With legs 14 and 18 so engaged, fixed gear assembly 24 meshes with gear 26 in a secure and rotationally precise manner. Fixed gear assembly 24 of leg 18 is housed within fixed gear cavity 53 in leg 14 in the assembled tool 10 . When the legs 14 and 18 are pivoted around their common axis as defined by projected axis spindle 12 and axis spindle socket 16 , fixed gear assembly 24 meshes with and turns gear 26 , which in turn meshes with and turns gear 30 , which meshes with and turns gear 34 , which meshes with and turns gear 38 , which meshes with and turns gear 42 . Gears 26 , 30 , 34 , 38 and 42 are each precisely located for accurate meshing and rotation by axis pivots 40 located in close tolerance within gear center holes 44 as shown in the figures. Any or all of the gears may include dial indicia 43 for the purpose of measuring any angle reading throughout a full revolution of either leg 14 or leg 18 . As indicated in FIG. 11 , each of the gears 24 , 26 , 30 , 34 , 38 and 42 is supplied with dial indicia 43 which are comprised of straight lines radiating outward from the rotational center of these gears. The purpose of these several gears is to simultaneously provide a variety of useful angle measurements on scales specifically suited to the work at hand. For example, the indicia on fixed gear assembly 24 would be marked with a protractor scale, in a 0°-180°-0° format, providing the actual angle determined by the relative positions of leg 14 and leg 18 ; in turn, gear 26 would provide the protractor scale in a 180°-0°-180° format, gear 30 would provide a scale for the miter saw setting for miter joints, gear 34 would provide a scale for the miter saw setting for butt joints, gear 38 would provide a scale for the roof pitch reading in ‘inches of rise per lineal foot’, gear 42 would provide a scale for gradients expressed as a percentage. This example is one of many configurations possible, dependent only on the angle measurements chosen for the several gears and the relative positions of these several interchangeable gears, whose interchangeability is described below. In the preferred embodiment, fixed gear assembly 24 and gears 26 , 30 , 34 , 38 and 42 are the same diameter and have the same number of gear teeth, thus gears 26 , 30 , 34 , 38 and 42 are interchangeable to suit the user's preference. Gears 26 , 30 , 34 , 38 and 42 may also be reversible, thus providing their reverse side for additional angle measurements. Further, the interchangeable design of the gears provides the opportunity to substitute additional gears provided with specialized scales for use in any field of endeavor requiring precise measurement and layout of particular angles for particular purposes. The various gears would be so marked, or colored, as to provide immediate identification and differentiation of the various scales. It should be apparent to those practiced in the art that interchangeability and reversibility of the gears is not a necessary component of the invention and that the various gears need not be identical in shape, interchangeable or reversible for the invention to function as intended; all such non-interchangeable and non-reversible configurations are contemplated by the inventor. A means for accurately reading these several angle measurements is provided by indicator line 28 placed along the center of gear cover 22 as shown in the figures. It should be understood that many other locations for indicator line(s) 28 on gear cover 22 and/or leg 14 are possible and are contemplated by the inventor. In the preferred embodiment gear cover 22 is transparent and indicator line 28 is provided on the surface of gear cover 22 which is closest to gears 24 , 26 , 30 , 34 , 38 and 42 . In the preferred embodiment gear cover 22 is of a form that provides beveled edges 48 which securely mate with dovetail channel 52 providing a secure location for gear cover 22 . Gear cover 22 is retained by friction, ball catch, screw(s), latch(es), magnet(s) or any of the many suitable means that should be apparent to those skilled in the art. The inventor contemplates all such means of securing gear cover 22 in its assembled location within dovetail channel 52 . So located, gear cover 22 retains gears 26 , 30 , 34 , 38 and 42 securely in their proper working locations with their respective gear center holes 44 engaged with their respective axis pivots 40 . Areas of the surfaces of gear cover 22 which are not necessary areas for viewing angle readings determined by indicator line 28 may be masked so as to provide a well delineated reading environment for the several angle readings so provided. It should be understood by those practiced in the art that gear cover 22 may be opaque and readings can be accomplished through openings and/or lenses in its surface; further, it should be understood that many variations of gear retention and reading means for the various scales and indicia are possible and that all such alternatives are contemplated by the inventor. It should be understood that fixed gear assembly 24 may or may not be constructed in union with leg 18 , but in its final form tool 10 comprises a bottom leg 18 that is in fixed union with fixed gear assembly 24 , such that, in operation, leg 18 is a single piece rigidly attached to, or constructed with, fixed gear assembly 24 . In operation tool 10 simultaneously provides the miter joint angle measurement, the actual angle made by the legs 14 and 18 , the complementary angle measurement of the actual angle, the supplementary angle measurement of the actual angle, roof pitch angles, gradients and/or any angle measurement to which the several scales are adapted. It should be understood by those practiced in the art that any number and any size or variety of gears can be employed in infinite configurations and that all such alternate deployments of gears driven by fixed gear assembly 24 are contemplated by the inventor. It should be further understood by those practiced in the art that, as an alternative, supplement, or addition to the preferred embodiment in which the various gears mesh directly with one another, that a gear-toothed belt drive, friction belt drive, or similar means might be employed as an alternative, supplementary or additional means of rotating all, or some, of the various gears and/or dials and that the inventor contemplates all such variations. Further, the inventor wishes it to be understood that various other friction inducing means other than ‘O’ ring 46 should be apparent to those practiced in the art and that the inventor contemplates all such friction inducing means including the substitution of a suitable magnet for ‘O’ ring 46 and bolt 50 , said magnet located in the bottom of the axis spindle socket 16 and magnetically engaging a magnetized projected axis spindle 12 . Alternate embodiments are contemplated by the inventor in which a wide variety of angle readings may be accomplished on the top surfaces, bottom surfaces and edges of, either or both of legs 14 and 18 in which leg indicia 45 and certain scales are employed at various significant intersections of legs 14 and 18 as they bypass each other while being adjusted to the work surfaces which are being measured.
As can be seen in FIGS. 3A , 3 B, 3 C and 3 D, leg 14 is provided with three peg holes 58 , 59 and 60 . In the preferred embodiment peg holes 58 , 59 and 60 are flush and perpendicular with the top surface of leg 14 . Peg holes 58 , 59 and 60 are entirely contained between the bottom and top surfaces of leg 14 . Peg holes 58 , 59 and 60 may be similarly placed in leg 18 . Peg holes 58 , 59 and 60 may be of the same shape as each other or they may be unique shapes. FIGS. 13A , 13 B, 13 C, 13 D, 14 and 15 illustrate laser device 54 . Laser device 54 is intended for projecting diametrically opposed laser beams 64 and 65 in diametrically opposite directions from each other. Laser device 54 is fitted with three pegs 67 , 68 and 69 that precisely match the shape or shapes of peg holes 58 , 59 and 60 . Pegs 67 , 68 and 69 may be of the same shape as each other or they may be unique shapes. Pegs 67 , 68 and 69 are fit perpendicular to the bottom surface 62 of laser device 54 . Bottom surface 62 is in a single plane. Bottom surface 62 is parallel with laser beams 64 and 65 . The relative positions of pegs 67 , 68 and 69 are such that they fit respectively in peg holes 58 , 59 and 60 and in so doing they attach laser device 54 to leg 14 or leg 18 such that laser beams 64 and 65 are parallel to the angle chosen on leg 14 or leg 18 , according to the application chosen. In the preferred embodiment pegs 67 , 68 and 69 are circular and made of steel, either magnetized or not magnetized. It should be understood that other shapes and materials are contemplated for pegs 67 , 68 and 69 . It should also be understood that magnetic attachment is one of many means contemplated for attaching laser device 54 to leg 14 and/or leg 18 . Laser beams 64 and 65 are energized from a battery(ies) contained within laser device 54 . Laser beams 64 and 65 may be generated from a single source and redirected on diametrically opposite paths. Laser beams 64 and 65 may also be generated separately. Laser beams 64 and 65 may be generated not only as single lines, but might also be projected as planes or any number of planes. In operation laser device 54 is affixed to tool 10 by placing pegs 67 , 68 and 69 in peg holes 58 , 59 and 60 . It should be recognized by those practiced in the art that various other means of attaching laser device 54 to tool 10 are possible and those ways are contemplated by the inventor. Laser beams 64 and 65 are employed to project angles. In the preferred embodiment, the union of tool 10 and laser device 54 projects laser beams 64 and 65 along one side of the angle made by the legs 14 and 18 . The other side of the angle made by the legs 14 and 18 represents the base line from which the particular angle is being calculated and projected. Whichever of the legs 14 and 18 that does not have the laser device 54 mounted on it is the leg that is set parallel to the base line. Laser beams 64 and 65 are by design always parallel to one side of the angle being measured and projected. Laser beam 64 is aimed at the spring point of the angle that is to be projected. Laser beam 65 projects the chosen angle along and beyond the angle made by the legs 14 and 18 . It should be understood by those practiced in the art that there are alternate embodiments for a laser, or lasers, in which the laser function(s) are an integral part of tool 10 in addition to laser device 54 , or in place of laser device 54 . All such alternate embodiments are contemplated by the inventor. It should be understood that sighting scopes may be substituted for, or mounted in unison with, the laser beam in laser device 54 . Laser device 54 as herein described is also intended for use with tool 11 , described in the first alternate embodiment below. Additionally, laser device 54 is intended for all alternate embodiments described herein and those other embodiments contemplated by the inventor which should be apparent to those practiced in the art.
The following description of the first alternate embodiment of the invention utilizes the same reference numbers as those described in the preferred embodiment above in such cases where members are the same in both embodiments. New reference numerals have been assigned in cases where members are new or in some respects different when comparing the two embodiments. FIGS. 16-31 disclose the first alternate embodiment, tool 11 , in which leg 15 is provided with a projected axis spindle 13 at the center of the circle of which circular shaped end 20 is a part. The projected axis spindle 13 is provided with threaded bolt hole 37 at the center of the circle of which circular shaped end 20 is a part, as shown in the figures. Leg 19 is provided with axis spindle socket 84 at the center of the circle of which circular shaped end 20 is a part. Leg 19 securely houses assembly washer 70 which is so constructed as to provide a secure fit in recess 71 for rotatably engaging projected axis spindle 13 with bolt 51 as bolt 51 passes through bolt hole 33 which is provided in washer 70 at the center of the circle of which circular shaped end 20 is a part. A portion of projected axis spindle 13 is provided with projected axis spindle gear teeth 74 for reasons that will become apparent below. As shown in the figures, fixed gear assembly 25 is housed within fixed gear cavity 53 in order to drive the gear train of top leg 15 in the same fashion as fixed gear assembly 24 drives the gear train of top leg 14 of tool 10 in the preferred embodiment; the latter being illustrated in FIG. 11 . As tool 11 is assembled, bolt 51 passes through bolt hole 33 into threaded bolt hole 37 , so assembling leg 15 and leg 19 such that they rotate securely in relation to each other with an axis the center of which is located at the center of the circle of which circular shaped end 20 is a part. ‘O’ ring 47 is provided as a frictional interface between projected axis spindle 13 and washer 70 , with adjustable rotational friction for legs 15 and 19 provided as bolt 51 is tightened or loosened to the tool user's preference. In this first alternate embodiment ‘O’ ring 47 is located in ‘O’ ring channel 80 which is concentrically located on the end of projected axis spindle 13 which houses threaded bolt hole 37 at its center. Accurate rotation of legs 15 and 19 is ensured by the close-tolerance fit of projected axis spindle 13 as it revolves within axis spindle socket 84 . Projected axis spindle gear teeth 74 are fixedly engaged with fixed gear assembly 78 by meshing with the mating internal gear 82 contained at the center of fixed gear assembly 78 ; fixed gear assembly 78 then meshes with and turns gear 86 , which in turn meshes with and turns gear 90 , which meshes with and turns gear 94 , which meshes with and turns gear 98 , which meshes with and turns gear 102 . Gears 86 , 90 , 94 , 98 and 102 are each precisely located for accurate meshing and rotation by axis pivots 72 located in close tolerance within gear center holes 76 as shown in the figures. Any or all of the gears may be provided with dial indicia 43 for the purpose of determining any angle reading throughout a full revolution of either leg 15 or leg 19 . As indicated in FIG. 30 each of the gears 78 , 86 , 90 , 94 , 98 and 102 is provided with dial indicia 43 which are comprised of straight lines radiating outward from the rotational center of these gears. The purpose of these several gears is to simultaneously provide a variety of useful angle measurements on scales specifically suited to the work at hand. For example, the indicia on fixed gear assembly 78 would be marked with a protractor scale, in a 0°-180°-0° format, providing the actual angle determined by the relative positions of leg 15 and leg 19 ; in turn, gear 86 would provide the protractor scale in a 180°-0°-180° format, gear 90 would provide a scale for the explementary angle in a 0°-360° format, gear 94 would provide a scale for the explementary angle in a 360°-0° format, gear 98 would provide a scale for the miter saw settings for constructing equiangular polygons employing miter joints, gear 102 would provide a scale for the miter saw settings for constructing equiangular polygons employing butt joints. This example is one of many configurations possible, dependent only on the angle interpretations chosen for the several gears and the relative positions of these several interchangeable gears, whose interchangeability is described below. In the preferred embodiment, fixed gear assembly 78 and gears 86 , 90 , 94 , 98 and 102 are the same diameter and have the same number of gear teeth, thus gears 86 , 90 , 94 , 98 and 102 are interchangeable to suit the user's preference. Gears 86 , 90 , 94 , 98 and 102 may also be reversible, thus providing their reverse side for additional angle measurements. Further, the interchangeable design of the gears provides the opportunity to substitute additional gears provided with specialized scales for use in any field of endeavor requiring precise measurement and layout of particular angles for particular purposes. The various gears would be so marked, or colored, as to provide immediate identification and differentiation of the various scales. It should be apparent to those practiced in the art that interchangeability and reversibility of the gears is not a necessary component of the invention and that the various gears need not be identical in shape, interchangeable or reversible for the invention to function as intended; all such non-interchangeable and non-reversible configurations are contemplated by the inventor.
A means for accurately reading these several angle measurements is provided by indicator line 28 which is placed along the center of gear cover 22 as shown in the figures. It should be understood that many other locations for indicator line(s) 28 on gear cover 22 and/or legs 15 and 19 are possible and are contemplated by the inventor. In this first alternate embodiment gear cover 22 is transparent and indicator line 28 is provided on the surface of gear cover 22 which is closest to gears 78 , 86 , 90 , 94 , 98 and 102 . In this first alternate embodiment gear cover 22 is of a form that provides beveled edges 48 which securely mate with dovetail channel 52 providing a secure location for gear cover 22 . Gear cover 22 is retained by friction, ball catch, screw(s), latch(es), magnet(s) or any of the many suitable means that should be apparent to those skilled in the art. The inventor contemplates all such means of securing gear cover 22 in its assembled location within dovetail channel 52 . So located, gear cover 22 retains gears 86 , 90 , 94 , 98 and 102 securely in their proper working locations with their respective gear center holes 76 engaged with their respective axis pivots 72 . Areas of the surfaces of gear cover 22 which are not necessary areas for viewing angle readings determined by indicator line 28 may be masked so as to provide a well delineated reading environment for the several angle readings so provided. It should be understood by those practiced in the art that gear cover 22 may be opaque and readings can be accomplished through openings and/or lenses in its surface; further, it should be understood that many variations of gear retention and reading means for the various scales and indicia are possible and that all such alternatives are contemplated by the inventor. It should be understood that fixed gear assembly 25 may or may not be constructed in union with leg 19 , but in its final form tool 11 comprises a bottom leg 19 that is in fixed union with fixed gear assembly 25 . In operation tool 11 simultaneously provides the miter joint angle measurement, the actual angle made by the legs 15 and 19 , the complementary angle measurement of the actual angle, the supplementary angle measurement of the actual angle, the explementary angle measurement of the actual angle, roof pitch angles, gradients, miter saw settings for constructing equiangular polygons employing miter joints, miter saw settings for constructing equiangular polygons employing butt joints and/or any angle measurement to which the several scales are adapted. It should be understood by those practiced in the art that any number and any size or variety of gears can be employed in infinite configurations and that all such alternative deployments of gears driven by fixed gear assembly 25 and projected axis spindle gear teeth 74 are contemplated by the inventor. It should be further understood by those practiced in the art that, as an alternative, supplement, or addition to the preferred embodiment in which the various gears mesh directly with one another, that a gear-toothed belt drive, friction belt drive, or similar means might be employed as an alternative, supplementary or additional means of rotating all, or some, of the various gears and/or dials and that the inventor contemplates all such variations. Further, the inventor wishes it to be understood that various other friction inducing means other than ‘O’ ring 47 should be apparent to those practiced in the art and that the inventor contemplates all such friction inducing means including the substitution of a suitable magnet for ‘O’ ring 47 and bolt 51 , said magnet located in the bottom of the projected axis spindle 13 and magnetically engaging a magnetized assembly washer 70 . In this alternate embodiment there would be no bolt 51 and assembly washer 70 would have no bolt hole 33 and thus assembly washer 70 would be secured to leg 19 with screws at a point or points located around the outer edge of assembly washer 70 or by any of several other means which should be apparent to those practiced in the art. Alternate embodiments are contemplated by the inventor in which a wide variety of angle readings may be accomplished on the top surfaces, bottom surfaces and edges of either or both of legs 15 and 19 in which leg indicia 45 are employed at various significant intersections of legs 15 and 19 as they bypass each other while being adjusted to the work surfaces which are being measured. Tool 11 , so constructed in this first alternate embodiment, provides a gear train on both legs 15 and 19 for the purpose of displaying dial indicia 43 for any and all angle measurements that might be provided by the precisely pivoting legs which pivot around the center of the circle of which circular shaped end 20 is a part. It should also be understood by those practiced in the art that the first alternate embodiment here described may be so employed so as to deploy a gear train on leg 19 alone, or leg 15 alone, as might be desired for a given assembly of the inventions here described.
It should be understood by those practiced in the art that there are a number of arrangements of interlocking “pins”, “springs”, “cams”, “clips”, “catches”, “levers”, “latches”, “screws”, “projections”, “magnetism”, “holes”, “grooves” and “openings” that will secure projected axis spindle 12 / 13 of leg 14 / 15 in rotational union with axis spindle socket 16 / 84 of leg 18 / 19 together such that they provide tool 10 / 11 with a leg 18 / 19 that revolves securely and accurately around projected axis spindle 12 / 13 of leg 14 / 15 . The inventor contemplates all of these embodiments, including ‘snap-together’ designs and designs employing spring loaded ball catches (with or without an ‘easy release’ button) in addition to those represented in the figures.
The following description of the second alternate embodiment of the invention utilizes the same reference numbers as those described in the preferred embodiment and first alternate embodiment above in such cases where members are the same as those used in either or both of those embodiments as well as in this second alternate embodiment. New reference numerals have been assigned in cases where members are new or in some respects different as utilized in the second alternate embodiment. The second alternate embodiment is applicable to any of the gear trains illustrated in the preferred embodiment and first alternate embodiment described above, as detailed below. FIGS. 32-34 disclose the second alternate embodiment which employs compound gears, the purpose of which are to employ compound gearing to rotate certain gears at a compounded rate as compared to fixed gear assembly 24 of leg 18 of the preferred embodiment, as well as fixed gear assembly 25 of leg 19 and fixed gear assembly 78 of leg 15 of the first alternate embodiment. The compounded rate of rotation of one gear relative to another provides the ability to have certain gears with accurate fractional readings of those results provided by any of the gears described in the preferred embodiment and first alternate embodiment above. It should be understood that the number of gear teeth shown on particular gears in the Figures are not necessarily indicative of the actual number of gear teeth; the depictions of the gear teeth in the Figures are in some instances abbreviated or drawn out of scale for the purpose of clear illustration. For example, FIG. 32 is a plan view of the second alternate embodiment's compound gear train illustrating a gear assembly 110 which revolves at the same, directly proportional, rate as either of the fixed gear assemblies 24 , 25 or 78 , just as each of the gears in the depicted embodiments of tool 10 and tool 11 revolve at the same, directly proportional, rate as fixed gear assemblies 24 , 25 or 78 ; in every case gear assembly 110 is either directly engaged with either of the fixed gear assemblies 24 , 25 or 78 , or is engaged by idler gears such that gear assembly 110 rotates at the same, directly proportional, rate as the fixed gear assemblies 24 , 25 or 78 . In the second alternate embodiment, gear 114 revolves at a rate 180 times greater than that of gear assembly 110 . A full revolution of gear 114 thus provides its full dial face for depiction of fractional readings of any single whole degree increment portrayed on gear assembly 110 , in doing so a more precise reading of a specific angle is accomplished. More specifically, in this example gear assembly 110 is providing the readings for miter cuts on a miter saw, for which the entire 360° dial must be divided into 180 equally spaced dial indicia 43 . Gear 114 thus turns one full revolution for each 1/180 th revolution of gear assembly 110 . The result is a gear 114 which displays fractional readings in tenths, hundredths, or whichever fractional reading is desired. For the purpose of this example, gear 116 is marked as a 180°-0°-180° protractor and revolves at the same rate as gear assembly 110 . The increased number of rotations for gear 114 in comparison to gear assembly 110 and gear 116 is accomplished with compound gears as described below and illustrated in the figures. FIG. 33 is an exploded view of the second alternate embodiment's compound gear train illustrating the components shown in section view 34 and depicted in FIG. 34 . For the purpose of this description leg 14 is the leg upon which the second alternate embodiment's compound gear train is depicted. It should be understood that the second alternate embodiment's compound gear train is suitable for any and all of the legs 14 , 15 , and 19 and that the inventor contemplates all such embodiments. FIG. 34 is a section view of the second alternate embodiment depicted in plan in FIG. 32 . As assembled, gear assembly 110 is located on axis pivot 122 ; idler gear 118 is located on axis pivot 124 ; compound gear 112 is located on top of idler gear 118 on axis pivot 124 ; idler gear 120 is located on axis pivot 126 ; gear 114 is located on top of idler gear 120 on axis pivot 126 ; and gear 116 is located on axis pivot 128 . Gear assembly 110 , while manufactured or assembled as a single piece, comprises two gears, the lower of those two gears, lower gear 106 is closest to leg 14 and engages idler gear 118 , while the upper gear, upper gear 108 , engages the upper gear 113 of compound gear 112 . Compound gear 112 is manufactured or assembled as a single piece and comprises two gears, the lower of those two gears, lower gear 111 is closest to gear 118 and engages gear 114 , while the upper gear, upper gear 113 , engages gear 108 . Idler gear 118 , being thus engaged with lower gear 106 , in turn engages idler gear 120 , which in turn engages gear 116 . This train of gears 106 , 118 , 120 and 116 is driven by a fixed gear assembly, either 24 or 25 or 78 , directly or through idler gear(s), the result being gears 106 and 116 which revolve at the same, directly proportional, rate as the fixed gear assemblies 24 or 25 or 78 . Upper gear 108 of gear assembly 110 contains 120 teeth around its circumference and is engaged with the 6 toothed upper gear 113 of compound gear 112 . The lower gear 111 of compound gear 112 has 45 teeth around its circumference and is engaged with 5 toothed gear 114 . In this second alternate embodiment, compound action of the upper level gears causes the compounded increase in the number of revolutions of gear 114 , providing the fractional readings desired by providing a gear 114 which turns 180 full revolutions for each single revolution of gear assembly 110 . It should be understood by those practiced in the art that infinite deployments of gear ratios may be employed in such a compound gear train and the inventor contemplates them all. It should be further understood that the second alternate embodiment's compound gear train may comprise as few or as many compound gears as desired, in any number of layers and ratios, and that the inventor contemplates all such combinations of gears. Further, it should be understood that the second alternate embodiment's compound gear train herein described is driven by either fixed gear assembly 24 or fixed gear assembly 25 or fixed gear assembly 78 , just as the fixed gear assemblies 24 and 25 and 78 drive the gear trains previously described and depicted in the preferred embodiment and first alternate embodiment denoted respectively as tool 10 and tool 11 above and in the figures. It should be further understood by those practiced in the art that, as an alternative, supplement, or addition to the second alternate embodiment in which the various gears mesh directly with one another, that gear-toothed belt drives, friction belt drives, or similar means might be employed as an alternative, supplementary or additional means of rotating all, or some, of the various gears and/or dials and that the inventor contemplates all such variations. It should be further understood that the compounding of the gear action might be accomplished with epicyclic or planetary gearing or by other gearing means and the inventor contemplates all such variations.
It should be further understood that any number of different scales and indicia can be deployed on any of the gears, leg surfaces or leg edges of the invention, throughout an infinite number of conceivable angle layouts. The inventor contemplates all such variations of the layout of the scales and indicia.
It should be understood by those practiced in the art that all of the above described gears, and those parts in contact or close proximity with those gears, as assembled, may include any of a number of common friction reduction means such as, but not limited to, low-friction materials employed in the construction of the several legs, gears, and gear covers; low-friction washers, bushings, lubricants, or bearings at points of contact between a gear face and another gear face or a gear face and either of the legs 14 , 15 and 19 and/or gear cover 22 . Such a friction reduction means might be a separate part or might be molded, or affixed, directly onto the gear or the contact area of legs 14 , 15 , and 19 and/or gear cover 22 . Similarly placed ball-bearings, roller bearings or other means might be used to reduce friction and might be a part of, or intermediary for, any of the gears, axis pivots, legs, or gear covers. The inventor contemplates all such friction reduction means.
Although specific embodiments of the invention have been described it should be recognized that additional modification and other alternate embodiments may be apparent to those skilled in the art.
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A multiple gear driver having first and second fixed gears and first and second rotatable gears, the first fixed and rotatable gears located on a first member, and the second fixed and rotatable gears located on a second member, the first and second fixed gears having a common axis so that the first fixed gear drives the second rotatable gear and the second fixed gear drives the first rotatable gears when the first and second member are moved relative to each other.
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BACKGROUND OF THE INVENTION
The present invention relates to mine roof expansion anchors of the type having a radially expansible shell and a tapered plug moveable axially within the shell to effect expansion thereof. More specifically, the invention relates to novel structures of mine roof expansion anchors and tapered plug elements thereof for installation together with a resin grouting mix in a drill hole in a mine roof, or the like, and to methods of installation of combined resin-mechanical anchors.
For many years, one of the most popular means of providing support and reinforcement to mine roofs and other subterranean structures has been the mechanical expansion anchor. Such anchors have been proposed in a wide variety of designs having in common a radially expansible shell portion and a tapered plug having an internally threaded, axial bore. The threaded end of a bolt or other elongated rod is engaged with the bore of the tapered plug and the shell is suitably supported in surrounding relation to the smaller end of the plug. The end of the rod carrying the anchor is inserted into a pre-drilled hole in the rock structure, and the shell is expanded into tight engagement with the drill hole wall by rotation of the bolt to move the larger portion of the plug into the shell.
More recently, the effectiveness and useful life of anchorages have been enhanced by the use of quick-setting resin grouting mixes conjointly with mechanical anchors. Such mixes are commercially available in elongated, breakable tubes or cartridges having a diameter approximating that of the drill hole, and separate compartments containing a resin and a catalyst which are in a flowable condition prior to mixing. The lengths of the resin cartridge and bolt are so related to the depth of the drill hole that forced insertion of the bolt crushes the cartridge against the end of the drill hole, releasing the two components which are mixed to the extent necessary as they pass through and around the anchor and end of the bolt, and by rotation of the bolt to move the plug axially into the shell. Upon mixing of the components, the grouting mix hardens in a few seconds.
Since the resin cartridge is positioned between the blind end of the drill hole and the upper end of the expansion anchor, the components of the grouting mix must flow around and/or through the anchor components when the cartridge is broken. Ideally, the cured grouting mix should surround at least those portions of the anchor components not in direct, compressive engagement with the drill hole wall, as well as the upper portion of the bolt, usually to a position somewhat below the lower end of the anchor. Expansion anchors disclosed in a number of U.S. patents, including U.S. Pat. Nos. 4,859,118, 4,969,778 and 5,009,549, provide resin flow passages in the form of axial grooves in the tapered plug between the surfaces thereof which engage the inner surfaces of the shell. In the anchor of applicant's U.S. Pat. No. 5,316,414, resin flow passages are provided by axial grooves in the opposing wedge and/or shell surfaces.
It is a principal object of the present invention to provide a mine roof expansion anchor having novel and improved means for flow of resin mix components around and through the shell.
Another object is to provide an improved expansion shell for a mine roof anchor which enhances performance of the anchor, particularly when used with a resin grouting mix.
A further object is to provide an expansion shell with uniquely positioned resin flow passages for use in combined resin-mechanical anchorages for rock structure supports.
Still another object is to provide a novel method of anchoring the distal end of a mine roof bolt in a drill hole using both a mechanical anchor and resin to achieve enhanced performance.
Other objects will in part be obvious and will in part appear hereinafter.
SUMMARY OF THE INVENTION
In accordance with the foregoing objects, the invention is embodied in a mechanical expansion anchor having the usual plurality of circumferentially spaced leaves or fingers which are radially expansible by axial movement therebetween of a tapered nut or camming plug in response to rotation of an elongated bolt threadedly engaged with the tapered plug. The end of the bolt carrying the anchor is inserted into a preformed drill hole in the rock formation to be supported with a resin grouting mix, preferably in a two-compartment cartridge, inserted between the anchor and the blind end of the drill hole.
The expansion shell leaves have the usual smooth inner surfaces for contact with the compression surfaces of the camming plug, and radially extending serrations or teeth for contact with the drill hole wall. The shell of the present invention is distinguished from the prior art by at least one groove in the external surface of at least one leaf providing a passageway for flow of resin mix components from the upper to the lower end of the shell. The groove is at least as deep as the height of the individual serrations on the outer shell surface. Preferably, at least one groove is provided in each shell leaf, extending axially for at least the serrated portion of the leaf surface.
The method of the invention involves causing a portion of the resin components to flow through passages in the areas between the opposing surfaces of the shell leaves and the drill hole wall.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an expansion shell element of a mine roof expansion anchor embodying the present invention;
FIG. 2 is a front elevational view of the shell;
FIGS. 3 and 4 are sectional views on the lines 3--3 and 4--4, respectively, of the shell of FIG. 2;
FIG. 5 is a front elevational view of an assembled mine roof expansion anchor including the shell of FIGS. 1-4, inserted into a drill hole in a mine roof together with a resin cartridge;
FIG. 6 is a front elevational view, showing the anchor assembly of FIG. 5 fully installed in a drill hole with the resin components; and
FIG. 7 is a top plan view in section on the line 7--7 of FIG. 6.
DETAILED DESCRIPTION
Referring now to the drawings, in FIGS. 1-4 is shown a preferred embodiment of the expansion shell of the present invention, denoted generally by reference numeral 10. In the illustrated embodiment, shell 10 includes two, physically separate, essentially identical halves 12, 12' each having two leaves with a series of serrations extending radially outwardly at equally spaced intervals over the entire length of each leaf. The same reference numerals are used to denote corresponding portions of the two shell halves, those numerals for one shell half including a prime sign.
Shell halves 12, 12' each include a pair of leaves 14, 14' and 16, 16' integrally joined at what is termed their lower ends by bridging portions 18, 18'. Each of shell halves 12, 12' has upper and lower ends and each of leaves 14, 14', 16, 16' have respective, inner and outer surfaces. In accordance with the usual practise in the design of mine roof expansion anchor shells, the leaf outer surfaces are formed with a plurality of radially extending teeth or serrations, while the inner surfaces are essentially smooth for sliding contact with opposing surfaces of a conventional, tapered, camming plug.
The expansion shell of the present invention is distinguished from prior art shells by the presence of grooves providing passageways in the outer surfaces extending between the upper and lower ends of the leaves. In the illustrated embodiment, each of leaves 14, 14' and 16, 16' includes a single groove 20, 20' and 22, 22', respectively, extending linearly between the upper and lower ends thereof. The illustrated grooves are essentially identical to one another, each being arcuate in plan view (FIGS. 4 and 7) and having an inner end extending longitudinally substantially parallel to the central axis of the shell, as indicated by lines X--X and Y--Y in FIG. 3. The depth of the grooves is preferably at least as great as the height of the serrations on the outer shell surface through which the grooves extend to ensure longitudinal continuity of the grooves. However, the minimum thickness t 1 within the grooves is preferably not more than a few thousandths of an inch less than the thickness t 2 at the edges of the leaves (FIG. 4).
Turning now to FIGS. 5-7, the expansion shell of FIGS. 1-4 is shown as part of a typical anchorage system for a mine roof bolt. Drill hole 44 is formed in rock structure 46, extending from surface 48 (FIG. 5) to a blind end 50 (FIG. 6). Drill hole 44 has a depth an inch or so greater than the length of the portion of bolt 52 positioned in the hole. Bolt 52 has threads extending from distal end 54 for a portion of its length to mate with the internal threads of a central bore in conventional tapered camming plug 56. The proximal end of bolt 52 (not shown) has an integral head or other means for engagement by a power wrench to effect insertion and rotation of the bolt in a well-known manner, thereby urging a bearing plate carried by the proximal end of the bolt into tight engagement with surface 48 and tensioning the bolt.
In the illustrated form, the mechanical expansion anchor includes bail element 58 having a medial portion with elongated legs extending from opposite sides thereof. The leaves of the respective shell halves are separated by gaps through which opposite legs of bail element 58 extend. The shell halves are maintained in assembled relation with one another and with tapered plug 56 by bail element 58, with the small end of the plug extending into the upper end of the shell structure. Studs 60, 60' on bridge portions 18, 18' extend through openings near the terminal ends of the bail legs; after the bail legs are so placed, tabs 62, 62', shown in their initial, outwardly extending condition in FIGS. 1, 2 and 5, are bent toward one another to partially cover and maintain the bail legs in assembled relation with the shell halves, as seen in FIG. 5.
A commercially available form of breakable cartridge 66, holding two components of a resin grouting mix in separate compartments, is inserted into drill hole 22 ahead of distal end 54 of bolt 52, carrying the mechanical expansion anchor. As bolt 52 is forcibly pushed into drill hole 44 to bring distal end 54 of the bolt near blind end 50 of the drill hole, cartridge 66 is ruptured, releasing the components which are initially in a flowable state. The grouting mix components around plug 56, through the gaps between shell leaves and shell halves, and through grooves 20, 20', 22 and 22'.
After bolt 52 is fully inserted, it is rotated by the aforementioned power wrench in a direction causing plug 56 to travel axially down the bolt threads, forcing the progressively larger portion of the plug into the space surrounded by the shell leaves. In so doing, outer surface portions of plug 56 slidingly engage the opposing, internal surfaces of the leaves, forcing the serrated, external surfaces of the leaves into gripping engagement with the wall of drill hole 44. Rotation of the shell is inhibited by frictional engagement of its outer surface with the drill hole wall, and rotation of the plug is inhibited by engagement of ribs on opposite sides of the plug in the gaps between the shell halves. Continued application of torque to bolt 52 up to a predetermined maximum tensions the bolt to a desired degree to compress and reinforce the rock strata. The two components of the resin grouting are mixed to the degree necessary to initiate hardening by the hydraulic pressures developed as cartridge 66 breaks, by their flow around the plug and through the shell groove and by rotation of bolt 52. In a typical installation, only about 3 seconds of bolt rotation is required and hardening of the resin grout is essentially complete in about 10 seconds.
It will be understood that the invention may be practised with a wide variety of anchor designs, in addition to the embodiment illustrated herein. These include not only bail-type anchors, but also those having a unitary shell structure initially held in position by a support nut on the bolt. Also, the number of shell leaves may be other than four. The resin grooves may be other than arcuate in plan view, e.g., triangular, and more than one groove may be provided in one or more of the leaves. The grooves may extend from top to bottom of the shell angularly or spirally with respect to the shell axis, rather than parallel. Furthermore, the grooves may be of variable width, with portions defining relatively narrower or wider passageways for resin flow. In any case, a further advantage provided by the invention is that the sharp edges at each side of the grooves tend to engage the drill hole wall as the bolt is rotated, thereby inhibiting undesired rotation of the shell.
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A mechanical expansion anchor and radially expansible shell for use therein having particular application in combination with resin grouting materials. The anchor includes a conventional, tapered camming plug moveable axially upon a mine roof bolt to move the shell leaves outwardly into gripping engagement with the drill hole wall. The shell is distinguished by the provision of grooves in the outer surfaces of the shell leaves, extending between the upper and lower ends of the leaves. Components of a resin mix inserted into the drill hole in advance of the expansion anchor, carried on the end of the bolt, flow through the grooves in the outer leaf surfaces to the area below the anchor.
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BACKGROUND OF THE INVENTION
Aiming at improvements of embroidering exactitude and safety Japanese patent application No. 33791/86 teaches that at a first actuation of the start key an embroidering frame is moved without reciprocating a needle vertically in order to recognize an embroidering scope with respect to the embroidering frame and confirm an outer configuration of a pattern, so that an actual embroidering operation is carried out firstly at a second starting operation.
However, when a plurality of the same letters are stitched by the embroidering machine, the operating efficiency would be lowered if confirmation is made each time.
SUMMARY OF THE INVENTION
An object of this invention is to remove the shortcomings of the prior art, and provide a computer operated embroidering machine wherein in case of stitching a plurality of the same patterns, once having confirmed the embroidering scope in stitching one sheet of a fabric to be processed with the aid of the embroidering frame, confirmation of the scope may be omitted by an operator's disposal, and when issuing an instruction or order for omitting the confirmation due to the operator's error such an order is automatically recognized and nullified provided that the scope has never been confirmed, or parameters concerning pattern size and others have been changed during the preceding confirmation.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a function block diagram of the initializing control system of the invention;
FIG. 2 is a perspective view of a sewing machine in connection with a control device containing the system of the invention;
FIG. 3 is a plan view of an operating panel of the control device of FIG. 2;
FIG. 4 is a block circuit diagram of the control system of the invention; and
FIG. 5 is a flow-chart of a program part relevant to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As apparent from a function block diagram shown in FIG. 1, in a computer operated embroidering machine which is provided with a stitch forming instrument a including a needle for forming stitches in a fabric to be processed; an embroidering frame b for holding the fabric; a drive c for reciprocating vertically the needle and changing relative positions between the needle and the frame b; memory d for storing data indicating the relative positions and various pattern information groups; a pattern selecting instrument e for selecting desired patterns for the information in memory d; a parameter setting instrument f for setting how to dispose the selected pattern and in what direction to embroider it, how to enlarge or reduce the size of the pattern or how to space the patterns one from each other; a control instrument g for carrying out calculations used to control the stitch forming instrument a and the drive c; and a starting instrument h for initiating the start of the actual embroidering after having finished preparations such as pattern selections, and setting of parameters; an initial controlling system of the computer operated embroidering machine is provided with an instrument i for confirming an embroidering scope by tracing an outer configuration of pattern group with respect to the embroidering frame without reciprocating the needle vertically; an instrument j for ordering confirmation and omission of the scope; an instrument k for memorizing the condition when the embroidering scope has been once confirmed after selection of the pattern; an instrument l for recognizing changes in setting of the parameters with respect to the confirmation of the preceding embroidering scope in the same pattern after having confirmed the scope; an instrument m for judging if the order of confirming or omitting the scope is made available or not from the content of the confirmation and memory instrument k and the change recognizing instrument l when issuing an order of confirming and omitting the scope; and an instrument n for deciding a mode which at first confirms the embroidering scope after starting and performs the actual embroidering by a next start, or a mode which does not confirm the scope after starting but at once performs the embroidery. When the instrument j is not operated, the embroidering frame is moved at the first starting without reciprocating the needle vertically and traces the outer configuration of the pattern groups, and the embroidering is stitched at the second starting. When the instrument j is operated, the confirmation is omitted also at the first starting.
When the instrument j is operated and it is recognized from its contents that the scope has never been confirmed, and when it is recognized that the pattern information has been changed when confirming a preceding embroidering scope, the confirmation and omission of the scope is nullified.
In FIG. 2, numeral 1 designates an embroidering frame which holds a fabric to be processed and is positioned such that a vertically moving needle 2 is set therewithin. Numeral 3 denotes an X-Y shaft drive mechanism for controlling X-Y positions of the embroidering frame 1.
An embroidering part is composed of the needle and a lower thread loop taker device. A machine body 4 includes a motor for driving a main shaft of the sewing machine. The X-Y shaft drive mechanism 3 includes a stepping motor for driving X shaft and a stepping motor for driving Y shaft, mechanisms to be cooperated therewith, a power source switch, a transformer, a power source circuit, driver circuits for the stepping motors and so on.
Numeral 6 designates a control box for controlling and managing all operations of the machine body 4. The control box 6 includes a separate floppy disc driver 7, a key board 8, LCD display 9 and electronic control circuits.
The power source of the electronic circuit is supplied from the source circuit in the X-Y control mechanisms 3, and signals are communicated with the main machine body 4 via a cable 5. Compressed original embroidering data are written in an ordinary floppy disc by means of a data input device (not shown) during the preparation of the original data, and pertinent data are read in after inserting the disc into the floppy disc driver 7.
FIG. 3 is an enlarged view of the key board 8.
MODE key switches a mode to directly select letters from a key board by operating a corresponding key or indirectly select the letters by a numerical code entered by pressing number keys only. The number keys 0 to 9 input the code number or directly select the number and set the mutual space.
CLEAR key cancels erroneous input of the key, and return to an original stitching point during stopping of stitching.
LETTER AC key cancels all of selected and registered pattern numbers.
If FRAME BACKWARD KEY is operated during stopping while embroidering, only the frame goes backward as if stitching back on a part already stitched without moving the needle, that is, a frame back function is carried out. On the other hand, if FRAME FORWARD key is operated, only the frame goes forward without moving the needle, that is, a frame forward function is carried out.
With respect to ENTER key, when the pattern selection is an indirect mode by the code input and if ENTER key is pushed after the pattern code number has been pushed, ENTER key registers this code number. In a case of the direct mode, ENTER key is not necessary, since the code number is automatically registered.
READ DATA key is pushed after all patterns have been registered, whereby the embroidering data and the indication data of the required patterns, the letters, the data of enlarging and reducing rates of the pattern, the data of letter frames, and other controlling data are read out from the floppy disc.
SPACE key is a key for manual setting of spaces, e.g. between the letters at an optional value, not at a fixed reference.
LAYOUT key selects directions and arrangements of letters, and their directions and arrangements are indicated by LEDs (v) to (xii) where (xi) and (xii) indicate arc arrangements. If LAYOUT key is pushed repeatedly, LEDs in the above arrangement indications are lighted in succession, until the pushing is stopped at a desired position. Then the code of the arranging condition is registered.
SIZE key changes the size of the letter, and enlargement, standard size or reduction may be selected by pushing the key repeatedly.
For increasing degree of freedom of adjusting the letter, the enlarging rate or the reducing rate are changed into data.
Outwardly directed four arrows control manual feed of the embroidering same to bring the frame to a required position. Inwardly directed four arrows return the frame to the central origin.
NEEDLE POSITION key designates a starting position of a letter group (pattern group) with respect to the present position of the needle (shown with nodes (.) as indicated by LEDs (i) to (iv)). (i) indicates a centering, and when a plurality of letters are embroidered, they are divided around the center of the present needle position. If (ii) is designated, the stitching starts at the present position. The arc stitchings are at positions (iii) and (iv).
When the arrangement selected by LAYOUT key is positioned between (v) and (x), the designation of NEEDLE POSITION can be changed in a range of (i) or (ii), and when the arrangement is (xi) or (xii), the designation can be selected in a scope of (iii) or (iv).
In the relation between LAYOUT key and NEEDLE POSITION key, LAYOUT key has preference to NEEDLE POSITION key. Therefore, when NEEDLE POSITION key is (iii) at the arc stitching and if the arrangement is changed from the arc stitching to an ordinary stitching (e.g. (v)), NEEDLE POSITION is moved to (i) automatically
When START key is pushed, after a required letter or pattern is selected and the data are read out from the floppy disc, the embroidering operation is made available. Since the needle traces at its end point the outer configurations of the letters and patterns stitched out by first pushing of START key, only the frame is moved without moving the needle, whereby it is possible to confirm whether the embroidering range matches the frame. The frame moving data for confirming the range are made in reference to the letter frame data kept per each of the patterns. After the frame moving range has been confirmed and when, for example, NEEDLE POSITION is at (i), the centering is done and the embroidering starts there.
When the frame moves to show the embroidering range and if a calculated result is produced exceeding the moving limits of X-Y mechanism of the sewing machine, the embroidering range is not confirmed but a warning is issued nodifying such an exceeding. When the frame is moved according to the outer configuration of the embroidering range, the frame is temporarily stopped for further confirmation, for example, at each of the corners of a square locus, and a conversion is calculated from the compressed data of the letter to obtain the final embroidering data at the temporary stopping, taking into account parameters setting enlargement and reduction.
The above mentioned conversion is made from the compressed data not only during moving the frame but also during actually stitching embroidering.
STOP key stops the sewing machine during operation.
STYLE key designates letter styles when selecting the letters by the direct selection mode, and letter styles 1 to 5 may be designated by pushing STYLE key. For example, when a key M in the key board is pushed under the condition of STYLE No. 1, a letter style being selected is "M" in roman type, and when the key M is pushed by designation of STYLE No. 2, a letter being selected in "m" an italic type. This may be accomplished by determining a letter code as 1 1 2 2, to be formed automatically when M key is pushed under STYLE No. 1, and by determining a letter code as 1 3 2 2, to be formed automatically under STYLE No. 3.
When the selected letter is to be stitched in an arc arrangement, RADIUS/ANGLE key is used for setting parameters therefor. When pushing this key, a radius for the arc stitching and an angle setting mode are input. A parameter for forming the arc arrangement in reference to what part of the radius of the arc and a circle, i.e., 360° is determined in this mode.
SYMBOL key designates so-called one point pattern which is different from each of the keys (A, B, . . . ?) in the keyboard. If, for example, the key "A" is pushed after pushing SYMBOL key, there appears, for example, a heart mark instead of "A". This is performed automatically by changing the code similarly to the above mentioned changing of the letter style.
When the stitching origin is moved by pushing the radially directing arrows, LOCATION key shows the needle position as the digital value of X, Y coordinates. When this key is pushed, it shows the present position of the needle in the X, Y coordinates, the full length, height of the selected pattern group, spaces therebetween, and radius and angles of the arc arrangement.
While each of the desired letters is selected and when INTERRUPT key is pushed between the letters, this key determines a color change code for automatically stopping the sewing machine after embroidering one letter and before embroidering a next one. If the letter is kept selected while inputting this code, the sewing machine is stopped automatically when embroidering is finished and it is possible to issue a message requiring changing of a color.
The color changing code is input by a pattern data input device during making the pattern data. This is performed while switching, e.g., an image of a bird and when a colour is changed.
The present system may designate not only automatic stop in response to the color change code, but also the color change by the operator.
SKIP SEWING SCOPE key is provided in accordance with the present invention, and designates omission of confirmation of the embroidering scope after the selected pattern has been once stitched and when the same pattern is stitched again. However, if the embroidering scope has not been confirmed though the omission is designated, or if the embroidering parameter is changed after the confirmation has been done, this designation is nullified.
Reversely, SEWING SCOPE key confirms only the embroidering scope. The confirmation by this key is the same as confirmation of the embroidering scope after operation of START key but different in the mode after the confirmation. An embroidering actuation is shifted to the actual embroidering operation by a next actuation of START key, but in a case of SEWING SCOPE, such a shifting is not made, but this is an independent confirmation mode of the embroidering scope.
A next reference will be made to a control circuit block diagram shown in FIG. 4.
CPU is a central processing unit or a micro processor having an address bus terminal for supplying address information, a data bus transmitting instructions or data by bi-directional transmission in relation with memory or I/O device and terminals of control, and having therewithin an instruction register, a counting unit, accumulator and other registers.
ROM is a read-only-memory, RAM is a random-access-memory, and I/O is an interface enabling a program to transfer data between peripheral devices and the micro processor.
The above mentioned CPU, ROM, RAM and I/O are connected with the address data control bus as shown, and composes a main micro computer control system of the present initializing system.
A disc FD is an external memory called a floppy disc. A large amount of pattern information or data groups are stored therein by magnetic means. FDD is a floppy disc drive which rotates the floppy disc to read in and write out by way of the data random access.
SVM1 is a single chip type micro computer for controlling X shaft and serves as a slave computer for the main micro computer system that is, it controls the drive for X shaft in desired steps and in a desired direction.
SVM2 is a single chip type micro computer for controlling Y shaft and is the same as the slave computer in services and function.
SVM3 is a single chip type slave computer for controlling the machine motor for driving the main shaft of the sewing machine, and starts, stops and speed-controls the sewing machine in accordance with instructions or order from the main micro computer.
DVx is X shaft stepping motor and a driver for driving SM1, DVy is Y shaft stepping motor and a driver for driving SM2.
SC is a control circuit of the machine motor M, and KEY denotes a key panel part or matrix of the key board explained with reference to FIG. 3, and the matrix is connected with the main computer.
DISPLAY is a display comprising LED and LCD.
FIG. 5 is one embodiment of a flow chart of a program for parts concerned with the present invention.
The program starts by supplying the electric power. A flag in RAM referred to under a name of HENKA by an initial routine is cleared to 0 0. The flag HENKA is set to F F when the parameter of the size of the pattern is and, after the selected pattern has been once embroidered. In the initial routine, a flag CNT1 is cleared to 0 0, and is set to F F when the selected pattern has been confirmed with respect to the embroidering scope, and is cleared when a new pattern is selected.
LOOP1 is a wait routine, and various settings may be made during a waiting period, such as settings of pattern codes, registrations, writing-in of the pattern data, changings of the needle positions by the radially directing arrows, size of the letter and others. START key is accepted by this routine.
When START key is pushed, the routine is moved from LOOP1 to LOOP2 by discriminating the start of ST6. The above mentioned embroidering scope is confirmed during this period, and the routine is moved from LOOP2 to ST14 by the second pushing of START key. When pushing SKIP SEWING SCOPE of the key of designating confirmation and omission of the embroidering scope in LOOP1, the routine is about to moving from LOOP1 to LOOP3 by discriminating the step ST7, but in this period the embroidering scope interrogated or judged for confirmation or omission by ST16 and ST17. Only when the omission is determined by this judgement, the routine is moved to LOOP3 including ST18, and circulates LOOP3 until a subsequent first pushing of START key. When START key is firstly operated, the routine is moved to ST14 by discrimination of ST18 and to the actual embroidering.
In the step ST0 after the INITIAL step where CNT1=0 0, the routine proceeds to ST6 and continuously circulates the loop of ST7-ST8-ST9-ST10-ST0-ST6. In this loop, the settings such as the pattern selection, the data read-in and sizing are processed.
This processing is dealt with in steps ST8, ST9 and ST10, and the routine is always returned to this loop after processing. When the designation of confirming and omitting the embroidering scope is made under this condition, that is, a condition that a selected pattern has not yet been started, the routine is moved from ST7 and ST16. Since CNT1=0 0 herein, a mesage telling "confirmation, omission and non-permission of embroidering scope" is indicated at ST19 and the routine is again returned to LOOP1. The designation of confirming and omitting the embroidering scope is nullified.
START key is firstly pushed without designating omission, and the routine is moved from ST6 to ST11, and the embroidering scope is confirmed. In this case, the data of the selected letter frames are totalled and points of the outer configurations of the whole embroidering patterns are calculated, and in reference to these data the embroidering scope is confirmed. At each of the tops of the scope, the confirmation is temporarily stopped and during the stoppage embroidering position data are calculated from the pattern compression data, because it is necessary to prepare in advance the stitching data for the subsequent actual embroidering of the pattern. When the step of ST11 is finished and the routine is moved to ST12, the routine of LOOP2 for waiting for a next second start is circulated continuously.
"Other processing" in the routine of LOOP2 means to return the routine to the original LOOP1 by pushing CLEAR key. The routine is moved to ST14 by the second pushing of START key in LOOP2. During this period, the conversion to the actual stitching data is carried out continuously from the compressed data. Development to RAM of the converted position data is not done during each of the stitchings, but is done predominantly in advance. Since the stored amount is much in dependence on the patterns, a ring system is employed for storing large amount of data in a limited capacity of RAM. That means, the data are stored until the last storing location or range of the RAM is filled, and if a further storage is necessary, it is made from the initial storing location or range of the RAM.
In the initial RAM range the preceding data are destroyed by the newly stored data and, therefore, the preceding data, should be those which has been already stitched. Considering the frame back, a restriction is provided that new data are not input until a range to which the frame is returned at a fixed amount.
When embroiderings of all the patterns have been finished by ST14 and the routine is moved to ST15, the flag HENKA is cleared to 0 0. The flag CNT1 is set at F F, and it is memorized that a pattern stitched out has been once confirmed about the scope, and the routine is returned to LOOP1.
When returning to LOOP1, since CNT1=F F at ST0 the routine is moved to ST1, and if the parameter is not changed at LOOP1, the routine is moved from ST1 to ST2, and since HENKA=0 0 at ST2, the data conversion is made repeatedly from the compressed data/unit time (several ms) to the actual stitch data within this loop. In this data conversion, data concerning patterns having been just finished are stored at first storing range of the RAM. At the preceding start, the conversion was made at the confirmation of the scope, and at this time the omission to confirm the scope is ordered by SKIP SEWING SCOPE key, and since it is possibly practiced, the data conversion is in advance developed during the waiting routine of LOOP1 for the case of carrying out the embroidery by the first START key. However, in LOOP1, if the parameter is changed the routine at ST1 is moved to ST4 and HENKA flag is set with F F and is moved to LOOP1. Therefore, the data conversion of the unit time is not performed by ST3. Once the parameter is changed, it is not changed as the parameter and the routine at ST1 is moved to ST2. However, since HENKA=F F at ST2, the data conversion of the unit time of ST3 is skipped. When the order is issued to omit confirmation of the scope by SKIP SEWING SCOPE key after once embroidering and under a condition that the data conversion is done by ST3 without changing of the parameter, the routine is moved from ST7 to ST16, and it is moved to ST17, and moved to ST18 by HENKA=0 0 so that a condition waiting for start of LOOP3 is made. When the first START key is pushed, the routine is moved to ST14, and the embroidery is practised without confirming the scope. The routine is returned to LOOP1 after the embroidering and if LETTER AC key is pushed there, the routine is moved from ST10 to ST23 and CNT1 is cleared to 0 0.
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An apparatus is disclosed relating to a control system of an embroidering machine controlled by a microcomputer for stitching names or other patterns.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to lasers and more particularly to unstable resonators capable of accommodating a gain medium having high gain and large bandwidth to provide an output beam having good optical qualities and high bandwidth resolution.
2. Description of the Prior Art
Coherently pumped dye lasers having bandwidths appropriately narrowed in frequency are utilized for many applications. The coherently pumped dye laser is characterized by an active medium having high gain, small cross-sectional area and large gain bandwidth and is capable of providing laser radiation having bandwidths with high resolution by utilizing intracavity dispersive optical elements and intracavity etalons. Since the cross-sectional area of the active medium is typically very small, beam expansion optics are required to illuminate a sufficient area on the dispersive optics to obtain the desired narrowing of the radiation bandwidth. Only modest narrowing of the bandwidth is obtainable without expanding the intracavity radiation since the proper operation of the dispersive optics is functionally dependent on the size of the intracavity laser radiation.
The principal areas of the prior art which are improved by the present invention are the elimination of the intracavity beam expanding optics and the use of a resonator configuration having transverse mode discrimination capable of providing a laser beam confined to the lowest loss mode and of minimizing the effect of inhomogeneities in the active medium. Prior art resonators for use in conjunction with a dye gain medium typically have little transverse mode control capabilities.
A general discussion of unstable resonators with related references is presented by Chenausky, et al in U.S. Pat. No. 3,969,685 filed Dec. 6, 1974 and held with the present application by a common assignee. These references do not disclose the utilization of unstable resonators having high gain medium such as dye.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide an unstable resonator having high magnification. Another object is to provide a laser beam having a narrow bandwidth, from a dye gain medium.
According to the present invention an unstable resonator having high magnification comprises a first optical cavity, defined at one end by a first mirror and at the other end by a diffraction grating, including a reflector mirror having an aperture and a reflective surface capable of optically connecting the first mirror and the diffraction grating wherein the first mirror and the reflector mirror are positioned on and symmetrically about a centerline axis, and a second optical cavity, partially superimposed on the first optical cavity, defined at one end by the first mirror and at the other end by a second mirror positioned on and symmetrically about the centerline axis and having a focal length much less than the separation between the respective mirrors, wherein the first and second mirrors are optically connected through the aperture in said reflector mirror. In one embodiment the unstable resonator further includes an active gain medium disposed within the second cavity and means within the second cavity for out coupling a laser beam from the resonator.
A primary feature of the present invention is the high magnification of the unstable resonator. Additionally, the unstable resonator is formed with a pair of cavities in optical communication with one another. The first and second mirrors have concave reflective surfaces centrally located on a centerline axis and separated from one another sufficient to have a common focal plane. Also, the small focal length of the second mirror produces a second cavity having a high magnification. The aperture in the reflector mirror is centrally positioned about the centerline axis near the common focal plane and is capable of providing spatial filtering to suppress high order modes of the radiation within the second cavity. The second cavity is capable of expanding the radiation to provide radiation having a large diameter to the first cavity. The diffraction grating defining one end of the first cavity is capable of narrowing the bandwidth of the radiation to obtain high resolution. In an embodiment of the present invention, the second cavity is capable of accommodating an active medium, having high gain and small transverse dimensions, between the second mirror and the reflector mirror. The second mirror has a partially reflecting surface capable of partially reflecting and partially transmitting the intracavity radiation. Also, the second mirror is formed with material transmissive at the wavelength of the radiation and is capable of out coupling from the resonator a laser beam having a continuous cross section. Additionally, the resonator is capable of accommodating an etalon to further improve the resolution of the bandwidth.
A primary advantage of the present invention is the narrow bandwidth of the laser radiation produced without utilizing transmissive intracavity beam expansion optics. Additionally, the transverse mode discrimination of the unstable resonator minimizes the effect of inhomogeneities in the active medium. Also, the high magnification of the resonator allows the aperture in the reflector mirror to function as a spatial filter capable of discriminating against high order resonator modes to produce a laser beam having high optical quality. Additionally, the laser beam has good far field characteristics suitable for optical communication and optical radar and the high resolution of the bandwidth of the laser beam is suitable for isotope separation.
The foregoing and other objects, features and advantages of the present invention will become more apparent in the light of the following detailed description of the preferred embodiments thereof as illustrated in the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a simplified schematic of the present invention showing the principal optical elements cooperating with a gain medium to provide a laser beam;
FIG. 2 is a simplified schematic of the present invention showing the optical path of the radiation within the resonator; and
FIG. 3 is a simplified schematic of the present invention in which a laser beam is out coupled from the resonator by a reflector mirror.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The apparatus as shown in FIG. 1 is a simplified schematic of the present invention for an unstable resonator having high magnification with coupled cavities. The unstable resonator 10 has a first cavity 12 defined at one end by a first mirror 14 having a concave surface 16 with a focal length of f 1 and at the other end a diffraction grating 18 having grating lines 20 and a second cavity 22, partially superimposed on the first cavity, defined at one end by the first mirror 14 and at the other end by a second mirror 24 having a second concave surface 26 with a focal length of f 2 and includes a reflector mirror 28 having a flat reflective surface 29 with an aperture 30 located between the first mirror and the second mirror. The first mirror, the second mirror and the reflector mirror are all concentrically located on a centerline axis 32 with the first and second mirrors having a common focal plane 34. The flat reflective surface of the reflector mirror intercepts the centerline axis at an angle and forms a folded optical path between the concave surface of the first mirror and the diffraction grating to provide line of sight communication therebetween to define the optical path of the first cavity. An etalon 36 is located within the first cavity between the grating 18 and the reflector mirror 28 and a dye cell 38 having a high gain medium and small transverse dimensions is located within the second cavity between the reflector mirror 28 and the second mirror 24. A laser beam 40 is out coupled from the resonator through the second mirror 24 formed with material transmissive at the wavelength of the laser beam.
FIG. 2 shows a simplified ray trace of the optical path within the resonator. Radiation 42 expanding from the common focal plane 34 of the first and second mirrors is incident onto the concave surface 16 of the first mirror 14 and is reflected into the first cavity as a collimated beam 44 having a large diameter. The collimated beam 44 is reflected by the flat reflecting surface 29 of the reflector mirror 28 and is incident onto the diffraction grating 18. The collimated beam retroreflected by the grating is reflected by the flat reflecting surface 29 and is collected by the first mirror and focused at the common focal plane 34. The radiation diverging from the common focal plane is collected by the reflecting surface 26 of the second mirror and reflected back through the aperture 30 to the first mirror as a second collimated beam 46 having a reduced diameter. Multiple reflections of the second collimated beam between the first and second mirrors compresses the second collimated beam toward the centerline axis to promote the desired mode characteristic of the resonator. This process continues until natural diffraction of the compressed radiation is exactly compensated for by the compression of the radiation within the second cavity. Eventually, the second collimated beam expands, as for example, by diffractive spreading and scattering onto the first mirror which results in the collimated beam 44 within the first cavity whereupon the cycle is repeated. Thus, if the reflection losses at the second mirror are small, the coupled cavities form a high Q resonator. The large magnification (f 1 /f 2 ) of the second cavity, which is a confocal negative branch unstable resonator, eliminates the need for transmissive intracavity beam expanding optics to provide the collimated beam of radiation 44 having a large diameter to the first cavity. The diameter of the second collimated beam within the second cavity is a function of the reciprocal of the resonator magnification (f 2 /f 1 ).
Referring now to FIG. 1 and 2. In operation, the reflector mirror 28 directs the collimated beam 44 within the first cavity 12 to the diffraction grating 18. The collimated beam is diffracted by the grating lines 20 to obtain frequency narrowing of the radiation bandwidth. The grating typically has a large number of grating lines per millimeter, for example at least six hundred, to provide adequate narrowing of the broadband gain profile typically exhibited by dye gain medium. Since the obtainable frequency narrowing is proportional to the number of lines illuminated by the laser radiation, the diameter of the beam incident on the diffraction grating should be large in order to obtain optimum conditions for spectral narrowing.
The first cavity 12 is capable of accommodating an etalon 36 typically of the Fabry-Perot type to provide additional resolution to the bandwidth of the radiation. Resolutions of the order of 1 gigahertz are readily obtainable. The etalon is typically located within the resonator to intercept the large diameter radiation to minimize "walk off" losses. FIG. 1 shows the etalon located between the reflector mirror and the diffraction grating in close proximity to the latter.
The radiation retroreflected by the grating and incident onto and reflected by the first mirror will be Fourier transformed at the common focal plane 34. Since the magnification of the second cavity is high, typically greater than 20, the focal plane distribution will be similar to an Airy function. Thus, the aperture in the reflector mirror can act as an intracavity spatial filter which will reject high order mode components. The high order components are reflected from the surface of the reflector mirror towards the grating. Since these components are diverging from the common focal plane 34, the grating 18 will not retroreflect the high order components back into the second cavity. Consequently, high order mode losses will exceed those of the desired mode and the lower loss modes will dominate. Additionally, since there is considerable freedom in locating the reflector mirror along the centerline axis 32, the spatial filtering and subsequent rejection properties of the reflector mirror may be easily altered by moving the position of the grating or by translating the reflector mirror along the centerline axis from the preferred position at the point of intersection of the common focal plane with the centerline axis. Since the dominant mode of the coupled unstable resonator is of the negative branch type, the inversion symmetry generated at the common focal plane will be beneficial in averaging out inhomogeneities within the resonator. The size of the aperture is dependent upon the magnification of the resonator.
In the preferred embodiment of the present invention the first and second mirrors have spherical reflective surfaces and the aperture in the reflector mirror is circular. It is to be recognized that cylindrical reflective surfaces on the first and second surfaces can also be employed with a rectangular shape aperture in the reflector mirror.
The dye cell 38 having high gain and large gain bandwidth is located within the second cavity between the reflector mirror and the second mirror and has dimensions small compared to the focal length of the second mirror. The size of the aperture 30 within the reflector mirror is such that the resonator will efficiently operate only with the dye cell located between the reflector mirror and the second mirror 24. The size of the aperture is such that locating a gain medium between the first mirror 14 and the reflector mirror would result in the overall laser operation being dominated by the first cavity.
In operation, laser radiation is regenerated within the gain medium located within the second cavity. The second mirror 24 is formed with material transmissive at the wavelength of the laser radiation. The second concave surface 26 is a partially reflective surface capable of reflecting a portion of the radiation incident thereon and of transmitting a portion of the radiation which passes through the second mirror to form the laser beam 40. Additionally, an aperture within the second cavity may also be utilized to couple the laser beam from the resonator. It is to be noted that the aperture could be centrally located within the first or second mirrors. Alternately, a second reflection surface on the back side of the reflector mirror cooperating with the reflective surface of the second mirror as shown in FIG. 3 will function as a stripper mirror to out couple a laser beam having a central portion with zero intensity in the near field. It is to be recognized that the use of an aperture or a stripper mirror to out-couple the laser beam 40 from the resonator will typically require the second mirror to have a surface capable of reflecting nearly all of the incident radiation.
It is to be noted that since the magnification of the resonator is large, typically in excess of 20, the unstable resonator having high magnification with coupled cavities concept can be applied to only a very limited range of laser devices, specifically devices which have simultaneously high gain, low energy output and large gain bandwidth. Low magnification unstable resonators are not suitable for these devices since high magnification is required in order to illuminate a large portion of the grating to minimize the bandwidth of the laser beam.
Although this invention has been shown and described with respect to preferred embodiments thereof it should be understood by those skilled in the art that various changes and omissions in form and detail thereof may be made therein without departing from the spirit and scope of the invention.
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An unstable resonator having high magnification and capable of accommodating an active medium having high gain and small dimensions is disclosed. The unstable resonator, formed with a pair of coupled cavities, has a diffraction grating capable of providing high resolution of the bandwidth of radiation from a high gain medium such as a dye medium and is capable of providing a laser beam with a continuous cross-section having far field characteristics of high quality.
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FIELD OF THE INVENTION
The present invention pertains to a sewing machine with a needle bar driven in an upwardly and downwardly movable manner with a needle feed mechanism, a feed dog and the needle driven oscillatingly in the direction of feed, a stitch regulating device associated with the feed mechanism, and a device for controlling the sewing machine and for approaching a predetermined end point of a seam at a spaced location from the edge of a workpiece, the device comprises a sensor, which is arranged in front of the needle and triggers the operation for positioning the needle at the seam end point during the passage of the workpiece edge, the device has a pulse generator determining the speed of rotation and the angular position of a machine shaft and a computer, which controls the number of residual seam stitches and, via an adjusting device, the setting of the stitch regulating device for reaching the seam end point as a function of the distance between the needle and the sensor and the angular position of the machine shaft, which is determined at the time of the edge recognition.
BACKGROUND OF THE INVENTION
A means for approaching the end point of a seam, in which this operation is triggered by means of a sensor scanning the passage of the workpiece edge extending at right angles or at an angle to the seam, is known from DE 33 24 715 C2 (U.S. Pat. No. 4,528,923) in a sewing machine with lower and needle feed. The means comprises, furthermore, a pulse generator detecting the speed of rotation and the angular position of a machine shaft, by which the size of the partial stitch already pushed during the edge recognition is determined. The number of residual seam stitches, which are unchanged in length, and the length of the shortened end stitch or the length of a plurality of uniformly shortened residual seam stitches are calculated by means of a computer as a function of the distance between the middle position of the needle of the sewing machine and the sensor, the seam distance and the length of the partial stitch yet to be pushed.
To adjust the stitch regulating device accurately and also comparatively rapidly, the computer prompts the presetting of a stop for limiting the movement stop of a follower member coupled with the stitch regulating device. This follower member is moved very rapidly against the stop before the beginning of the one shortened end stitch or of the first of several shortened residual seam stitches by means of a compressed air cylinder and the stitch regulating device is thus adjusted to the desired shortened stitch length.
It is expressly emphasized in the DE-C2 that the adjustment of the stitch regulating device takes place during the short time available during the phase of standstill between the needle and the workpiece. This should be understood to mean that the exact adjustment of the stitch regulating device can take place only in the middle of the phase of feed of the feed dog and the needle and consequently with the lower needle feed.
The same situation that was described in the specification of the DE-C2 concerning the sewing unit for sewing calender envelopes of the firm of Adler would otherwise occur. A sewing machine with lower feed is used in this prior-art sewing unit. When the stitch regulating device is set to the stitch length zero in this unit during the feed motion in order to interrupt the feed motion of the workpiece as a result, this can be performed with sufficient accuracy only if the feed dog has performed exactly half of its feed motion during the adjustment of the stitch regulating device and is therefore in the middle of the needle. Because of the existing kinematics of stitch regulating devices, the feed dog always assumes the middle position during the adjustment of the stitch regulating device to zero. If the adjustment of the stitch regulating device is performed before or after the middle position of the feed dog, the latter will therefore perform a forwardly or backwardly directed offset movement toward the middle of the needle. Since this happens while a feed step is being performed, during which the feed dog is in contact with the workpiece, the workpiece also performs the offset movement of the feed dog, and this movement is therefore also called pushing movement.
Such an offset movement also occurs in the sewing machine with lower and needle feed known from the above-mentioned DE 33 24 715 C2 during the adjustment of the stitch regulating device. The effects of this on the stitch length of the sewing stitch to be performed thereafter are illustrated in the drawing on the basis of the movement of the needle, whose tip describes elliptical movement paths.
FIG. 4 shows the movement path of the needle 5 during a feed cycle, during which the stitch regulating device is set to the stitch length S and the needle 5 feeds the workpiece W together with the feed dog 9 by the amount of the set stitch length S in the direction of feed V. The movement path of the needle 5 is now symmetrical to the middle of the needle Nm.
FIG. 5 shows the situation that would occur if the stitch length Sb of a residual seam end stitch located at the end point of the seam were detected by means of the computer after an edge recognition and the stitch regulating device were set to the stitch length Sb during the return phase of the needle and the feed dog. After the completion of the last feed cycle, the last point of insertion of the needle 5 or the point at which the needle exits is located at a distance S/2 in the direction of feed V behind the middle of the needle Nm. If the stitch regulating device is set to the lower value Sb, the needle bar first performs an offset movement in the direction of the middle of the needle because of the above-mentioned existing kinematics of stitch regulating devices. The needle bar then moves in front of the middle of the needle Nm by the amount Sb/2 when viewed in the direction of feed V. A stitch length of Sz=S/2+Sb/2 is thus obtained for the next sewing stitch. If, e.g., the stitch length is S=4 mm and a stitch length of Sb=1 mm was calculated for the residual seam end stitch, a stitch length of Sz=4/2+1/2=2.5 mm would be obtained for the last stitch. The last stitch would thus be too long by 1.5 mm.
To avoid such an offset movement leading to an unusable result, the adjusting movement of the stitch regulating device must be, as was mentioned, very rapid, i.e., sudden in the middle of the feed phase. However, the consequence of this is that the adjustment operation causes a vibration of the sewing machine and a corresponding noise. If, by contrast, the adjustment operation shall take place more slowly, the sewing machine would have to be briefly stopped for this purpose, which would interrupt the sewing operation and lead to a loss of time.
These problems are avoided in the means known from DE 33 42 391 C1 (U.S. Pat. No. 4,587,915) such that the setting of the stitch regulating device remains unchanged in this means for the performance of a single shortened end stitch or a plurality of shortened residual seam stitches, and the feed dog is raised, instead, during its return phase, which normally takes place in the lowered position, until it pushes the workpiece back against the normal direction of feed by the amount by which the next end stitch or residual seam stitch shall be shortened. Aside from the fact that this means is technically highly complicated, another drawback lies in the fact that it may sometimes lead to inaccurate results because the feed dog, which now acts as the only feed means, is operating against the normal direction of feed of its teeth during the reverse push, and a slip, whose amount depends very strongly on the properties of the particular fabric of the workpiece, may therefore develop between the feed dog and the workpiece.
SUMMARY OF THE INVENTION
The basic object of the present invention is to provide a sewing machine with a means for approaching a predetermined end point of a seam, which has a simple design and in which the adjustment of the stitch regulating device can be carried out without interruption of the sewing operation.
The present invention is based essentially on the idea of adjusting the stitch regulating device during the phase of return of the feed means before the sewing of a shortened end stitch or residual seam stitch such that the offset path of the feed means, which thus arises, is also taken into account, so that the end stitch of the seam is carried out with the necessary stitch length and the seam is terminated precisely at the point predetermined by the amount of the particular seam distance.
The process is also suitable for sewing uniformly shortened residual seam stitches. However, the particular offset path, which is consequently the current offset path, must be taken into account in this case for sewing every individual residual seam stitch, and the stitch regulating device must be set separately for every individual residual seam stitch.
The law that is equally applicable to both types of seam end management, by which the amount of the offset path is taken into account without having to determine it directly, is described.
The adjusting device for the stitch regulating device is formed by a stepping motor. This design of the adjusting means, which is simple compared with the state of the art, is made possible by the fact that by taking into account the offset path of the feed means, which arises during the adjustment of the stitch regulating device, the adjustment operation does not need to take place abruptly, but it can be performed during the comparatively long time of the return phase of the feed means.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a view of a sewing machine with a schematic block diagram of the control means;
FIG. 2 is a schematic view of a seam section with a shortened residual seam end stitch;
FIG. 3 is a schematic view of a seam section with a plurality of uniformly shortened residual seam stitches;
FIG. 4 is the movement path of the needle during the performance of a feed cycle;
FIG. 5 is the movement path of the needle after the adjustment of the stitch regulating device with the effect of the offset movement occurring during the adjustment; and
FIG. 6 is the movement path of the needle after the adjustment of the stitch regulating device with the compensation of the offset movement, which compensation is performed in the process.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in particular, in the sewing machine 1 , the base plate is designated by 2 and the upper housing by 3 . A needle bar 4 , which can be moved up and down, is arranged with a needle 5 in the head of the upper housing 3 . A hook shuttle, not shown, cooperates with the needle 5 in the known manner.
The feed mechanism 6 of the sewing machine 1 is designed as a lower and needle feed, as in the sewing machine according to DE 33 24 715 C2 mentioned in the introduction, and it therefore comprises a feed dog 7 arranged in the base plate 2 and the needle 5 . The needle bar 4 is accommodated for this purpose in the known manner in a needle bar pendulum, which is not shown in the drawings. The feed dog 7 and the needle bar pendulum are connected to a drive mechanism, which is partially coupled with one another, and which corresponds to the drive mechanism disclosed in the DE-C2 and therefore will not be shown and described here once again.
A common stitch regulating device 8 is used to set the amount of feed of the feed mechanism 6 . It has a first adjusting mechanism 9 shown schematically in FIG. 1 for the feed dog 7 , and this mechanism 9 corresponds to the adjusting mechanism 26 in the above-mentioned DE-C2. The stitch regulating device 8 has a second adjusting mechanism, not shown, for the needle 5 , which comparably corresponds to the adjusting mechanism 44 in the DE-C2.
An adjusting shaft 10 , which is connected to the adjusting shaft of the second adjusting mechanism in the usual manner via coupling members, is associated with the adjusting mechanism 9 , so that the two adjusting mechanisms always have the same setting value and are always set to the same stitch length. The adjusting shaft 10 is connected to a stepping motor 11 . Due to the two adjusting mechanisms being coupled, the stepping motor 11 is used for both and there is, on the whole, a common adjusting means for the stitch regulating device 8 .
A positioning motor 12 arranged in the base plate 2 with a control 13 is used to drive the sewing machine 1 . The positioning motor 12 drives, among other things a drive shaft 14 for the feed dog 7 in a manner not shown more specifically. A pulse generator 15 is arranged at the positioning motor 12 , the pulse generator 15 being used to determine the speed of rotation of the sewing machine 1 and the angular position of the drive shaft 14 when an edge K 2 of a workpiece W passes through the light beam of a photoelectric cell, of which only a sensor 16 arranged at the head of the upper housing 3 is shown.
A control means 17 , which contains a computer 18 , is associated with the sewing machine 1 . The computer 18 comprises essentially a processor 19 , an I/O member 20 and at least one EPROM 21 . The control means 17 contains, furthermore, an operating element 22 connected to the computer 18 .
The mode of operation is as follows:
The scanning point A of the sensor 16 is located at a distance L from the middle position M of the needle 5 . During the preparation of a seam B 1 consisting of sewing stitches N of a stitch length S at a distance a from the edge K 1 of a workpiece W, the sensor 16 reports the passage of the edge K 2 of the workpiece W through the scanning point A.
The size Sa of the partial stitch not yet completed at the time of the recognition of the edge, which is to be taken into account subsequently during the residual seam extending over the length 1 , is determined by means of the computer 18 in the same manner as described in the above-mentioned DE 33 24 715 C2.
In the case of the manner of seam end management shown in FIG. 2, in which the partial stitch yet to be pushed is taken into account only during the residual seam stitch NRe, the number of residual seam stitches NR to be formed with unchanged stitch length S and the length Sb of the residual seam end stitch NRe are now calculated by the computer 18 as a function of the residual seam length 1 and the stitch length S set originally.
The length Sb of the residual seam end stitch NRe now forms the desired stitch length necessary for ending the seam B 1 exactly at point E. To compensate the offset path of the feed dog 7 and the needle 5 , which arises during the adjustment of the stitch regulating device 8 , the computer 18 calculates from this, moreover, the value Sen to be actually set according to the formula
Sen =2 ×Sb−Sea.
Here,
Sen=new stitch length to be set
Sb=necessary desired stitch length for the residual seam end stitch NRe
Sea=old stitch length set; this corresponds to the original stitch length S in this seam end variant.
Calculation Example:
S=Sea =4 mm
Sb =1 mm
Sen =2×1 mm −4=−2 mm.
This means that the stitch regulating device 8 must be set to the value −2 mm, i.e., to a reverse stitch of 2 mm, by means of the stepping motor 11 during the return phase of the feed means 5 , 7 . If this has thus happened, the feed mechanism 6 performs a forwardly directed feed motion over a length of 1 mm to form the residual seam end stitch NRe, as it corresponds to the necessary desired stitch length Sb.
FIG. 6 shows this situation on the basis of the movement path of the needle 5 . After completion of the feed cycle of the last residual seam stitch NR with the stitch length S=4, the point at which the needle exits is located at a distance of S/2=2 mm behind the middle of the needle Nm. If the stitch length Sen=−2 mm is set, the needle bar 4 remains in the area behind the middle of the needle Nm because of the reverse feed to be set, and a new point of insertion, which is located −2/2=−1 mm behind the middle of the needle, arises for the needle 5 . It follows from this that the residual seam end stitch NRe is indeed formed with a stitch length of 1 mm.
The offset movement of the feed dog 7 and the needle 5 , which arises during the adjustment of the stitch regulating device 8 taking place during the return phase of the feed dog 7 and of the needle 5 , is thus compensated. If this compensation of the offset movement did not take place and the stitch regulating device 8 were set at the value of the desired stitch length of 1 mm, an effective stitch length of 2.5 mm would be obtained for the residual seam end stitch NRe, as is shown in FIG. 5, as a consequence of which the actual end point of the seam would be beyond the desired end point E by 1.5 mm.
If the first sewing stitch of the second seam B 2 along the workpiece edge K 2 is to have the same length as the residual seam end stitch NRe to obtain a symmetrical design of a seam corner area, the stitch regulating device 8 must be set to the value
Sen =2 ×Sb−Sea
=2×1 mm−(−2 mm)
=4 mm.
This value corresponds to the normal stitch length S. Consequently, while the first sewing stitch of the second seam has reached the desired length of 1 mm, the second sewing stitch and all further sewing stitches are formed with the normal stitch length 4 mm while the setting of the stitch regulating device 8 now remains unchanged.
To perform the type of seam end management shown in FIG. 3, in which the partial stitch yet to be pushed is taken into account in the case of, e.g., three uniformly adapted residual seam stitches NRv, the computer 18 now calculates the number of residual seam stitches NR to be formed with unchanged stitch length S and the length Sc of the three shortened residual seam stitches NRv as a function of the residual stitch length 1 and the stitch length S set originally.
The length Sc of the residual seam stitches NRv forms here the desired stitch length of the last three residual seam stitches NRv that is necessary for ending the seam B 1 exactly at point E. To compensate the offset path of the feed dog 7 and of the needle 5 , which arises during the adjustment of the stitch regulating device 8 , the computer 18 calculates, moreover, the value Sen to be actually set for every individual of the last three residual seam stitches NRv, doing so according to the formula
Sen =2 ×Sc−Sea.
This formula corresponds exactly in terms of its contents to the above-mentioned formula. The only difference is that the desired stitch length of the last three residual seam stitches NRv is called Sc in this formula, whereas the desired stitch length of the only residual seam stitch NRe was called Sb in the first-mentioned formula.
Calculation Example:
S =4 mm
Sc =3 mm.
First Shortened Residual Seam Stitch NRv
Sen =2 ×3 mm−44 mm=2 mm
The original stitch length S=4 is to be used here for Sea.
Second Shortened Residual Seam Stitch NRv
Sen =2×3 mm−2 mm=4 mm
The stitch length Sen=2 mm set before is to be used here for Sea.
Third Shortened Residual Seam Stitch NRv
Sen =2×3 mm −4 mm=2 mm
The stitch length Sen=4 mm set before is to be used here for Sea.
It follows from this that the stitch regulating device 8 must be set separately for every individual residual seam stitch NRv for sewing a plurality of uniformly shortened residual seam stitches NRv in order to compensate the current offset path occurring in the particular case.
If the starting area of the second seam B 2 shall look like the end area of the first seam B 1 with this type of seam end management, and this seam therefore begins with three shortened sewing stitches of a length of 3 mm each, and the sewing of this seam is then to be continued with a stitch length of 4 mm, the stitch regulating device 8 must be set to the value Sen=4 mm for the first sewing stitch, to the value Sen=2 mm for the second sewing stitch and to the value Sen=4 mm for the third sewing stitch. Sewing can then be continued with the last setting value, because this value corresponds to the normal stitch length S=4 mm.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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A sewing machine has a device for steering towards a predetermined end (E) of a seam (B 1 ). An alternating movement of the feed elements of the sewing machine, which occurs when the stitch adjusting device is set, is taken into consideration in the calculation of the target stitch length (Sb) of the final optionally shortened end stitch (Nre) of the seam, in such a way that the setting value that deviates from the target stitch length is produced.
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FIELD OF THE INVENTION
This invention relates to an apparatus for dispensing a pressurized fluid from a container. More specifically, it relates to an apparatus for dispensing carbonated beverages, where the apparatus includes a plug utilizing a double sealing configuration, a siphon tube containing flow obstructing devices that reduce the pressure of the fluid in discrete stages as it is dispensed, a sealing mechanism that assures proper alignment between the apparatus and the container, and a connecting shaft configuration which allows the connection between the handle and the head to move in a linear direction as the handle pivots.
BACKGROUND OF THE INVENTION
A universal problem in dispensing carbonated fluids from commercial containers, large containers in particular, is that the sealing cap must be removed from the container each time the fluid is dispensed, thereby permitting carbon dioxide to escape. Frequently, by the time the container is half empty, the remaining fluid has lost enough carbonization to render it “flat.” When this occurs, the fluid becomes undesirable to consume and is discarded along with the container. This essentially nullifies the savings of buying a large container. Further, when these containers are discarded prematurely, they contribute to waste disposal problems. It has been estimated that if all the bottled carbonated beverages were sold in 2 liter sized bottles, bottling, packaging and distribution costs could be reduced by an estimated 30% or more.
With these problems in mind, there have been many different types of fluid dispensers created, of many and varying designs. While such devices have achieved commercial acceptance, at least to some limited extent, many suffer from a number of known disadvantages. One such deficiency lies in the fact that most known fluid dispensers are structurally complex and are thus difficult and expensive to manufacture.
A further and very significant disadvantage of many known fluid dispensers lies in the fact that to dispense the fluid, a propelling force must be employed. In general, such means include a piston-type fluid actuating mechanism and/or a pressurized gas (e.g., carbon dioxide) cartridge. Specific examples of devices involving the use of piston-type fluid actuating mechanisms for dispensing the fluid are disclosed in U.S. Pat. Nos. 2,547,109; 3,458,090 and 2,837,247. Further examples of known prior art devices, including those which employ the aforementioned carbon dioxide cartridges, are disclosed in U.S. Pat. Nos. 565,922; 1,648,575; 2,049,851; 2,189,643; 2,199,655; 2,915,251; 3,154,224 and 3,221,953. Notwithstanding the fact that a large number of such designs are known, it has been found that the piston-type actuating mechanism, as well as the carbon dioxide cartridges, are very often difficult to operate and by their inherent nature involve additional expense, both in the original purchase price of the device as well as in the overall expense of their operation and maintenance.
A solution to such problems that avoids the need for external propelling force utilizes the pressurized fluid itself as the motive force for removing the fluid from the bottle. Such devices typically employ a flow control valve mechanism and a mechanism for sealing the fluid in the bottle. In the prior art, however, typical dispensers place the flow control valve mechanism in the upward flow section of the dispenser device. A stagnation problem and the increased likelihood of attracting insects occurs when fluid collects in crevices of the valve assembly. When the next discharge of fluid occurs, this residual amount of fluid, after having stagnated and collected bacteria, is discharged along with the clean fluid in the bottle into the drinking container and consumed by the unsuspecting user.
Some devices of the prior art have attempted to overcome these drawbacks by placing the spring-type valve mechanism in the downward spout of the container. U.S. Pat. No. 5,292,038 by Seney is one such device. Although superior to other devices, the Seney device does not solve the additional problem of the discharge spout retaining a few drops of the liquid after the dispensing step is complete. In Seney, the pressurized fluid flows from the bottle up through a siphon tube, through a passage and down a downward spout, past a valve assembly, further down a discharge spout and finally out a discharge port and into a glass or other receptacle. The drawback of such devices as the Seney patent is that the valve assembly is located midway down the discharge spout, as opposed to being located at the distal end of the discharge spout. This configuration results in a few drops of the liquid adhering to the discharge spout after the user has released the valve. These drops will subsequently fall onto the counter top or other surface which is supporting the bottle, causing a mess and creating unsanitary conditions.
The prior art also contains devices which have the additional disadvantage of emitting a high pressure stream of liquid at the very outset of the dispensing step. For example, a soda dispenser sold by Jokari, 1205 Venture Court, Carrollton, Tex., has a configuration which allows fluid to be held under pressure just behind the dispensing nozzle when the apparatus is in the closed position. As a result of this design, it is possible for fluid to spray out of the nozzle in a small, fast stream when the nozzle is first opened. A device is needed which would prevent fluid from being retained under pressure just behind the discharge port, so as to not cause spraying at the start of the dispensing step.
Another drawback of the prior art is that many of the liquid dispensing devices contain valve actuating mechanisms which are not easy to use. For example, U.S. Pat. No. 4,194,653 discloses a device containing a valve mechanism which requires the user to press down on a cap which is mounted atop the apparatus. Such devices are difficult and uncomfortable to use. A device is needed which uses an actuating mechanism that is easy to use.
Yet another disadvantage of the devices presently known for use in dispensing liquids under pressure is that many such devices contain inadequate sealing mechanisms between the bottle and the device. For example, many do not have any sort of system to assure that the top of the bottle is lined up directly with the underside of the device to assure that the device is properly seated on the bottle. The result of such systems is that the top of the bottle neck may be bent slightly, thus possibly destroying the air-tight seal.
Another drawback in the prior art is that many of the dispensers use little more than a tube for transferring the liquid from the bottle to the dispenser. As a result, large quantities of carbon dioxide gas may escape from the liquid as it is dispensed, which causes the liquid to have a “flat” taste. An apparatus is needed which is capable of allowing increased retention of gaseous carbon dioxide in the liquid after it has been dispensed, as well as decreased foaming. Such a device would allow the fluid that has been dispensed to appear and taste better.
Yet another disadvantage of the prior art is that many devices which contain valve systems use configurations that cause the valve stem to move in a non-linear direction. In other words, as the valve is being actuated, the member which connects the valve to the handle moves slightly downward rather than in a straight line. Such members are often located within linear chambers. Such linear chambers typically include seals or other methods to prevent fluid from flowing into the member chamber. Because the member does not move in a linear direction, there is the increased possibility of wear and tear, and eventually leakage into the member chamber. Once fluid has leaked into the member chamber, it is possible for the fluid to leak out of the apparatus and onto the counter top, thus causing a mess. A device is needed which allows the member connecting the valve to the handle to move in a linear direction, such that the likelihood of leakage will be minimized.
The present invention provides a dispensing apparatus that overcomes the disadvantages of such prior known apparatus.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the invention to provide a liquid dispensing apparatus that is simple in construction, inexpensive to manufacture, which is easily disassembled into several component parts by hand for easier cleaning, and which will minimize the loss of gaseous carbon dioxide from the liquid being dispensed. It is also an object of the invention to prevent spraying the fluid from the valve at the start of the dispensing process, and to prevent dripping of the fluid from the apparatus during the dispensing process as well as after dispensing is complete.
According to the present invention, there is provided a dispenser which includes a head element, a siphon tube, and a handle. Inside the head element is a chamber for fluid communication between an inlet port and a discharge port. The chamber contains a double plug seal mechanism for controlling fluid flow. The double seal plug generally includes a plug containing a forward end designed and shaped to form a watertight seal with the discharge port.
When the apparatus is in the closed position, the double seal plug is located fully forward, in a narrow portion of the plug chamber. The narrow portion of the plug chamber is sized and shaped to form a watertight connection with the aft end of the double seal plug. Thus both the forward end and the aft end of the double seal plug are designed to seal at different locations within the plug chamber, hence the name “double seal” plug. An actuator is connected to the double seal plug such that engaging the actuator causes the double seal plug to move aft, thus moving the double seal plug from the narrow portion of the plug chamber to a wider portion, and permitting fluid to flow through the head.
There are several benefits to the double seal plug/plug chamber configuration of the present invention. The primary benefit is that when the apparatus is returned to the closed position, all of the fluid in the plug chamber which is forward of the aft end of the double seal plug drains out of the apparatus. As a result, the narrow portion of the double seal plug chamber does not contain any fluid under pressure which might tend to spray out in a stream the next time the apparatus is used. Another benefit of the placement of the double seal plug fully forward in the seal plug chamber, and adjacent to the discharge port, is that there is no fluid forward of the plug when the apparatus is in the closed position. As such, the likelihood of drops of fluid clinging to the apparatus, and then dripping onto the counter top supporting the beverage container after the apparatus is used to dispense fluid, are eliminated or greatly reduced.
The present invention has particular utility for use in dispensing carbonated beverages such as soft drinks, beer, various carbonated mixes, etc., that are typically bottled in relatively large, (i.e., 24 to 32 fluid ounces) resealable bottles or containers. While the apparatus of the invention may be employed for dispensing any type of pressurized fluids, from any size or type container, the double seal plug aspect described herein can be used for controlling the flow of any type of fluid, whether pressurized or not.
The present invention also includes a siphon tube which dips below the surface of the fluid to be dispensed. The siphon tube of the preferred embodiment contains flow obstructing elements. The flow controllers are objects generally shaped and located to obstruct the flow of the fluid being dispensed. Such a configuration will result in the dispensed fluid retaining more carbon dioxide or other gases, as are present in fluids such as soft drinks, thus preventing the beverage from losing its taste or becoming “flat”.
The present invention also has a novel configuration for connecting the double seal plug to the actuator which allows the connecting element to be operated in a linear direction only. The connecting element in the preferred embodiment is retained in a watertight shaft. The aft end of the connecting shaft contains a retaining device which fits within a slot located in the actuator. The shape and location of the slot allows the connecting element to move forward and aft in a linear direction, as opposed to moving in any sort of angular manner relative to its “resting” position. This linear movement eliminates the likelihood of the shaft rubbing against the chamber which seals it, thus reducing the wear and tear to the shaft and seal which comes from normal use. This configuration also reduces or eliminates liquid escaping through the chamber. Finally, the present invention includes a screw-type connector for connecting the apparatus to the fluid container. The connection is configured to assure that the head is aligned on the beverage container and therefore no fluid or gas will escape.
These and other objects and advantages of the present invention will become apparent from the following detailed description when viewed in conjunction with the accompanying drawings, which set forth certain embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The following figures set forth the preferred embodiment of the present invention:
FIG. 1 illustrates a cutaway half-section of the entire dispenser apparatus attached to a container having a threaded neck.
FIG. 2 a illustrates an enlarged cutaway half-section showing portions of the head, connecting shaft, and actuator when the apparatus is in the “closed” position.
FIG. 2 b illustrates a cutaway half-section of the apparatus in the “closed” position, where the apparatus is attached to a container having a threaded neck.
FIG. 3 a illustrates an enlarged cutaway half-section showing portions of the head, connecting shaft, and actuator when the apparatus is in the “partially actuated” position.
FIG. 3 b illustrates an enlarged cutaway half-section of the apparatus in the “partially actuated” position, where the apparatus is attached to a container having a threaded neck.
FIG. 4 a illustrates an enlarged cutaway half-section showing portions of the head, connecting shaft, and actuator when the apparatus is in the “open” position.
FIG. 4 b illustrates a cutaway half-section of the apparatus in the “open” position, where the apparatus is attached to a container having a threaded neck.
FIG. 5 a is an enlarged cutaway half-section of the forward end of the plug chamber, with the apparatus in the “closed” position.
FIG. 5 b illustrates a cutaway half-section of the apparatus in the “closed” position, where the apparatus is attached to a container having a threaded neck.
FIG. 6 a is an enlarged cutaway half-section of the forward end of the plug chamber, with the apparatus in the “partially actuated” position.
FIG. 6 b illustrates a cutaway half-section of apparatus in the “partially actuated” position, where the apparatus is attached to a container having a threaded neck.
FIG. 7 a is an enlarged cutaway half-section of the forward end of the plug chamber, with the apparatus in the “open” position.
FIG. 7 b illustrates a cutaway half-section of the apparatus in the “open” position, where the apparatus is attached to a container having a threaded neck.
FIG. 8 is an enlarged cutaway half-section of the actuator and the lower portion of the head, depicting the annular opening by which the head attaches to a fluid container, with no container present.
FIG. 9 a illustrates an enlarged cutaway half-section of the siphon tube in isolation with flow controllers present.
FIG. 9 b is a cross-sectional view taken on line A—A of FIG. 9 ( a ).
FIG. 10 a illustrates the forward edge of the actuator, with hatched lines depicting internal chambers.
FIG. 10 b illustrates a side view of the actuator, with hatched lines depicting internal chambers.
FIG. 10 c illustrates a cross-sectional view of the actuator, taken on line A—A of FIG. 10 ( b ).
Like reference characters indicate corresponding parts throughout the several views of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described with reference to FIGS. 1 through 10. In this description, the term “forward” shall be used to indicate that portion of an element, or another item, that is located closer to the discharge port of the apparatus than the portion of the element or item being discussed. The term “aft” shall be used to refer to that portion of an element that is located further from the discharge port, and closer to the distal end of actuator 22 , than the item under consideration. The terms “above” or “higher” shall be used to describe that an element that is at a higher vertical position than other elements when the sealing and dispensing mechanism is in the upright position, as would be the case when the apparatus is affixed to a fluid container. The words “below” or “lower” shall mean at a lower vertical position, or closer to the base of the fluid container.
FIG. 1 shows the entire dispensing and sealing apparatus 10 . The apparatus 10 is installed on a typical fluid container 36 which contains a pressurized fluid 34 . After the manufacturer's sealed cap (not shown) is removed from the fluid container 36 , the sealing and dispensing apparatus 10 is attached in its place. With reference to FIG. 1, it can be seen that the apparatus includes, in a broad sense, a head 20 for attaching atop fluid container 36 , a siphon tube 40 , and an actuator 22 . The head generally comprises an inlet port 60 for receiving fluid into the head, a discharge port 33 for discharging fluid from the head, and a fluid chamber 47 such that fluid may flow from the inlet port 60 to the discharge port 33 . Fluid chamber 47 in the preferred embodiment has a vertical section adjacent to inlet port 60 , and a plug chamber 49 that slopes downward at a forty-five degree angle and terminates in discharge port 33 .
Within seal plug chamber 49 are narrow portion 51 and wider portion 43 . In the preferred embodiment, discharge port 33 is adjacent to and in fluid connection with narrow portion 51 . The forward end of plug chamber narrow portion 51 includes conical reducer portion 55 . Seal plug chamber narrow portion 51 is adjacent to and in fluid connection with seal plug chamber wider portion 43 . Seal plug chamber narrow portion 51 has a smaller cross section for fluid flow than wider portion 43 . In the preferred embodiment, seal plug chamber wider portion 43 is fluted. By “fluted,” it is to be understood that seal plug chamber wider portion 43 has both longitudinal supports about its inner perimeter which provide strength and grooves, or fluted portions, in between these longitudinal supports. The longitudinal supports are at approximately the same diameter axially as the inner wall of seal plug chamber narrow portion 51 . The fluted portions, however, extend further axially from the center of plug chamber wider portion 43 than do the longitudinal supports. Thus, by virtue of the fluted portions, the overall cross-sectional area available for flow is greater in plug chamber wider portion 43 than in plug chamber narrow portion 51 .
The fluid flow process through the head 20 of the preferred embodiment can be appreciated with reference to FIG. 1 . Specifically, pressurized fluid 34 flows from the inlet port 60 through the fluid chamber 47 , then into plug chamber wider portion 43 , past double seal plug 39 , then past plug chamber narrow portion 51 , and finally out the discharge port 33 and into the drinking receptacle. In an alternative embodiment, double seal plug 39 is not located in the fully forward aspect of the apparatus; instead, there is additional fluid chamber forward of double seal plug 39 .
Located centrally within plug chamber 49 is a double seal plug 39 which is uniquely designed to address the problems of the prior art discussed above. Double seal plug forward end 31 is sized and shaped to form a watertight seal with the discharge port 33 , located at the forward end of the plug chamber narrow portion 51 . Double seal plug aft end 41 has the same size and shape as plug chamber narrow portion 51 , such that double seal plug aft end 41 forms a watertight seal with narrow portion 51 when the apparatus is in the closed position. Also in the preferred embodiment, seal plug 39 and seal plug chamber narrow portion 51 are approximately round. Any person skilled in the art will know that there are many other geometrical configurations which are available, as long as a watertight seal is formed between seal plug aft end 41 and plug chamber narrow portion 51 .
With reference to FIGS. 5-7, the benefit of double seal plug 39 in the preferred embodiment can be demonstrated by the series of figures which depict the movement of the double seal plug 39 during the process of dispensing pressurized fluid 34 . FIGS. 5 a and 5 b depict the present invention in its closed position, which is also its resting state, in which no beverage is flowing. As depicted in FIG. 5 b, actuator 22 is in the fully forward position. As shown in FIG. 5 a, connecting shaft 29 and double seal plug 39 are likewise fully forward. In fact, it should be noted that throughout the opening and closing processes, connecting shaft 29 is located primarily in the seal plug chamber. In the closed, the outer perimeter of double seal plug aft end 41 is flush against the inner wall of plug chamber narrow portion 51 , thus forming a water-tight seal and preventing the flow of the pressurized fluid 34 .
The user begins the process of dispensing fluid 34 by depressing the aft end of actuator 22 . When the user depresses actuator 22 with sufficient force to overcome the resistance of compression spring 27 , double seal plug 39 is pulled aft. FIG. 6 b depicts the present invention with the actuator 22 partially depressed, prior to the start of beverage flow through the apparatus. Although double seal plug 39 is no longer fully forward in this configuration, it is still far enough forward to prevent fluid flow, as there remains a watertight seal between double seal plug aft end 41 and the inner wall of plug chamber wider portion 43 .
As the user depresses actuator 22 further, the apparatus reaches the “open” position and fluid 34 begins to flow through the head. FIGS. 7 a and 7 b depict such a typical configuration of the apparatus in the open position. Specifically, actuator 22 is depressed far enough aft and down to cause double seal plug aft end 41 to withdraw into plug chamber wider portion 43 . In this configuration, fluid 34 is able to flow between double seal plug aft end 41 and plug chamber wider portion 43 , then finally out discharge port 33 .
After sufficient fluid has been dispensed, the user releases actuator 22 and the series of events as depicted in FIGS. 5-7 is reversed. However, additional features of the present invention are more fully understood by considering this closing process.
As described above, FIGS. 7 a and 7 b depict the apparatus in the open position, wherein fluid would flow between the double seal plug aft end 41 and plug chamber wider portion 43 . As actuator 22 is partially released, double seal plug aft end 41 moves forward and again forms a watertight seal with plug chamber narrow portion 51 , thus preventing the flow of fluid. This configuration is depicted in FIGS. 6 a and 6 b. As this occurs, all fluid forward of the double seal plug aft end 41 is able to drain out discharge port 33 . Thus, there is no beverage trapped forward of double seal plug aft end 41 when the apparatus is in the closed position, as depicted in FIGS. 5 a and 5 b.
Moreover, the seal plug configuration of the preferred embodiment contains an additional advantage in that double seal plug forward end 31 is located at the forward end of fluid chamber 47 when the actuator 22 is completely released. Stated another way, there is no discharge conduit forward of double seal plug forward end 31 when the apparatus is in the closed position. As a result, it is significantly less likely that there will be any drips of fluid adhering to the forward end of the apparatus after the dispensing step.
Finally, another advantage of the seal plug configuration of the present invention concerns the likelihood that fluid under pressure will forcibly spray out of the discharge port at the very beginning of the discharge step. Specifically, as the apparatus returns to the closed position all fluid forward of the double seal plug aft end 41 is able to drain out discharge port 33 . This configuration prevents fluid from “spraying” out discharge port 33 at the start of the dispensing step. In other words, because there is no fluid under pressure in the narrow portion 51 of plug chamber 49 when the apparatus is in the closed position, there will be no stream of fluid 34 forced between the double seal plug forward end 31 when actuator 22 is only slightly depressed. These innovations both reduce the possibility of fluid dripping from nozzle discharge port 33 onto the countertop or refrigerator shelf subsequent to the dispensing process. Furthermore, these innovations and the lack of fluid entrapment pockets exposed to the atmosphere reduces the possibility that fluid will be left to stagnate in the plug chamber 49 after dispensing is complete.
Other advantages of the present invention concern the configuration of actuator 22 . These aspects can best be understood with references to FIGS. 2-5, and 10 . Actuator 22 contains a pivot assembly, which includes a retaining device such as pivot pin 24 . As a result of the pivot assembly, when combined with other aspects of the present invention, the user is able to operate the dispensing apparatus 10 between the closed position and the open position by depressing the aft end of actuator 22 , even though connecting shaft 29 is retained within a linear connecting shaft chamber. In other words, the design of actuator 22 allows for connecting shaft 29 to travel linearly at all positions between the fully open position and the fully closed positions even though actuator 22 pivots.
The ability of connecting shaft 29 to move linearly at all times can be attributed in part to the presence of a slot, such as driver pin slot 21 in actuator 22 . Driver pin 23 is attached to the aft end of connecting shaft 29 such that driver pin 23 has a horizontal orientation that is also perpendicular to connecting shaft 29 . Driver pin slot 21 is oriented so as to allow driver pin 23 to travel along the length of driver pin slot 21 as the actuator is pivoted between the open and closed positions. This can be better appreciated with reference to FIGS. 2-4 and 10 , and a discussion of the invention in various states of opening.
First, FIGS. 2 a and 2 b depict dispensing apparatus 10 in the “closed” position. In this configuration, connecting shaft 29 is fully forward, as is actuator 22 . FIGS. 3 a and 3 b depict dispensing apparatus 10 in a partially actuated position, or a position which is closer to being “open” than the position depicted in FIGS. 2 a and 2 b. In this configuration, actuator 22 is slightly pivoted about a pivot pin 24 . Connecting shaft 29 has been pulled aft slightly, and driver pin 23 has traveled from its “closed” location to a lower position within driver pin slot 21 . FIGS. 4 a and 4 b next depict actuator 22 fully opened, with connecting shaft 29 in its fully aft position. Driver pin 23 has now traveled to an even lower position within driver pin slot 21 than in FIGS. 2 a and 2 b. It should be noted that even though actuator 22 has pivoted, connecting shaft 29 has traveled in a straight line at all times.
In the preferred embodiment, actuator 22 contains connecting shaft slot 71 . These aspects of actuator 22 can be better understood with reference to FIGS. 10 a and 10 c. Connecting shaft slot 71 allows the aft end of connecting shaft 29 to pass through the forward edge of actuator 22 . Also, the aft end of connecting shaft 29 has flat portion 38 by which the aft end of connecting shaft 29 fits through connecting shaft slot 71 . Just aft of driver pin slot 21 is a narrower slot, driver pin recess slot 81 , which allows the aft end of connecting shaft 29 to avoid rubbing against actuator 22 as it travels along driver pin slot 21 .
Although FIGS. 10 a and 10 c depict actuator 22 of the preferred embodiment in its isolated configuration, it is to be understood that in its normal configuration, actuator 22 is connected to head 20 as previously described. FIGS. 10 a and 10 c show the top view of actuator 22 as cut along Line A—A to more clearly denote the relative positions of connecting shaft slot 71 , driver pin slot 21 , and driver pin recess slot 81 .
Yet another aspect of the present invention can be see with reference to FIG. 1 . As discussed above, double seal plug 39 is connected to actuator 22 by connecting shaft 29 . Connecting shaft 29 passes through connecting shaft chamber 26 . At the forward end of connecting shaft chamber 26 is located connecting shaft seal 25 , which is a water-tight seal designed to prevent the flow of fluid into connecting shaft chamber 26 . It should be noted that connecting shaft seal 25 is not a separate, individual piece, but rather a constriction of the material used to form head 20 at the forward end of connecting shaft chamber 26 .
The present invention also relates to a pressure-reducing mechanism in conjunction with dispensing a fluid. More specifically, the present invention relates to a siphon tube which contains one or more flow controllers which serve to gradually reduce the pressure of the beverage being dispensed by obstructing the flow of the beverage. These obstructors also serve to reduce the amount of foaming that occurs during the dispensing process. This aspect of the present invention can be better appreciated by reference to FIGS. 1 and 9.
According to the present invention, siphon tube 40 extends from head 20 into fluid 34 . Inside siphon tube 40 are located one or more flow controllers 48 . The flow controllers 48 force the fluid to flow through a narrow channel between the perimeter of flow controller 48 and the inner wall of siphon tube 40 . After the fluid passes each flow controller 48 , the fluid then enters a relatively unobstructed segment of siphon tube 40 , denoted on FIG. 1 by the number 50 . As the fluid passes the next flow controller, the process repeats itself, resulting in yet another small reduction in pressure. The final effect of this aspect of the present invention is to minimize the overall loss of gases such as carbon dioxide in the fluid, as well as any foaming, if any, thus resulting in improved taste and feel of the beverage to the user as compared to one large drop in pressure. It should be noted, however, that not all beverages would require the use of a series of flow controllers, such as, for example, seltzer, and therefor an alternative embodiment of the present invention would have no flow controllers.
It has been determined that, although at least one obstructor is needed if the pressure step-down process of using flow controllers is to be used, any number of flow controllers may be used limited only by the number of obstructors that may fit vertically within the siphon tube. It is to be understood that flow controllers 48 may be any shape which is conducive to gradually reducing the pressure of the fluid as it is dispensed. For example, the flow controllers may be approximately spherical, as is the case in the preferred embodiment. Other shapes may work also, but best results are achieved with flow controllers that do not contain sharp comers, but instead have smooth surfaces.
It has also been determined that the distance between flow controllers may vary, yet still result in an effective siphon. For instance, the siphon tube may be packed with flow controllers from top to bottom, such that the top of one flow controller is touching the bottom of the one above it. Alternatively, the obstructors may be arranged in the siphon tube such that there is a gap between them.
A third approach, as used in the preferred embodiment, would be to affix the flow controllers to a shaft, such that there is a gap between each of the obstructors, and then to insert the shaft into the siphon tube. An additional advantage to this last configuration is that the shaft and the flow controllers may be removed from the siphon tube for cleaning. The cross section of the flow controllers should be sufficient to cause a pressure drop of noticeable magnitude. In the preferred embodiment, for example, the axial cross-section of each flow controller 48 is between approximately 90% and approximately 95% of the axial cross-section of siphon tube 40 . In other words, between 90% and 95% of the cross-sectional area available for flow in siphon tube 40 is blocked the widest part of a flow controller. In alternative embodiments, however, the ratio of flow controller cross section to siphon tube cross section may be significantly lower, for example, as low as 80%.
According to the present invention, at least one flow controller nub 52 is located on the perimeter of at least one flow controller 48 . Each flow controller nub 52 , being located on the horizontal perimeter of flow controller 48 , ensures that a gap is maintained for fluid flow between the outer perimeter of flow controller 48 and the inside wall of siphon tube 40 . Flow controller nubs 52 may be of any size and shape which will accomplish the purpose of ensuring separation between flow controllers 48 and the inside wall of siphon tube 40 . In the preferred embodiment, three flow controller nubs 52 are located on the perimeter of each flow controller 48 , with each flow controller nub being located approximately 120 degrees apart.
These aspects of the preferred embodiment can be seen with reference to FIG. 1 . In the preferred embodiment, flow controller shaft 42 is located inside siphon tube 40 . Flow controller shaft 42 has multiple flow controllers 48 attached along its longitudinal axis. At the upper end of flow controller shaft 42 is flow controller shaft thread end 59 . Flow controller shaft thread end 59 screws into head 20 , thus allowing for removal of flow controller shaft 42 from siphon tube 40 for cleaning. The preferred embodiment also includes a siphon tube extension 46 which attaches to the lower end of siphon tube 40 , thus permitting the flow controller aspects of the present invention to be maintained entirely withing siphon tube 40 . In an alternative embodiment, there is no siphon tube extension 46 ; rather, siphon tube 40 extends to below the level of the fluid 34 .
The preferred embodiment of the present invention utilizes friction fits to hold the inlet end of siphon tube 40 inside the longitudinal center hole of reducer connecting bushing 30 , and also to hold reducer connecting bushing 30 inside inlet port 60 . Such a configuration also aids in easy disassembly. It is to be understood, however, that other methods of engaging siphon tube 40 and reducer connecting bushing 30 are well known in the art, and would fall within the spirit and scope of the present invention.
The present invention also relates to an improved method for attaching dispensers to beverage containers. More specifically, head 20 of the present invention includes portions defining an annular opening for receiving the threaded top of a beverage container. The top of this annular opening is shaped so as to encourage an exact alignment between the head 20 and the neck of fluid container 36 .
Referring to FIG. 8, head 20 contains annular opening 56 which includes an inner perimeter 28 , and an outer perimeter containing female threads 45 for removably engaging the fluid container (not shown) to dispensing head 20 . Annular opening outer perimeter and inner perimeter meet at an angle less than ninety degrees to form annular groove 58 . In the preferred embodiment, annular groove 58 is “v”-shaped such that the top of the neck of fluid container (shown in FIG. 1 as 36 ) is forced into vertical alignment with annular opening inner perimeter 28 as dispensing apparatus 10 is fully engaged. The most commonly used size for a carbonated beverage container is a 28 mm threaded neck, although the invention should not be limited to this size. The device can be modified to be of any desired size. It should be noted that neither fluid container 36 nor its external male threads 53 (shown in FIG. 1) are part of the claimed invention.
The dispensing apparatus 10 is connected to fluid container 36 by rotating dispensing apparatus 10 so as to engage both sets of threads. Rotation continues until an airtight seal is achieved between beverage container 36 and head 20 .
To dispense fluid from the preferred embodiment, the user simply screws the dispensing apparatus 10 onto the external male threads 53 of fluid container 36 . The user then gently agitates the contents of the container 36 by shaking lightly. Next, the user depresses actuator 22 with sufficient force to overcome the resisting force of compression spring 27 , and fluid will flow through the apparatus into a glass or other receptacle.
It should be noted that the various elements of the present invention may be used to achieve the purposes described herein alone or in combination. For example, the double seal plug configuration may be used in any fluid control device, with or without other elements of the present invention.
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The disclosed invention is directed to a sealing and dispensing apparatus that is used to preserve the contents of a carbonated beverage container. It includes a novel double plug seal located in a plug fluid chamber having a wider portion and a narrow portion. The double seal plug engages at its forward end with the discharge port. The aft end of the double seal plug engages the narrow portion of the plug fluid chamber. Taken together, the double seals allow for reduced spraying and leakage of fluid from the apparatus, both during and after fluid is dispensed. The invention also relates to a novel method for attaching the plug to the actuator. It also relates to an improved design for attaching an apparatus to a beverage container, and a novel design for gradually reducing the pressure of the fluid to be dispensed, thus preserving the carbon dioxide or other gases within the fluid.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an object reflector detecting apparatus for determining the position of markings or installations by emitting a light from a polarized light source and then by detecting a specified reflector.
2. Description of Background Art
The object reflector detecting apparatus has been used for determining the height level in the works of the civil engineering or the architecture.
Recently, a semiconductor visible laser has been put to practical use and thus an object reflector detecting apparatus using the semiconductor visible laser has been developed. However, the output of the semiconductor visible laser is limited in view of safety of a worker and therefore the measurement accompanied with confirmation by visual observation is limited within a relatively short working distance.
Japanese Patent Application No. 289042/1992 filed on Oct. 27, 1992 discloses a rotary laser irradiating apparatus in which the position of a specified reflector arranged at a predetermined position is reciprocally scanned by a laser beam in order to extend the working distance.
In the rotary laser irradiating apparatus disclosed in Japanese Patent Application No. 289042/1992, a specified pattern is formed on the reflector in order to surely detect the object reflector.
However, since the object reflector detecting apparatus is used in various places, it is impossible to discriminate if the reflected signal pattern is that from the object reflector or from a non-object reflector and therefore it is difficult to perfectly exactly identify the object reflector and the non-object reflector and thus a scanning operation would be sometimes caused at an erroneous position.
Especially, when the laser beam from the rotary laser irradiating apparatus perpendicularly strike a non-object reflector having a reflecting surface such as a glittering member, the incident optical axis and the reflection optical axis correspond with each other and thus an intensive reflected light (hereinafter referred to "regular reflection light") enters into a detecting section of the apparatus. Accordingly, when the regular reflection light would take an arrangement similar to that of the predetermined pattern signal, the scanning error will be caused although the distance between the apparatus and the non-object reflector is long.
In addition, when there is any glitter flat member such as a glass plate near a working site, an other optical path would be sometimes formed between the apparatus and the specified reflector. In such a case, there is a problem that an erroneous scanning operation would be caused to the virtual image of the glitter member by detecting a reflected light (hereinafter referred to "multiple reflection light") of said other optical path.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide an object reflector detecting apparatus which can surely identify the predetermined object reflector with effectively expelling the reflected lights from any other members than the specified object reflector.
According to the present invention, there is provided an object reflector detecting apparatus for identifying an object reflector by emitting a light from a polarized light source toward the object reflector and then detecting a reflected light from the object reflector characterized in that the light emitted from said polarized light source is a polarized light of which direction of polarization is specially defined, the polarized lights between said reflected light and said emitted light are different in the direction of polarization, and said object reflector detecting apparatus is adapted to detect only a component of the direction of polarization from said object reflector.
(Principles of the Invention)
1. The method for eliminating the regular reflection light is based on a fact that the direction of polarization of the regular reflection light is kept in the direction of polarization of the emitted light from the polarized light source of the object reflector detecting apparatus.
That is, it is possible to detect only the reflected light from the object reflector and thus to eliminate the regular reflection light by defining the light emitted from the polarized light source to a predetermined direction of polarization, reflecting the emitted light by the object reflector while changing its direction of polarization, and then detecting only the light having the predetermined direction of polarization. In this case, the object reflector includes a birefringent member to change the direction of polarization.
The polarized lights used in the present invention include both a circularly polarized light and a linearly polarized light. The direction of polarization in the circularly polarized light means right-hand and left-hand rotations and the direction of polarization in the linearly polarized light means two directions of the light orthogonally crossing with each other.
The means for reflecting the light at the object reflector with changing the direction of polarization may be formed by a birefringent member producing a quarter-wave phase difference on the orthogonally crossing axes, the birefringent member being mounted on a whole surface of the reflector. The direction of polarization of the light can be changed with being reciprocally passed through the birefringent member.
FIGS. 1-4 show the conditions in which the direction of polarization of the light can be changed by the birefringent member. FIG. 1 shows the reflections of the circularly polarized light both at the object and the non-object reflectors. FIG. 2 shows the condition of the circularly polarized light entered into the object reflector. FIGS. 3 and 4 show the conditions as to the linearly polarized light corresponding to FIGS. 1 and 2, respectively.
2. The method for preventing the multiple reflection is based on a fact that the reflection on the glitter surface such as a glass surface has a characteristic of polarization. This characteristic of polarization uses a reflection characteristic of the linearly polarized light to reflect only a light having a component of specified direction.
More particularly, it uses a nature that the reflected light becomes a linearly polarized light due to the characteristic of polarization when the light from the light source is a circularly polarized light. That is, by arranging the axis of the birefringent member of a quarter-wave attached onto a whole surface of the object reflector about 45° relative to the scanning direction (i.e. the direction of rotation) of the polarized light source, the direction of the linearly polarized light running from the reflecting surface toward the object reflector becomes a condition orthogonally crossing with the direction of the characteristic of polarization of the opposite surface when the linearly polarized light is reflected by the object reflector. Thus, this light becomes difficult to be reflected when it is again returned to the reflecting surface and in the event does not return to the polarized light source of the object reflector detecting apparatus. FIG. 5 shows this condition.
In addition, when the light from the light source of the object reflector detecting apparatus is a linearly polarized light, the same effect can be achieved by arranging the direction of polarization of that light to correspond to the scanning direction of the light source so that the direction of polarization corresponds to or orthogonally crosses with the direction of the characteristic of polarization of the reflecting surface. When the linearly polarized light from the object reflector detecting apparatus orthogonally crosses with the characteristic of polarization of the reflecting surface, the intensity of light will be damped by the characteristic of polarization of the reflecting surface. On the other hand, when the linearly polarized light from the object reflector detecting apparatus corresponds to the direction of the characteristic of polarization of the reflecting surface, the light once passes through the reflecting surface. However, since the direction of polarization of the light is changed by the object reflector to the orthogonal direction similarly to the circularly polarized light, the intensity of the light will be damped at the reflecting surface in a return path. FIG. 7 shows the case when the linearly polarized light from the object reflector detecting apparatus corresponds to the direction of the characteristic of polarization of the reflecting surface.
3. In the object reflector detecting apparatus, it is a common way to rotate the irradiation direction of light by arranging the semiconductor laser of the light source at a stationary section in view of the stability of the axis of rotation and by rotating optical elements such as a pentagonal prism and the like. In this case, although the semiconductor laser is linearly polarized, the direction of polarization is also rotated accompanying with the rotation of the irradiation direction.
The method for defining the direction of polarization is based on a fact that the direction of rotation of circularly polarized light does not change although the apparatus is rotated around the optical axis. That is, as shown in FIG. 7, the semiconductor laser changes the linearly polarized light to the circularly polarized light using the birefringent member providing a quarter-wave phase difference. When passing the circularly polarized light through a rotary optical element such as a pentagonal prism, the light emitted from the optical element is not influenced by the rotating optical element and thus the direction of rotation of this circularly polarized light is always kept same.
That mentioned above is a case to define the light emitted from the apparatus to the circularly polarized light. On the other hand, when defining the light emitted from the apparatus to the linearly polarized light, this is achieved by passing again the circularly polarized light through the birefringent member providing the quarter-wave phase difference arranged at the axis of rotation as shown in FIG. 8. The direction of the linearly polarized light can be freely chosen by rotating the axial direction of the birefringent member.
The detecting section is adapted to detect only the reflected light from the object reflector by selecting, using the polarizer, the linearly polarized light which is passed through the birefringent member providing the quarter-wave phase difference and changed from the reflected circularly polarized light passed through the pentagonal prism.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing a reflection of the circularly polarized light caused by the object reflector;
FIG. 2 is a detailed explanatory view showing a reflection of the circularly polarized light caused by the object reflector;
FIG. 3 is a schematic view showing a reflection of the linearly polarized light caused by the object reflector;
FIG. 4 is a detailed explanatory view showing a reflection of the linearly polarized light caused by the object reflector;
FIG. 5 is an explanatory view showing that the scanned circularly polarized light reflected by any member other than the object reflector does not return to the detecting apparatus;
FIG. 6 is an explanatory view showing that the scanned linearly polarized light reflected by any member other than the object reflector does not return to the object reflector detecting apparatus;
FIG. 7 is an explanatory view showing the optical system of the object reflector detecting apparatus of the present invention for rotary scanning a circularly polarized luminous flux;
FIG. 8 is an explanatory view showing the optical system of the object reflector detecting apparatus of the present invention for rotary scanning a linearly polarized luminous flux;
FIG. 9 is a schematic view showing the optical system of the object reflector and the object reflector detecting apparatus of the present invention;
FIG. 10 is a front elevational view showing the object reflector of the present invention; and
FIG. 11 is a side elevational view showing the object reflector of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of an object reflector detecting apparatus of the present invention will be hereinafter described with reference to the accompanying drawings.
One embodiment of a rotary laser irradiating apparatus having an object reflector detecting apparatus of the present invention will be hereinafter described. As shown in FIG. 9, the rotary laser irradiating apparatus has a series of optical elements arranged on an optical axis 0 of a laser luminous flux emitted from a semiconductor visible laser 3 driven by a pulse driving circuit 2, these optical elements being a collimator lens 4, a tilt compensating section 6, a reflecting mirror 8, a beam expander 9, an apertured mirror 7 having an aperture 7A through which the optical axis 0 passes, a birefringent member 11 providing a quarter-wave phase difference, and a beam rotary section 10. The pulse driving circuit 2 comprises a laser oscillator 2A and an LD driving circuit 2B. The rotary laser irradiating apparatus may be constructed without the tilt compensating section 6.
The tilt compensating section 6 is an optical system i.e. a liquid compensator adapted to reflect the laser luminous flux emitted from the semiconductor visible laser 3 always at a constant angle relative to the vertical despite the inclination of a polarized light source (not shown) and comprises a sealed glass 20, an oil bath 24 having a reflecting surface 22 of a liquid back, a sealed glass 26, and a biaxial tilt compensation balance adjustor i.e. an optical axis adjusting section 34 including a pair of prism members 30 and 32 for polarizing the optical axis 0. The beam expander 9 comprises a pair of lenses 36 and 38 each having a different focal length and is adapted to expand the width of the laser luminous flux.
The beam rotary section 10 is an optical system adapted to rotary scan in a horizontal plane the laser luminous flux vertically upwardly entered thereto and comprises a pentagonal prism 42 mounted on a rotary support 40. A gear 46 mounted on the bottom of the rotary support 40 meshes with an output gear 50 of a motor 48 driving the rotary support 40 via a reduction gear unit (not shown). The motor 48 is controlled by a control section 100.
An object reflector 60 for reflecting the laser luminous flux emitted from the pentagonal prism 42 is formed by two reflecting zones 62 and 64 vertically extending and spaced apart from each other as shown in FIG. 10 and comprises a substrate 60A, a reflector 60B, and a birefringent member 60C providing a quarter-wave phase difference, the reflector 60B and the birefringent member 60C being adhered to the substrate 60A. The reflector 60B may be formed by a plurality of retroreflection members such as corner-cube prisms or spherical reflectors. The birefringent member 60C is arranged at about 45° relative to the scanning direction (direction of rotation) of the circularly polarized light of the laser luminous flux emitted from the pentagonal prism 42.
A laser luminous flux detecting section 80 comprises a condenser lens 82, a polarizer 83, a pinhole plate 84 and a photoelectric transfer element 86, these elements being arranged on an optical axis 00 of reflected light and spaced apart by an appropriate distance from each other.
The output of the pulse driving circuit 2 forming the electric system of the rotary laser irradiating apparatus is inputted to the semiconductor visible laser 3. The electric system further includes the photoelectric transfer element 86 for receiving the laser luminous flux reflected by the object reflector 60, the motor 48 and the control section 100. The control section 100 performs a control for simplifying the view of the laser luminous flux, for example, by reciprocally scanning the laser luminous flux only within an angular range formed by two object reflectors 60.
The optical operation of the rotary laser irradiating apparatus will then be described. The linearly polarized laser luminous flux emitted from the semiconductor visible laser 3 is compensated in its direction so that is directed to a predetermined direction, and then enters the birefringent member 11 through the aperture 7A of the apertured mirror 7. The linearly polarized laser luminous flux is transformed into the circularly polarized light by the birefringent member 11 and then is rotated by the pentagonal prism 42 in a horizontal plane.
When the circularly polarized laser luminous flux enters the object reflector 60, it is transformed into the linearly polarized light by the birefringent member 60C of the object reflector 60, is reflected by the reflector 60B, enters again to the birefringent member 60C and is returned thereby to the circularly polarized light, and then enters to the pentagonal prism 42. The circularly polarized laser emitted downwardly from the pentagonal prism 42 is transformed into the linearly polarized light by the birefringent member 11, reflected by the apertured mirror 7 at a portion other than the aperture 7A, and then enters the polarizer 83. The linearly polarized laser luminous flux of a predetermined direction is selected by the polarizer 83 and enters the photoelectric transfer element 83 to be detected thereby.
Modifications of the embodiment illustrated above will be further described. Although the object reflector 60 is formed by two reflecting zones 62 and 64 in the illustrated embodiment, the object reflector 60 may be formed by only one reflecting zone when influence of the extraneous light is not so great.
In addition, although the light source i.e. the semiconductor visible laser and the detecting section are mounted on the stationary body and the laser luminous flux is rotary scanned by rotating only the pentagonal prism for a laser luminous flux rotation in the illustrated embodiment, it may be possible to rotary scan the laser luminous flux by rotating the semiconductor visible laser and the detecting section. In this case, the direction of the polarized light of the rotary scanned laser luminous flux is not rotated.
Although it is considered that the laser luminous flux emitted from the semiconductor visible laser is the linearly polarized light, it is, in actuality, not a purely linearly polarized light and thus contains a noise component. When the noise component exceeds an allowable amount, an additional polarizer may be arranged on the optical axis of the semiconductor visible laser to eliminate the noise component.
According to the combined object reflector detecting apparatus of the present invention, it is possible to surely identify the predetermined object reflector with effectively expelling the noise component which is a reflected light from any member other than the predetermined object reflector. Also according to the rotary irradiating apparatus of the present invention, it is possible to surely irradiate the predetermined angle range.
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An object reflector detecting apparatus for identifying an object reflector by emitting a light from a polarized light source toward the object reflector and then detecting a reflected light from the object reflector characterized in that the light emitted from said polarized light source is a polarized light of which direction of polarization is specially defined, the polarized lights between said reflected light and said emitted light are different in the direction of polarization, and said object reflector detecting apparatus is adapted to detect only a component of the direction of polarization from said object reflector.
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CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of PCT Application No. PCT/FI99/00729, filed on Sep. 9, 1999, which is incorporated herein by reference.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] Not applicable
BACKGROUND OF THE INVENTION
[0003] The present invention relates to a doctor blade for a papermaking machine in general and to a doctor blade constructed of plastic in particular.
[0004] Faces of rolls in a paper/board machine tend to be coated with impurities derived from the papermaking process. Doctor blades are used in order to remove these materials from roll faces. As the running speed of paper machines has increased, the amount of friction between the doctor blade and the roll face has also increased, resulting in increased temperature at the doctor blade/roll interface and of the doctor blade itself. This is a problem, because the materials conventionally used in doctor blades do not withstand such higher speeds. For example, at a paper machine speed greater than 1400 meters per minute, doctor blades made of conventional materials can start to melt and abrade rapidly, in which case they no longer operate in cleaning of the roll face.
[0005] From the prior art, many doctor blades made of different materials are known, including composite structures. In U.S. Pat. No. 4,549,933, a doctor blade for a paper machine is described, which blade consists of a number of alternating layers of fibre and carbon fibre. The fibre layer can consist of cotton, paper, fibreglass, or equivalents thereof.
[0006] On the other hand, in published German patent application DE 4137970, a doctor blade comprising fiber-reinforced plastic is suggested. The fibre-reinforced plastic contains from 60 to 90 per cent by weight of polyamide-6 or polyamide-66, and from 10 to 40 per cent by weight of reinforcement fibers. A polyamide, which is a thermoplastic resin, is used in order to increase the thermal conductivity of the blade.
[0007] In Finnish Patent FI 101,637, a caring doctor blade is described, which blade comprises a number of fibre layers in a laminate construction, where at least one layer of carbon fibre or at least one layer that contains a substantial proportion of carbon fibre is present. This patent further discloses that the blade contains grinding particles in direct vicinity of the carbon fibers and that the carbon fibers are oriented substantially obliquely in relation to the direction of the longitudinal axis of the blade, preferably in the cross direction of the blade.
[0008] Japanese Published Application JP 05-214696, discloses a doctor blade comprising polyethylene of very high molecular weight or fibre-reinforced polyethylene of very high molecular weight, which polyethylene is a thermoplastic resin.
[0009] Japanese Published Application JP 05-32118 describes a doctor blade which is made of a thermoplastic fibre composite material which contains from 30 to 80 percent by weight of polyphenylene sulphide (a thermoplastic resin), and from 20 to 70 percent by weight of either glass fibers, aramide fibers, or graphite fibers.
[0010] Finally, Japanese Published Application JP 05-13289 discloses a doctor blade which consists of a material that contains fibreglass, where the filament fibres have been immobilized in a resin parent material, such as epoxy resin.
[0011] As evidenced by the above prior art, a number of different thermoplastic resin materials have been suggested for use in a doctor blade. In spite of their desirable heat resistance properties, thermoplastic resins have not achieved commercial importance as doctor blade materials because of their high cost and because of their difficult workability. A thermosetting plastic from which high resistance to heat in operation is expected also requires a considerably high melting-processing temperature. In practice, in commercial products, epoxy resins have been used almost exclusively.
[0012] However, doctor blades that comprise an epoxy matrix tend to wear, or degrade rapidly, resulting in shorter service life. As machine running speeds increase, this problem has become even worse. As discussed earlier, higher machine operation speed increases the friction heat between the revolving roll and the doctor blade. This heat causes the epoxy in the doctor blade to soften and start to melt. The phenomenon of softening is increased by the wet conditions, for epoxy has a certain degree of tendency to absorb water. The softening and the melting have the effect that the roll face becomes coated with the blade material. This causes changes in the properties of adhesion, separation and surface energy in the roll face, which has a very detrimental effect on the operation of the papermaking machine.
[0013] A second serious drawback of epoxy is its poor suitability for pultrusion and for similar methods that would allow continuous manufacture of doctor blades.
[0014] Thus, it is an object of the present invention to provide such a material for a doctor blade that can endure high paper machine running speeds and, thus, high operating temperatures at the doctor blade/roll interface.
[0015] It is an additional object of the present invention to provide a doctor blade which can withstand high operating temperatures, and also possesses good mechanical strength and rigidity.
[0016] It is yet a further object of the present invention to provide a doctor blade that can be manufactured efficiently in a variety of ways, including continuous manufacturing processes, such as pultrusion.
[0017] These, and other objects and advantages, are achieved by the doctor blade of the present invention.
SUMMARY OF THE INVENTION
[0018] The present invention relates to a doctor blade for cleaning a roll face in a papermaking machine, comprising a thermosetting plastic polymer material selected from the group consisting of vinylesterurethanes and polyether amide resins. Other thermosetting plastic polymers can also be used, provided that their glass transition temperature (T g ) is at least 20° C. higher than the operating temperature at the blade/roll face interface at any operating speed of which the papermaking machine is capable of being operated. In addition to being able to endure high operating temperatures, the thermosetting plastic polymers of the doctor blades of the present invention also have high impact resistance. Since these materials do not come close to their T g temperature during operation, blade wear resulting from softening and/or melting is slower. Also, in such a case, the wear takes place in a controlled way without breaking of the tip of the blade. Controlled wear is important in order that the blade should remain sharp through its whole service life. Owing to high impact strength, the blade tip is not broken equally easily if some material adhering to the roll face passes under the blade in a running situation.
[0019] Owing to their nature of thermosetting plastic, the thermosetting plastic polymers for use in the doctor blades of the present invention are suitable for being processed by all methods that are used with thermosetting plastic, including pultrusion. Moreover, processing of these materials does not require considerably elevated temperatures, as the processing of thermoplastic resin materials does. In the manufacture of oblong pieces, such as doctor blades, suitability for pultrusion is a highly desirable feature, because it permits continuous manufacture, in which case the overall economy of the manufacture is better and the product is of uniform quality.
[0020] In accordance with a preferred embodiment of the invention, the doctor blades are composite structures further comprising reinforcing materials and/or filler materials. The reinforcing materials can be conventional fibre reinforcements, such as glass, carbon or aramide fibers, or structures woven out of said materials or mixtures of said fibre reinforcements. For example, a multi-layer structure can be made using structure fibreglass and carbon fibre reinforcements, where the alignment of said reinforcement fibers vary/alternate in different layers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Not applicable.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] In accordance with an embodiment of the invention, the doctor blade comprises a vinylesterurethane. This material is derived from a polyester-based polyol dissolved in styrene, and polyisocyanate. In the first stage of the reaction, when the polyol component reacts with isocyanate, in a what is called chain extension reaction, urethane bonds are formed. In the second stage of the reaction, the double bonds in the polyester polyol react with the styrene as radical polymerization and cross-link a network structure typical of thermoplastic resins in the material.
[0023] The resulting polymer, a vinylesterurethane, has a what is called hybrid structure in which there is both a urethane bond known from polyurethanes and a bond typical of vinylesters. The first and the second stage of the reaction take place typically at the same time. There are several different accelerator and initiator systems which can be used to control the speed of the reactions. Through the choice of a specific system and the selection of a given polyester polyol, it is possible to regulate the properties of the resulting vinylesterurethane as desired in view of the specific use to which a doctor blade comprising the vinylesterurethane will be put, and the method by which the blade will be manufactured.
[0024] In addition to the good mechanical properties of vinylesterurethanes (strength, modulus and toughness values equal or exceed typical values of polyester/epoxy materials with high toleration of temperature) these polymers are able to withstand high operating temperatures—the HDT temperature is up to 220° C. Moreover, the good mechanical properties of vinylesterurethane and its resistance to degradation caused by contact with other chemicals are retained at elevated temperatures, and it tolerates thermal aging well. Thus, a doctor blade comprising vinylesterurethane is particularly well-suited for use in modem high-speed paper machines, where the temperature at the blade/roll face interface, and hence the surface temperatures of doctor blades, becomes quite high.
[0025] The raw-materials used in the production of vinylesterurethanes are typically provided in solution form, and can be processed by means of methods typical of thermosetting plastic. In the manufacture of doctor blades in accordance with the present invention, preferably pultrusion is used. Further possible methods for manufacture of the doctor blades of the present invention are, for example, manufacture (1) by means of prepregs (setting and autoclave treatment), (2) by means of resin injection (RTM), or (3) by means of reactive injection moulding.
[0026] Where pultrusion is used, the speed of manufacture with vinylesterurethanes is up to four times higher than with vinylesters, which lowers the cost of manufacture. The adhesion of vinylesterurethanes to different fillers is good, and, for example, ceramic and metallic fillers or cut-off-fibre reinforcements can be employed with the vinylesterurethanes in addition to woven fibre reinforcements.
[0027] In accordance with another embodiment of the invention, the doctor blades comprise a thermosetting plastic called a polyether amide, or PEAR (PolyEther Amide Resin=PEAR), which is obtained from a reaction between bisoxazoline and a phenolic compound. The structure of this polymer is illustrated in a formula below describing structural units of polyether amide and structure of cross-linked polymer.
[0028] The polyether amide polymer illustrated in the formula above has the following properties, which lend themselves to the use of these materials in a doctor blade:
[0029] 1. excellent thermal stability in constant operation up to 180° C.;
[0030] 2. good adhesion to glass fibres, carbon fibres and metals (aluminum, steel) and to ceramics because of its chemical structure;
[0031] 3. good toughness (5-fold G 1c value as compared with epoxy);
[0032] 4. glass transition temperatures generally ranging from 225 to 295° C., depending on the hardening cycle and on the material modification;
[0033] 5. high modulus of elasticity (pure non-reinforced polyether amide in the category of thermosetting plastics has a modulus of elasticity of about 5100 MPa);
[0034] 6. it does not contain volatile components; and
[0035] 7. low coefficient of thermal expansion (42×10 −6 /°C.) as compared with other polymers.
[0036] Polyether amides are generally available as a solution and as a “hot melt” version. Polyether amide in solution form is, as a rule, used for the preparation of prepregs, in which case fibre reinforcements, if used, are impregnated with a solution that contains a polymer and a suitable solvent. The hot melt polymer is directly useable, for example, in a RTM method or in pultrusion, provided that the components are heated (about 160° C.) in order to lower the viscosity to a suitable level.
[0037] In the manufacture of the doctor blades in accordance with the present invention comprising polyether amides, the following techniques can be applied, which techniques are also suitable for other thermosetting plastics: manufacture by means of prepregs (setting and autoclave treatment); pultrusion; compression moulding; and RTM (resin transfer moulding).
[0038] From the point of view of doctor blade manufacture, the use of polyether amide accords the following advantages:
[0039] 1. very low exothermic generation of heat during hardening reaction (5 times lower than with epoxies and 10 times lower than with bismaleimides); even thick parts are possible;
[0040] 2. low hardening shrinkage (<0.8%; with epoxy about 3%);
[0041] 3. autoclave treatments at 180° C.; and
[0042] 4. after-hardening in an oven at 180 to 230° C.
[0043] Since polyether amide has good adhesion, among other things, to ceramics and to metals, if necessary or desired various ceramic or metallic filler particles can be mixed with polyether amide in a matrix without considerable deterioration of the mechanical properties of the material.
[0044] The present invention also embraces the use of other thermosetting plastic polymer materials besides vinylesterurethanes and polyether amides. Other thermosetting plastic polymer materials can be used in the doctor blades of the present invention, but those materials should have a T g that is at least 20° C. to 30° C. higher than the operating temperature, i.e., the blade tip temperature, at the blade/roll face interface at the operating speed of the papermaking machine for example a paper machine speed greater than 1400 meters per minute. It should also have high impact resistance, to prevent tip breakage.
[0045] It has been noticed that the doctor blades in accordance with the present invention have a remarkably improved resistance to wear and a prolonged service life as compared with blades that contain an epoxy matrix.
[0046] While the invention has been described with reference to some preferred embodiments, many modifications and variations are possible within the scope of the inventive idea defined in the following patent claims.
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A doctor blade for use in cleaning a roll in a paper machine comprises a thermosetting plastic polymer material selected from the group consisting of vinylesterurethanes and polyether amides.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns a device for delivering portions of uniform weight and/or volume of a pasty or doughy substance, in particular sausage meat or stuffing, the device comprising a housing having a supply and a discharge opening and a rotor fitting snugly within the housing and driven to rotate therein, which rotor has at least one pair of pistons, which are arranged radially displaceable within the rotor by supporting against a stationary controlling cam.
2. Description of Prior Art
A device of this type constructed as a supplementary apparatus is known from DE-PS No. 27 25 636. This device comprises conveying means which consist of a housing driven to rotate about a filling tube, in which housing there are two portioning chambers opposing each other diametrically. In each portioning chamber a piston is arranged to lie freely, which piston is supported by means of a roller on the inner surface of a controlling cam formed by a ring body. The controlling cam is arranged to be adjusted in its eccentricity with respect to the axis of the filling tube. The latter is interrupted by a separation wall effecting the separation of the filling tube into one part serving the supply and another part serving the discharge of the filling substance. Such filling substance fed under the pressure of the supply channel thus fills the portioning chamber connected to the supply channel, respectively, the contents of the portioning chamber then being delivered on the continuing rotation of the housing as a portion wholly or partially, depending on the set eccentricity through the discharge of the filling tube.
In this process the volume of the single portions can, at a maximum, only correspond to the volume of a portioning chamber obtainable when setting the maximum possible stroke of the eccentric. If smaller portions are handled it is disadvantageous that the portioning chambers are not emptied completely so that non-exchangeable remainder volumes of the filling substance remain in the portioning chambers.
A portioning device known from DE-AS No. 21 21 006 is limited in use in a similar manner and is disadvantageous with respect to its function. This device shows conveying means provided with a rotor having a double-effective stroke piston mounted to slide radially therein. This stroke piston is guided in a centre of rotation arranged eccentrically to the axis of rotation of the rotor by means of a sliding block guided in the stroke piston, the eccentricity being adjustable.
3. Object of the Invention
It is therefore a main object of the invention to suggest a portioning device having conveying means working according to the principle of a radial piston pump and being of compact structural size.
It is a further object of the invention to suggest a portioning device enabling the continuous production of equal portions of voluntary volume in a simple manner.
It is another important object of the invention to suggest a portioning device enabling the complete emptying of the portioning chambers.
SUMMARY OF THE INVENTION
In a device comprising a housing having a supply opening and a discharge opening and a rotor fitting snugly in the housing and being driven to rotate therein, the rotor having at least one pair of pistons which are arranged radially displaceable within the rotor by supporting against a stationary controlling cam, these objects are achieved according to the invention in that at least a section of the controlling cam controlling the ejection movement of the pistons is shaped such that the ejection of the substance volume occurs proportionally to the angle of rotation of the rotor.
Such conveying means can be manufactured very simply and offer the possibility of controlling the volume flow merely by a detection of the angle of rotation of the rotor. Thus, the conveying characteristic curve of the uneconomical, expensive and large known vane conveyors with cam controlled sliding blades, worm conveyors and axial piston conveyors such as normally used in this field of the art is obtained with the measure according to the invention. In the case of providing the conveying means with pistons controllable independently of each other the return movement of the pistons can be performed by means of a curved path for the purpose of improving the filling of the portion chambers, which path causes an exponentially increasing return movement with respect to the angle of rotation of the rotor.
An essential simplification results, however, if opposing pairs of pistons are connected rigidly with each other, because in this manner only one controlling cam is necessary which controls the stroke of the ejection movement of the displacer pistons, which controlling cam will effect simultaneously the withdrawal movement of the counter piston for filling the portioning chamber.
According to another embodiment of the device there is provided that the central angle referring to the axis of the rotor and comprising the area of the discharge opening of the housing is equal to or larger than the central angle also referring to the axis and including the circumference of the rotor between a trailing edge of the discharge opening of a piston and the leading edge of the subsequent piston. Thus, in each position of the rotor there is guaranteed an ejection proportional to the angle of rotation of the rotor.
According to a preferred embodiment the controlling cam is shaped as a circle involute, which, when seen under the aspects of manufacturing technique can be produced rather simply.
BRIEF DESCRIPTION OF THE DRAWINGS
Other and further objects of the present invention will be apparent from the following description and claims and are illustrated in the accompanying drawings, which by way of illustration schematically show preferred embodiments of the present invention and the principles thereof and what now are considered to be the best modes contemplated for applying these principles. Other embodiments of the invention embodying the same or equivalent principles may be used and structural changes may be made as desired by those skilled in the art without departing from the present invention and the scope of the appended claims. In the drawings
FIG. 1 shows a top view through a device according to the invention;
FIG. 2 shows a cross-section through the device of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1 a housing 2 of a conveyor 1 is provided with a supply opening 3 and a discharge opening 4 opposing the supply opening 3 centrally. The housing 2 surrounds a rotor 5 which is fitted in a self-sealing manner radially as well as axially and which is driven to rotate about an axis 6 in a suitable manner. The rotor 5 has recesses in the form of two grooves 7 of rectangular cross-section which extend centrally with their central axes and which intersect each other by an angle of 90°. The grooves 7 serve to receive two pairs of (displacer) pistons 8.1 to 8.4 fitted into the grooves 7 in an easy sliding fit and filling the cross-section of the grooves 7. The pistons of each pair are connected by connector shafts 9 being arranged to intersect in two different planes by mirror-inverted offsetting. The pistons 8.1-8.4 are provided with supporting cogs 10.1 to 10.4 which support against an inner controlling cam 11. This cam has a section formed as a (circle) involute 12 whose pitch circle centre coincides with the axis of the rotor 5. This section is composed by a starting portion 13 commencing on the periphery of the pitch circle, and an effective portion 14 including a rolling contact or roll-off angle of 90°, which effective portion 14 is followed by a guiding portion 15 extending concentrically to the pitch circle and extending over a central angle of 90°. The controlling cam 11 is arranged stationary with the housing. The supply opening 3 and the discharge opening 4 are arranged to expand in the manner of a chamber towards the rotor 5, their peripheral dimensions including a central angle 16 with respect to the axis 6. This angle 16 is preferably larger than a central angle 20 which is enclosed between a preceding and a trailing edge 17 resp. 18 of two neighbouring portioning chambers 19.1 and 19.2 resp. 19.3 and 19.4.
The functional phase shown in FIG. 1 may be regarded the basis for the consideration of the function:
Stuffing material preferably moving by slight super pressure through the supply opening 3 against the rotor 5 has, according to this representation, filled the portioning chamber 19.1 of the piston 8.1 facing downwardly in this figure and is positioned in front of the piston 8.4 just entered into the region of the supply opening 3 and arranged to the left hand of FIG. 1. When the rotor 5 is made to rotate in an counter-clockwise direction the right piston 8.2 composed with the left one via the connector shaft 9 to form a piston unit will be pushed towards the right by engagement of the supporting cog 10.2 with the effective portion 14 of the controlling cam 11. This effects the withdrawal of the left piston 8.4 with the consequence that the stuffing material can enter (float) into the increasing portioning chamber 19.4 thereof. During this process the piston 8.1 retains its radial position within the rotor 5 since in this phase of rotation the piston 8.3 connected with the piston 8.1 engages the controlling cam's 11 guiding portion 15 concentrical to the axis 6 with its supporting cog 10.3. After an angle of rotation of 90° the supporting cog 10.3 of the piston 8.3 has reached the transitional position between the effective portion 14 and the guiding portion 15, whereby the withdrawal movement of the piston 8.1 is ended. In the meanwhile the piston 8.1 has passed the region of the starting portion 13 of the controlling cam 11 with its supporting cog 10.1 and starts to climb up the effective portion 14 of the controlling cam 11. Since the corresponding piston 8.3 with its supporting cog 10.3 has reached the end of the guiding portion 15 of the controlling cam 11 at this moment (see position of the pistons 8.4/8.2 in FIG. 1) the ejection of the stuffing material from the portioning chamber 19.1 commences, which chamber in this position is already in connection with the region of the discharge opening 4. At the moment of the commencing of the ejection movement of the piston 8.1 the neighbouring preceding piston 8.2 has reached the transitional position between the effective portion 14 and the guiding portion 15 so that the ejection movement of this piston is ended.
If the rotor 5 is driven by means of a driving motor controllable with respect to its angle of rotation, then a signal which is proportional to the ejection volume may be derived with the described conveyor by means of a feed-back of the angle of rotation. Therefore it is possible with this device to produce equal portions by subsequent covering of equal angles of rotation. For this type of driving the use of a step motor has proved to be most appropriate.
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The invention concerns a device for delivering portions of uniform weight and/or volume, e.g. of sausage stuffing. Starting from known conveyors of the vane pump, worm and axial piston type used for this purpose a radial piston conveyor modified according to the invention is suggested which delivers portion volumes proportional to the angle of rotation of the rotor by controlling the radial pistons via a controlling cam formed as an involute.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to an improved guide string arrangement and repair method for well casing wherein the casing guide string below the repair point is connected to a casing milling tool by a swivel joint to prevent unwanted decoupling of the guide string from the work string.
2. Background
In well casing repair operations it is known to utilize any elongated section of drill pipe known as a guide string for installation in a section of casing, particularly when the casing is disposed in an open hole portion of the wellbore, to facilitate locating the separated portion of the casing for repair operations and for connection to a new section of casing. The so called guide string is disposed in the portion of the casing remaining in the wellbore for locating or piloting the new section of casing and for locating or piloting a casing repair mill.
However, the guide string, which may be coupled sections of drill pipe or flush joint pipe up to several hundred feet in length will, when connected below a casing repair milling tool or the like, impose sufficient angular momentum or flywheel effect as to cause unwanted decoupling of the guide sting from the milling tool if the milling tool abruptly stops or decelerates due to rough or jagged casing edges encountered by the cutting edges of the milling tool. The present invention overcomes this problem with an improved guide string assembly and casing repair method.
SUMMARY OF THE INVENTION
The present invention provides an improved guide string for use in well casing repair operations and an improved repair method wherein the guide string is unlikely to undergo decoupling from the casing milling tool or a portion of the drill string or work string supporting the milling tool and the guide string during casing repair work.
In accordance with an important aspect of the present invention a casing guide string is connected to a casing milling tool below the tool and disposed in a section of casing being repaired by a swivel member which permits rotation of the drill string or work string and the milling tool connected thereto while allowing the guide string to remain stationary and not generate any angular momentum or flywheel effect during rotation of the milling tool. In this way inadvertent decoupling of the guide string from the milling tool or decoupling of the milling tool from the drill string is less likely to occur.
The present invention also provides a unique guide string assembly for use in casing repair operations and the like wherein the guide string is connected to a casing repair tool or mill by a swivel member which permits rotation of the tool without rotating the guide string itself.
Those skilled in the art will recognize additional benefits and superior features of the present invention upon reading the detailed description which follows in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1 through 6 are diagrams illustrating, sequentially, certain steps in carrying out a casing repair method in accordance with the invention; and
FIG. 7 is a detail section view of an exemplary swivel interposed in the guide string used in the casing repair method.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the description which follows like parts are marked throughout the specification and drawing with the same reference numerals, respectively. The drawing figures are not to scale and are in substantially schematic form in the interest of clarity and conciseness.
Referring to FIG. 1 there is illustrated a well, generally designated by the numeral 10, in which multiple casing strings 12, 14, and 16 have been installed. In the exemplary well 10, the casing 16 has experienced some damage and at least a part 17 of the casing string 16 is to be removed from the well leaving another part 18 of the casing string in an open hole wellbore portion 20 of the well 10 below the casing 14. As indicated in the diagrams of FIGS. 1 and 2 the casing string 16 is parted at 21 to form the separate casing parts or sections 17 and 18. The section 18 is to remain in the open hole portion 20 of the wellbore and be connected to a new section of casing to be described herein. The casing section 17 is to be removed from the wellbore in a conventional manner after being separated from the section 18. This separation may be accomplished in several ways through failure of the casing, through intentional separation by milling or blasting or the like. Typically in an open hole portion of a wellbore such as the portion 20, the wellbore diameter is sufficiently large that the casing section 18 may become dislocated or leaned over against the wellbore wall after removal of the section 17. This presents certain problems in aligning the casing section 18 for connection to a new casing section and problems in repairing or dressing up the damaged upper end portion 22 of the casing section 18. Enlarged diameter open hole wellbore portions are likely to occur when, for example, compressed air is used as the drill cuttings evacuation fluid during the drilling process.
FIG. 1 illustrates the installation of an elongated pipe string or so called guide string 26 within the casing 16 preparatory to removal of the casing section 17 from the wellbore. The guide string 26 may be characterized by an elongated string of end-to-end coupled sections of flush joint pipe several hundred feet in length. Typically, preparation for support of the guide string 26 is carried out by installing a plug 28 in the casing section 18. The plug 28 may be cement or a mechanical device such as a conventional bridge plug. The lower end of the guide string 26 includes a conventional mule shoe element 29. The guide string 26 includes, at its upper end, a conventional so called safety joint generally designated by the numeral 32. The safety joint 32 is characterized by coupled sections of pipe wherein the threaded connection formed between the coupled sections 33 and 35, for example, includes relatively coarse threads to facilitate easy coupling and uncoupling.
The safety joint section 33 is, as illustrated, connected to a drill string or so called work string 34 which extends to the surface, not shown. One or more sections of conventional drill pipe 38 may be interposed between the safety joint 32 and the guide string 26. The safety joint 32 is, preferably, disposed so that it extends well above the upper distal end 22 of the casing section 18 so that when the connection between the work string 34 and the guide string 26 is released, by uncoupling the safety joint section 33 from the section 35 a sufficient amount of guide string and safety joint is extending above the upper and ragged distal end 22 of the casing section 18, as shown in FIGS. 2 and 3, to permit reconnecting the work string or drill string 34 to the guide string 26 when the casing section 17 has been removed from the wellbore.
FIG. 2 illustrates the condition wherein the work string 34 and the safety joint section 33 have been decoupled from the safety joint section 35 and the guide string 26 and removed from the wellbore and the casing section 17. In the condition illustrated in FIG. 2 the well 10 is ready for removal of the casing section 17.
Referring further to FIG. 3, after the casing section 17 is retrieved from the well 10, the drill string or work string 34 together with the safety joint section 33 is reinserted in the well and connected to the safety joint section 35. The guide string 26 is then raised to approximately the position shown by the alternate position lines in FIG. 3 with at least the lower end of the guide string, as indicated by the alternate position of the mule shoe 29, still within the casing section 18 to centralize the casing section 18 in the wellbore. With the upper end 27 of the guide string 26 disposed at or near the surface, not shown, in the raised position of the guide string, the safety joint 35 and drill string section 38 is removed from the guide string 26 and a suitable casing milling tool 44, FIG. 4, and a unique swivel assembly 46 are threadedly connected to the guide string 26. The guide string 26 is then lowered back into the casing section 18 by the drill string or work string 34 until the cutting elements 45 of the mill 44 engage the upper end 22 of the casing section 18.
Upon rotation of the drill string 34, the milling tool 44 will machine the upper end 22 of the casing section 18 to provide a smooth upper end face of the same diameter as the remainder of the casing section 18. In other words the upper end of the casing section 18 is refinished to have the same configuration as the remainder of the casing section. During rotation of the drill string 34 and the milling tool 44 the swivel 46 operates to prevent rotation of the guide string 26 with the drill string 34. In this way the substantial mass of the guide string 26 does not undergo rotation which would create significant momentum or a flywheel effect which, upon snagging or deceleration of the milling tool 44, could cause uncoupling of the guide string 26 from the milling tool 44, or respective sections of the guide string 26 may uncouple from each other as a result of angular momentum of the guide string.
The swivel 46 may take one of several configurations. However, referring to FIG. 7, an exemplary configuration of a swivel 46 is illustrated. The swivel 46 has an upper box member 51 which is adapted to be threadedly coupled to the milling tool 44 or a suitable intermediate member disposed therebetween. The swivel 46 also has a lower pin member 52 which is adapted to be threadedly coupled to the upper end 27 of the guide string 26. A suitable bearing 53 is interposed between the flanged upper end 55 of the pin member 52 and a retaining collar 57 of the box member 51, which collar is threadedly coupled to the box member, for example. In this way the member 52 is free to rotate relative to the member 51 and vice versa.
After the upper end 22a of the casing section 18 has been restored to a desired condition, as indicated by the dressed and machined transverse end face 22 in FIG. 5, the drill string 34, in assembly with the milling tool 44, the swivel 46 and the guide string 26, is retrieved back to the surface without removing the lower distal end of the guide string comprising the mule shoe 29 from the casing section 18. The drill string section 38 and the safety joint section 35 are then reconnected to the guide string 26 and the guide string is lowered into the casing section 18 until the distal end/mule shoe 29 engages the plug 28 as illustrated in FIG. 5.
The upper end 27 of the guide string 26 including the drill string section 38 and the safety joint section 35 now serve as a guide for a new casing section 17 which is lowered into the well 10 with a suitable casing bowl 60 connected to the lower distal end thereof and operable to be connected to the casing section 18. The casing bowl 60, sometimes known as a casing patch, may be of a type commercially available such as a type manufactured by Bowen Tools, Inc. of Houston, Tex. Upon connection of the new casing section 17 to the casing section 18 the guide string 26, including the safety joint section 35 and drill string section 38, may then be retrieved from the well 10 in a conventional manner by connecting the safety joint section 35 to the safety joint section 33, not shown in FIG. 6, and drill string or work string 34, also not shown in FIG. 6, connected thereto.
Thanks to the provision of the swivel 46 improved casing repair operations may be carried out without loss of the guide string or the like in the wellbore due to the angular momentum or flywheel effect of the guide string during casing milling operations and the like. The swivel 46 may be made of conventional engineering material as used for down hole tools and equipment used in the oil and gas well drilling industry. The components other than those described in some detail herein may be commercially available or utilize standard commercially available components familiar to those with skill in the art in the oil and gas well drilling industry. Although preferred embodiments of a well casing repair method and guide string assembly have been described in detail herein those skilled in the art will recognize that various substitutions and modifications may be made to the invention without departing from the scope and spirit of the appended claims.
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Well casing is repaired using a guide string for maintaining contact with a lower casing section disposed in the well, particularly an open hole portion of such well. The guide string is connected to a swivel and milling tool and lowered into the casing section remaining in the open hole portion of the well for machining the upper end of the casing section. The swivel prevents build-up of angular momentum of the guide string which may decouple the guide string from the milling tool when the milling tool rotatably decelerates or snags during the machining or milling operations. The milling tool and swivel may be retrieved and the guide string, with a safety joint or fishing head, reinserted in the well during installation of a new casing section.
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[0001] The invention relates to a shoe brake for a lift drive with at least two brake shoes, which generate a braking force at a brake drum and are releasable. The present application is a Continuation of PCT/CH2006/000134, filed 3 Mar. 2005.
BACKGROUND OF THE INVENTION
[0002] An internal shoe brake with two brake shoes has become known from the specification of JP 57107443. Two brake elements are provided per brake shoe, wherein a cut-out into which the brake element is insertable is provided at the brake shoe for each brake element. The brake element consists of a base plate carrying a brake lining, wherein the brake element fits into the shape on the arc of the brake shoe. The brake element inserted into the cut-out in the brake shoe is fixed in place at the brake shoe by means of clips.
[0003] The complicated production of the groove-shaped cut-outs is disadvantageous. Moreover, the brake elements can stick in the cut-outs due to contamination and abrasion dust.
[0004] The present invention is intended to avoid such disadvantage and to create a shoe brake which functions in an optimum manner under difficult operating conditions with brake elements arranged at brake shoes.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention is a shoe brake having brake shoes with brake elements carrying brake linings that are measurably mounted to the shoe. The positioning of the brake elements with respect to the shoe to which it is mounted is settable, thus allowing the orientation of the brake linings to be adjusted.
[0006] The advantages achieved by the invention are substantially to be seen in that an optimum setting of the brake linings on the brake drum can be achieved by the brake elements according to the invention. With an optimum setting of the brake linings, small brake moment adjustments can be made in the final checking at the factory. In addition, tolerances of all brake parts can be accounted for, wherein also wider tolerances can be accommodated. Wider tolerances in turn mean cheaper production of the brake parts. In addition, it is advantageous that the brake elements are easily releasable from the brake shoes, because they cannot be fixed by either abrasion dust or by contamination. The shape of the brake element and the cut-out at the brake shoe guarantees even after long operating times a precise placing of the brake elements on the brake shoes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present invention is explained in more detail in the following detailed description of a preferred, but nonetheless illustrative embodiment thereof, in association with the accompanying figures, in which:
[0008] FIG. 1 is a perspective illustration, partially in section, of an internal shoe brake in accordance with the invention;
[0009] FIG. 1 a is an elevation view of a shoe brake of the invention with two brake shoes;
[0010] FIG. 2 is a schematic illustration of a portion of a brake shoe according to the invention with brake element;
[0011] FIG. 3 is a view of the brake shoe of FIG. 2 , further showing a side panel for fastening of the brake element;
[0012] FIG. 4 is a perspective view of a brake shoe for an internal shoe brake; and
[0013] FIG. 5 is a perspective view of a brake shoe for an external shoe brake.
DETAILED DESCRIPTION OF THE INVENTION
[0014] FIG. 1 is a perspective illustration of an internal shoe brake consisting of a housing plate 2 , a housing ring 3 , a brake drum 4 and two brake halves 5 . 1 , 5 . 2 of identical construction. The brake drum 4 can be, for example, part of a drive pulley. The lefthand brake half 5 . 1 comprises an upper brake shoe 6 and a lower brake shoe 7 . The upper brake shoe 6 is mounted at an upper brake bearing 6 . 1 and has at the opposed free end an actuating roller 6 . 2 , and is pressed against the brake drum 4 by means of a compression spring 6 . 3 supported by the housing ring 3 . The upper brake shoe 6 is illustrated in section, for which reason its brake lining is not apparent in FIG. 1 . The section also runs through the roller axis at which the actuating roller 6 . 2 is arranged. The lower brake shoe 7 is constructed in mirror image to the upper brake shoe 6 . Parts of the lower brake shoe are provided with the following reference numerals: shoe bearing 7 . 1 , actuating roller 7 . 2 , compression spring 7 . 3 and brake lining 7 . 4 . The free ends of the brake shoes 6 , 7 are adjacent to each other.
[0015] An actuator in the form of a brake magnet is provided for release of the brake shoe pair 6 , 7 . The actuator 8 , which is arranged at an actuator plinth 8 . 1 connected with the housing plate 2 , acts by means of a pushrod 9 on an actuating fork 10 by which the actuating rollers 6 . 2 , 7 . 2 are acted on to roll against the spring force of the compression springs 6 . 3 , 7 . 3 . A brake lever 11 serves for manual release of the brake shoe 6 , 7 .
[0016] The right hand brake half 5 . 2 is constructed in mirror image to the lefthand brake half 5 . 1 . Parts of the righthand brake half 5 . 2 are provided with the following reference numerals: upper brake shoe 12 with shoe bearing 12 . 1 , compression spring 12 . 3 , and brake lining 12 . 4 ; lower brake shoe 13 with shoe bearing 13 . 1 , compression spring 13 . 3 , and brake lining 13 . 4 , actuator 14 with actuator plinth 14 . 1 , pushrod 15 , actuating fork 16 and brake lever 17 .
[0017] In left hand rotation of the brake drum 4 the brake shoes 6 , 13 are trailing and the brake shoes 7 , 12 leading. In a righthand rotation of the brake drum 4 the brake shoes 6 , 13 are leading and the brake shoes 7 , 12 trailing. The braking action is amplified in the leading brake shoes and is weakened in the trailing brake shoes.
[0018] FIG. 1 a shows a shoe brake with only two brake shoes. The reference numerals of the lower brake shoes of FIG. 1 have been used for analogous parts, with actuator roller 13 . 2 . The brake drum at which the brake linings engage is not illustrated.
[0019] FIGS. 2 and 3 show a brake shoe according to the invention with a brake element. The lower brake shoe 7 of the lefthand brake half 5 . 1 of FIG. 1 is illustrated in FIG. 2 and FIG. 3 . The remaining brake shoes 6 , 12 , 13 are of the same construction, as is a brake shoe of a shoe brake with only two brake shoes, as illustrated in FIG. 1 a . The brake shoe can also be constructed with more than one brake element. Such a brake element, placeable on the brake shoe 7 , is denoted by 20 . The brake element 20 consists of an segment-shaped base plate 20 . 1 which fits in a corresponding arcuate or segment-shaped recess 7 . 5 of the brake shoe 7 . The base plate 20 . 1 carries the brake lining 7 . 4 , which is, for example, glued and pinned to the base plate. A threaded hole 7 . 6 is provided in the brake shoe 7 , and threaded holes 20 . 2 are provided in the base plate 20 . 1 . The same threaded holes are provided on the other side (not visible) of the brake shoe 7 and the brake element 20 .
[0020] FIG. 3 also shows a side panel 21 which releasably connects the brake element 20 with the brake shoe 7 . The side panel 21 is connected to the base plate 20 . 1 by means of crews 20 . 3 , wherein the screws 20 . 3 fit in the threaded holes 20 . 2 . The side panel 21 has an elongated slot 21 . 1 , wherein a screw 7 . 7 extends through the longitudinal slot 21 . 1 and fits in the threaded hole 7 . 6 . The longitudinal slot 21 . 1 allows setting of the brake element 20 relative to the brake shoe 7 . The base plate 20 . 1 is displaceable in the segment-shaped recess 7 . 5 , wherein the brake lining 7 . 4 can be adjusted on the brake drum 4 . A similar side panel is provided on the other side, of the brake shoe 7 of the brake element 20 .
[0021] FIG. 4 shows, by way of example, a lower brake shoe 13 of the righthand brake half 5 . 2 with the brake element 20 according to the invention. In this construction a projection 13 . 10 is provided at the brake shoe 13 for reception of the compression spring 13 . 3 . The construction of the brake element 20 with the components brake lining 13 . 4 , recess 13 . 5 , screw 13 . 7 , base plate 20 . 1 , screws 20 . 3 , side panel 21 , etc., corresponds with the brake element illustrated in FIG. 2 and FIG. 3 .
[0022] The brake element 20 can also be used for external shoe brakes. FIG. 5 shows a brake shoe 22 for an external shoe brake, in which the brake drum is braked by means of the brake element 20 , which is illustrated in the preceding figures, at the outer side.
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A shoe brake has a brake element for generating a braking force has at least one brake element that is adjustably settable relative to the brake shoe. The brake element may include an arcuate or segment-shaped base plate that fits in a corresponding arcuate or segment-shaped recess in the brake shoe and is adjustably mounted to the brake shoe by a pair of side panels.
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BACKGROUND OF THE INVENTION
1. The Field of the Invention
This invention relates to wheeled carts and more particularly to that class being capable of being folded into a compacted condition.
2. Description of the Prior Art
The prior art abounds with carts for carrying about game and other heavy objects. U.S. Pat. No. 2,979,338 issued Apr. 11, 1961 to A. J. Dwyer discloses a game cart having a central wheel member, a pair of handle-like members and a bed member whereby each of such members are adapted to be joined together into an assembled cart and separated when in a nonuse condition. However, the Dwyer apparatus provides a quantity of loose components when such apparatus is in such nonuse condition. U.S. Pat. No. 2,992,834 issued July 18, 1961 to E. A. Tidwell et al. teaches a game cart having a three piece assembly in which a handle portion, a body portion and a wheel assembly are adapted to be bolted together so as to form a wheelbarrow apparatus upon which game can be carried. As in the case of the Dwyer apparatus, the Tidwell disclosure utilizes loose components during the time that the apparatus is disassembled.
U.S. Pat. No. 3,860,254 issued Jan. 14, 1975 to H. W. Wegener described a foldable packer vehicle utilizing a central wheel about which a foldable tubular framework is secured, which when folded up provides an apparatus having less bulk than when the apparatus is in the unfolded condition. However, when in such folded condition the device occupies a considerable amount of space, nevertheless, and requires a substantial amount of alignment efforts to bring the apparatus into an unfolded use condition.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a foldable utility cart which folds into a compact size when not in use.
Another object of the present invention is to provide a cart having great strength, capable of carrying large bulky objects over the roughest terrain when assembled.
Still another object of the present invention is to provide a cart which may be assembled with great ease, and without tools.
Yet another object of the present invention is to provide a cart which virtually springs into its expanded assembled condition when released from a storage condition.
A further object of the present invention is to provide a cart wherein all of the components thereof are attached to one another when such components are released from locked engagement with one another.
Another object of the present invention is to provide a cart which may be assembled in cold weather, even when wearing heavy gloves or mittens.
Still another object of the present invention is to provide a cart wherein such cart may have a four point support, for resting on the earth, if desired.
Yet another object of the present invention is to provide a cart having a handle portion, useful for wheeling such cart from place to place.
A further object of the present invention is to provide a cart having only a pair of wheels for engagement with rough terrain, thereby facilitating easy transportation of heavy objects thereon.
Another object of the present invention is to provide a cart having a sieve-like sheet for resting an animal carcass therein which permits body fluids to easily pass therethrough.
Still another object of the present invention is to provide a cart which may be fabricated from conventional components, be rugged in construction, durable and totally effective for its intended purpose.
Transporting animal carcasses or disabled persons over terrain represents a substantial problem because of the great weight of such objects and because of the unevenness of the terrain. These facts, coupled with the fact that many hunters operate alone requires that a cart apparatus of lightweight design be extremely rugged in construction and have the capability of being operated by one individual under all weather conditions. The assembly of the cart may be made substantially simpler if the use of nuts and bolts and other fastening devices are eliminated.
A heavy load may be carried from place to place by utilizing a pair of wheels in contact with the terrain. During such transportation, the cart is essentially balanced on the wheels. When it is desired to rest the cart, it is best to maintain the platform portion of the cart in a near horizontal position. Therefore, the handle portion, pivotably secured to the frame portion of the cart, is best utilized as supporting legs when such handle portion is no longer required in propelling the cart from place to place. When the cart is to be utilized as an animal carcass conveyance, a sieve-like flexible sheet can be employed so as to permit body fluids, such as blood, to seep therethrough thereby lightening the load during the wheeling process. Gun cases and other auxiliary equipment may be carried on the edges of the frame portion of the cart which also has straps affixed thereto, utilized to securely engage the load onto the frame portion of the cart.
These objects as well as other objects of the present invention will become more readily apparent after reading the following description of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present invention shown in assembled condition.
FIG. 2 is a rear elevation view of a portion of the present invention.
FIG. 3 is a cross-sectional view of a component of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The structure and method of fabrication of the present invention is applicable to a rectangular frame-like portion of a cart fabricated from four elongated members, each having a pair of portions adapted to be joined to one another with a slip-joint type fitting. The same slip-joint type fitting is employed with a pair of truss-like members, each having smaller portions, and each being attached to opposed elongated members of the frame portion of the cart. Truss members, having an X-like shape, and a cross bar member are each adapted with the slip-fit joint. A pair of wheels are affixed to the leg-like truss members providing a wheeled base for the cart. A pair of handles are pivotably secured to the frame portion of the cart, each being joined by another cross bar member and each, including the cross bar pivotably secured thereto, having the same slip-fit joint to the subportions thereof. A pair of arms are pivotably secured to the handle portions and are engageable to the opposed side members of the frame portion of the cart so as to position the handle members in an upward and outward position from the frame portion of the cart or in an outward and downward position, acting as legs, from the cart, when it is desired to maintain the cart in a near horizontal condition. A flexible sheet, fabricated from a cloth-like material, such as canvas, is attached to the frame portion of the cart utilizing a plurality of straps therefor. Holding straps, equalling four in number, are secured to the frame portion of the cart and employ a pair of buckles so as to be useful in securing an animal carcass or the like, when such carcass is resting on the flexible sheet. The flexible sheet is provided with small openings so as to permit body fluids to pass therethrough.
Each of the rigid elongated elements of the cart assembly, comprising all of the elongated elements thereof, save for the pair of arms, are fabricated from hollow tubular portions in which one portion has a uniform outside diameter and the other portion has one end thereof slightly enlarged for receiving a short length of the uniform diameter portion therein. When so engaged, the uniform diameter portion forms a loose fit into the slightly enlarged end of the nonuniform diameter portion. A flexible resilient material, such as a rubberized shock cord is inserted passing through both portions of each elongated member and has the end thereof secured to the remote ends of the tubular portions. The shock cord is prestressed so as to cause adjacent ends of the tubular portions to be urged into sliding contact with one another. However, when it is desired to fold up the tubular portions, a force exerted in opposite direction on the tubular portions causes them to become disengaged from one another and allows such portions to be positioned in side by side relationship, thereby allowing the elongated member to be positioned in a folded up shape. Since all the elongated members of the present invention are provided with the slip type joint described, the entire apparatus may be folded up into a compact shape. The straps, utilized to secure the animal carcass on the flexible sheet portion of the cart, may be utilized to maintain the components in such folded up condition. When it is desired to assemble the cart, the straps are released and the shock cords passing through the tubular portions of each elongated member tend to align such tubular portions into coaxial arrangement whereby the prestressing of the shock cord causes the tubular portions to practically snap into sliding engagement and practically, if not totally, automatically assemble the cart into an erected condition. A gentle shaking action, exerted on the metallic portions of the apparatus, can cause the entire apparatus to be disposed in an erected condition. In such condition the cart is ready for use, relying only upon a moderate force on each shock cord element to maintain such cart in the erected condition. Thus, no tools are required for assembly and during disassembly only an oppositely directed force, applied to the tubular portions, followed by folding such tubular portions into side by side relationship, allows the cart elements to be folded up into a storage condition, suitable for carrying about in the trunk compartment of a motor vehicle. The arm portions of the apparatus employ a rivet-like pivot arm at one end thereof and a slotted opening for use with a projecting rivet-like pin attached to the handle portion of the cart. In this manner, the handle portion may be maintained in a preferred position upwardly and outwardly from the frame portion of the cart or outwardly and downwardly in a leg-like position when it is desired to position the cart at rest. The carcass holding straps may be provided with buckles or other fasteners, if desired. A pair of gun cases may be removeably affixed to the sides of the foldable frame portion of the cart, utilizing fasteners of any type well known in the art, if desired. Lightweight aluminum tubing may be employed, thereby minimizing the capability of the apparatus rusting when exposed to rain. Because each elongated member is fitted with the slip type joint, the entire apparatus may be folded up into a shape no greater than two feet in length and having a diameter less than one foot. However, when the apparatus is erected, it is capable of carrying a full grown buck or other carcass of great size and weight.
Now referring to the figures, and more particularly to the embodiment illustrated in FIG. 1 showing the present invention 10 having frame elongated members 12, 14, 16 and 18, forming a rectangle and having flexible sheet member 20 disposed secured thereto utilizing loop-like straps 22. Dotted lines 24 simulate an animal carcass resting on sheet 20 and is secured thereon, utilizing flexible cloth-like straps 26. The flexible straps are secured at one end thereof to elongated members 14 and 18, utilizing loop-like portions 28. Buckles 30 secure the ends of straps 26 together. Elongated members 32 and 34, secured to elongated member 18, are identical to another pair of elongated members, not shown, affixed to elongated member 14, forming a V-like shape and having wheels 36 affixed to the ends thereof and journaled thereto. Elongated member 38 extends parallel to elongated members 12 and 16 and joins together elongated members 32 and 34, and the pair of elongated members, not shown, equivalent to elongated members 32 and 34 that are secured to elongated member 14. Elongated member 40 extends upwardly from the intersection of elongated members 32 and 34 and is secured to elongated member 14. Elongated member 32 is pivotably secured to elongated member 34, both being pivotably secured to elongated member 18. Elongated members 38 and 40 are pivotably secured to one another and to elongated members 32 and 34, utilizing pivot rods, not shown, therefor. Elongated members 42 and 44 are pivotably secured to elongated members 14 and 18, adjacent the ends of elongated member 16 and are provided with ends 46 disposed slightly bent relative to the longitudinal axis of the remaining portions of their length. Elongated member 48 is pivotably secured to elongated members 42 and 44 and extends parallel to elongated member 16. Ends 50, located at the free ends of elongated member 14 and 18, are bent upwardly relative to the plane defined by elongated members 12, 14, 16 and 18. Arms 52 are pivotably secured to elongated members 14 and 18, utilizing rivet-like pin 54 therefor. The other end of arms 52 are pivotably secured to elongated members 42 and 44, utilizing rivet 56 therefor. Rivet-like pin 54 engages slot 58, maintaining elongated members 42 and 44 in the upright use position shown. When ends 46 of elongated members 42 and 44 are permitted to move downwardly in the direction of arrow 60, elongated member 44 is shown in the position denoted by dotted lines 44a. Bar 52 is then rotated so as to occupy the position by dotted lines 52a, securing elongated member 44 in the position shown by dotted lines 44a, permitting present invention 10 to be maintained in a horizontal position. Elongated members 12, 14, 16, 18, 42, 44, 32, 34, 38, 40, 48 are each formed from two elongated member portions having a slip type joint 62 thereinbetween. Thus, such elongated members may be folded in half by separating the adjacent elongated member portions and causing them to reside in side by side relationship, if desired. Since all elongated members that are secured to one another are secured together pivotably, the remaining portions of the present invention 10 may be positioned in sensibly side by side relationship forming a bundle of components, accepting straps 26, buckles 30, arms 52 and flexible sheet 20. Since the only rigid elements comprising the last main components include arms 52, the remaining portions of the apparatus, with the exception of wheels 36, may be folded up with great ease. Wheels 36, possessing the small size, may be likewise located in a preferred position as desired. It should be noted that wheels 36 are journaled to elongated member 34.
FIG. 2 illustrates elongated member 64, in opposite relationship with elongated member 34, and serving the same supporting function therefor. Truss-like elongated member 66, is disposed annularly with truss-like elongated member 40, being pivotably secured thereto, utilizing pivot rod 68 therefor. It should be noted that elongated members 64 and 66 are provided with slip type joints 62. Gun cases 70 are secured to the sides of elongated members 34 and 64 utilizing fasteners 72 therefor.
FIG. 3 illustrates a typical elongated member, as shown in FIG. 1, illustrative of say elongated member 32 shown therein. Such elongated member is formed from portion 74, having end 76 thereof with a larger outside diameter than end 78. Portion 80 is shown disposed having a uniform outside diameter and has end 82 thereof disposed residing in end 76 of portion 74. Pivot rod 84, disposed at end 78 of portion 74 and pivot rod 86, disposed at end 88 of portion 80, may be used to pivotably secure elongated element 32 to elongated member 18 and elongated member 34, shown in FIG. 1. Additionally, such pin members join together the ends of shock cord 90 held in a relative taut position thereby. In this fashion, elongated member 30 is maintained in an assembled condition. When a force is applied to portion 74, in the direction of arrow 92 and when a simultaneous force is applied in the opposite direction to portion 80, portion 80 has end 82 thereof pulled outwardly from end 76 of portion 74, causing plastic flexible member 90 to expand in length and causing portion 80 to reside in the position shown by dotted lines 80a. When a force is applied to end 88a of portion 80, shown in position 80a, in the direction of arrow 94, portion 80 is disposed residing in the position shown by dotted lines 80b. Here, portion 80 is disposed in side by side relationship with portion 74, having portion 90b of the shock cord exposed. When the portion 80 is released from the position shown by dotted lines 80b, shock cord 90 causes portion 80 to straighten out and to be pulled into alignment with portion 74 so as to automatically align such components into elongated element 32. If desired, plastic member 90 may be stretched into any desired length, so as to allow portions 74 and 80 to be positioned at any regular relationship and distance relative to one another, consistent with the convenient folding up of the present invention 10, shown in FIG. 1.
One of the advantages of the present invention is a foldable utility cart which folds into a compact size when not in use.
Another advantage of the present invention is a cart having great strength, capable of carrying large bulky objects over the roughest terrain when assembled.
Still another advantage of the present invention is a cart which may be assembled with great ease, and without tools.
Yet another advantage of the present invention is a cart which virtually springs into its expanded assembled condition when released from a storage condition.
A further advantage of the present invention is a cart wherein all of the components thereof are attached to one another when such components are released from locked engagement with one another.
Another advantage of the present invention is a cart which may be assembled in cold weather, even when wearing heavy gloves or mittens.
Still another advantage of the present invention is a cart wherein such cart may have a four point support, for resting on the earth, if desired.
Yet another advantage of the present invention is a cart having a handle portion, useful for wheeling such cart from place to place.
A further advantage of the present invention is a cart having only a pair of wheels for engagement with rough terrain, thereby facilitating easy transportation of heavy objects thereon.
Another advantage of the present invention is a cart having a sieve-like sheet for resting an animal carcass therein which permits body fluids to easily pass therethrough.
Still another advantage of the present invention is a cart which may be fabricated from conventional components, be rugged in construction, durable and totally effective for its intended purpose.
Thus, there is disclosed in the above description and in the drawings, an embodiment of the invention which fully and effectively accomplishes the objects thereof. However, it will become apparent to those skilled in the art, how to make variations and modifications to the instant invention. Therefore, this invention is to be limited, not by the specific disclosure herein, but only by the appending claims.
The embodiment of the invention in which an exclusive privilege or property is claimed are defined as follows:
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A folding utility cart utilizes a plurality of elongated members, each having portions thereof engageable into one another and disengageable from one another so as to be folded up into a compact length when the cart apparatus constructed therefrom is in a storage condition. The portions each are made up from tubular members having an elastic member passing therethrough, connecting the portions together and biasing the portions towards one another at ends thereof adapted to partially telescope into each other in a slip-fit. The cart has pivotable handle means acting as a stand in one position and as an upright handle in another, connected to a major frame portion. A pair of wheels are suspended below the frame member, utilizing disengageable portions whereby the entire apparatus, when assembled, provides a cart-like apparatus having straps attached thereto for securing game or other heavy objects on a fabric-like sheet attached to the cart.
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This application claims the benefit of U.S. Provisional Application No. 60/637,644, filed Dec. 20, 2004, which is hereby incorporated by reference in its entirety.
BACKGROUND OF INVENTION
1. Field of Invention
This invention relates to wireless communication networks in which wireless communication devices send information to each other and/or a host computer.
2. Description of Related Art
As advances in technology enable the development of ever-smaller wireless devices such as sensors and actuators, there has been increasing interest in self-configuring multihop wireless networks of these devices, together with additional communication devices and software. Such networks, typically known as Wireless Sensor Networks (WSNs), have a number of potential uses. For example, WSNs may be employed for automated meter reading (AMR) applications, such as for metering residential heat, electricity, or water usage.
In examining the operation of WSNs, some questions arise: How might data be reported from device to device within a WSN? How may data from a network of devices be accumulated and passed to devices or applications outside the WSN? What are some requirements for timely, low power communication within such WSNs? What features may be incorporated to improve system reliability? Various aspects of the invention described below relate to reporting and accumulating data in such wireless networks.
SUMMARY OF INVENTION
In one aspect of the invention, a method for coordinating communication in a wireless sensor network includes associating a first node with a wireless sensor network having at least two nodes associated with each other in a parent/child relationship. The first node may be associated with the wireless sensor network such that the first node functions as a parent or a child to at least one other node. A wake up time may be determined for the first node to wake up and listen for, or to broadcast, a signal regarding communication with a parent or child node. The wake up time may be determined based on a detected temperature at the first node. For example, operating temperatures local to a device, such as a router, edge node or other in a wireless sensor network, may affect the operation of a timer. Thus, differences in temperatures between different nodes in the network may affect the devices' ability to coordinate communications with each other if the communication is scheduled to occur at specified intervals. By adjusting for temperature conditions at one or more nodes, time periods in different devices may be more accurately or consistently measured. Any adjustment made for temperature may cause an adjustment to an elapsed time measurement made by a clock (e.g., an elapsed time period measured by a clock may be adjusted by some temperature varying factor) or to a expected time period (e.g., a wake up time period between communication intervals may be adjusted based on measure temperature to account for variations in clock operation).
In another aspect of the invention, a method for coordinating communication in a wireless sensor network includes associating a first node with a wireless sensor network having at least two nodes associated with each other in a parent/child relationship. The first node may be associated with the wireless sensor network such that the first node functions as a parent or child to at least one other node. A wake up time may be determined for the first node to wake up and listen for a signal regarding communication with a second node that has a parent or child relationship with the first node. The wake up time may be determined based on a determined clock skew between a clock in the first node and a clock in the second node. Manufacturing or other variations between clocks used in two or more devices in the network may result in time being measured differently by the devices. A node, such as an edge node, router or other, may determine a clock skew (a difference in time measurement) between the node and another device with which the node communicates. For example, an edge node may expect a parent router to beacon at a predetermined time, but in fact, the router may beacon at the predetermined time+/−a clock skew. For future communication times, the edge node may use the clock skew to adjust an elapsed time period or expected time period to determine when the router will wake up for communication.
In one aspect of the invention, a node may use temperature adjustment and a clock skew to determine a wake up time for communication with another node in a wireless sensor network. For example, a node may adjust elapsed time measured by its clock based on a measured temperature, and adjust wake up times when the node is scheduled to communication with one or more other nodes based on a clock skew determined for each of the other nodes. The node may use a different clock skew for each other node with which the node communicates so that differences in clock operation may be optimally compensated.
In another aspect of the invention, a method for forming a wireless sensor network may include providing a plurality of nodes at a location where at least two of the nodes are adapted and positioned relative to each other to form a wireless sensor network. A signal may be beaconed from a first node that represents that the first node is not associated with a wireless sensor network and that the first node is adapted to function as a parent node. A second node may be associated with the first node such that the second node is a child of the first node and the first node is a parent of the second node, thereby forming, at least in part, a wireless sensor network. A third node that is capable of functioning as a cluster head may initially be associated with the wireless sensor network as a child of an association node in the wireless sensor network, and thereafter the association node may be commanded to function as a child of the third node such that the third node functions as a parent to the association node. In accordance with this aspect of the invention, a cluster head, such as a data accumulator or gateway, may be associated with an existing wireless sensor network such that the cluster head is initially made a child of at least one node (e.g., a router) in the network. Thereafter, the cluster head may instruct one or more nodes in the network (including its initial one or more parents) to adjust their hierarchical function in the network so that the cluster head functions as a parent to nodes in the network. The cluster head may further adjust the hierarchical function of nodes in the network, such as reversing existing parent/child relationships. (Designation of “association node” does not necessarily require the node to have any specialized capability. Rather, an “association node” may be any device with which the cluster head initially associates. For example, the “first” or “second” node may function as the “association node.”)
In another aspect of the invention, a wireless sensor network includes a cluster head, a shadow cluster head, and a plurality of nodes in communication with the cluster head and the shadow cluster head. The plurality of nodes may include at least one router or at least one edge node, e.g., at least one of the nodes including an associated sensor to collect sensor data. The cluster head and the shadow cluster head may be adapted to receive communications from a same set of nodes, but the cluster head and the shadow cluster head may use different multipath profiles to communicate with nodes in radio range. For example, the cluster head may communicate wirelessly with a same set of nodes, but communicate with those nodes using different communication paths. Thus, the shadow cluster head may provide a redundant link from the set of nodes to the cluster head.
In another aspect of the invention, a wireless sensor network may include a data accumulator, and a plurality of nodes in communication with the cluster head. The plurality of nodes may include at least one router or at least one edge node that provides sensor data to the data accumulator, and the data accumulator may be adapted to communicate wirelessly with a mobile device to transmit the sensor data to the mobile device. The data accumulator and the mobile device may use a same radio MAC and PHY, and the mobile device may use an IEEE 802.15.4 radio to communicate with the data accumulator. The nodes and the data accumulator may communicate wirelessly at a frequency of about 868 MHz, and the data accumulator and the mobile device may communicate at a frequency of about 2.4 GHz.
In another aspect of the invention, a method for forming a wireless sensor network includes providing a plurality of routers that are configured and arranged to form a wireless sensor network in which routers have a hierarchical parent/child relationship. A gateway may be provided in communication with the wireless sensor network, where the gateway is adapted to send and receive signals for the wireless sensor network to at least one device outside of the wireless sensor network. The routers in the wireless sensor network may each have a hop count that indicates a number of routers through which communications from the router pass to the gateway, and routers with a lower hop count may have a larger battery capacity than routers with a higher hop count.
These and other aspects of the invention will be apparent from the following description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Aspects of the invention are described below with reference to the following drawings in which like numerals reference like elements, and wherein:
FIG. 1 shows an example of a wireless sensor communication network (WSN).
FIG. 2 illustrates an algorithm for clock synchronization between beaconing events, adjusting for temperature.
FIG. 3 illustrates an algorithm for child node synchronization to parent, adjusting for clock skew.
FIG. 4 illustrates an example of hierarchical routing.
FIG. 5 illustrates an example of Router structure in a WSN.
FIG. 6 illustrates how a network might form around the first Router to join a WSN.
FIG. 7 illustrates a Data Accumulator being added to the WSN of FIG. 6 .
FIG. 8 shows the Data Accumulator adjusting parent/child relationships within the WSN of FIG. 6 .
FIG. 9 illustrates a Data Accumulator design.
DETAILED DESCRIPTION
Aspects of the invention are described below with reference to illustrative embodiments. However, it should be understood that aspects of the invention are not limited to those embodiments described below, but instead may be used in any suitable system or arrangement.
Aspects of the invention are described in relation to a wireless sensor communication network (WSN) 6 , in which routing and non-routing devices may be combined into a mesh or hierarchical structure, as shown, for example, in the illustrative embodiment of FIG. 1 .
As shown in FIG. 1 , WSN 6 components may include:
Edge Nodes. Edge Nodes 1 may include small, battery-powered wireless radio transceivers that may provide low-bandwidth wireless connectivity for attached devices such as sensors (e.g., temperature, humidity, power or fuel consumption) and actuators (e.g., fans, LEDs, switches). Within the mesh or hierarchical structure of a WSN 6 , Edge Nodes 1 may have parent nodes through which the Edge Nodes 1 may send and/or receive data; an Edge Node 1 's parent may be a Router 2 , a Data Accumulator 3 , or a Gateway 4 . Edge Nodes 1 may report data periodically, such as once a day, and may sleep for extended periods of time to reduce battery consumption. Edge Nodes 1 may communicate via a WSN 6 , but may not expend power supporting other devices within the WSN 6 (i.e., Edge Nodes 1 may not serve as parents, only as children). Routers. Routers 2 may be specialized nodes that self-organize into a WSN 6 backbone. Routers 2 may repeat or route the data transmitted on the WSN 6 . They may transmit or relay messages to other nodes on the network, including Edge Nodes 1 , Routers 2 , Data Accumulators 3 , or Gateways 4 . A Router 2 may also be configured to collect and report its own sensor readings periodically, in addition to forwarding network traffic on behalf of other nodes. Routers 2 may also have parents; a Router's 2 parent may be another Router 2 or a Data Accumulator 3 . Routers 2 may expend more power than Edge Nodes 1 , as energy may be required to maintain network connections and to forward traffic on behalf of other devices. Nonetheless, a Router 2 may still operate for years on a small battery as shown herein. Alternatively, Routers 2 may be line powered. Data Accumulators. A Data Accumulator 3 may accumulate data readings from devices in the WSN 6 . The Data Accumulator 3 may be at the root of the WSN's 6 network tree. A Shadow Accumulator 3 b , located near the Data Accumulator 3 a , may be integrated with the Data Accumulator 3 a and may serve as a backup by mirroring the data collected by the Data Accumulator 3 a . Each Data Accumulator 3 may be connected through a serial, network, bus, or other connection to a Gateway 4 , which in turn may pass data to an enterprise application. Gateways. Gateways 4 may be mechanically similar to Routers 2 , except that, in place of re-transmitting messages, they may provide an interface to a different physical or logical network. Gateways 4 may serve as portals to different types of networks, terminating the WSN 6 protocol and translating communications to a different protocol appropriate for the new network. Alternatively, a Gateway 4 may act as a bridge, encapsulating WSN packets in another protocol such as TCP/IP. Gateways 4 may be configured for networks such as Ethernet, WiFi, cellular, RS232, BACnet, LonWorks, or even simply binary switch outputs. In some configurations, Edge Nodes 1 and/or Routers 2 may connect directly to Gateways 4 , providing a real-time connection to remote devices. Host. A Host 5 may operate on a computer running Windows, Linux, or another environment suitable for the particular application. A Host 5 may include Host Software, which may provide an interface to the WSN 6 , direct data into a database, or offer GUI applications that may present data, allow actuation (if applicable), or support network administration. In one embodiment, as shown in FIG. 1 , the Host 5 may operate on a handheld device. In such an embodiment, the handheld device may support a walk-by scenario, wherein a handheld device may communicate with a Data Accumulator 3 via a Gateway 4 to extract the network's data. This scenario is discussed in more detail below. Cluster head. A cluster head is any device, such as a Router, Data Accumulator or Gateway, that can act as a parent of all descendents in a WSN 6 .
A WSN 6 may be designed to support hundreds of devices reporting daily. The WSN 6 may support only Routers 2 or permutations of Routers 2 and Edge Nodes 1 as appropriate for different applications. System capacity may primarily be limited by the battery life of Routers 2 close to Data Accumulators 3 , as such Routers 2 may need to expend power passing traffic to and from a large number of more distant devices. System capacity may be increased with larger batteries on such Routers 2 .
In this specification, “node” or “device” may refer to an Edge Node 1 , Router 2 , or other networked device. Within the system, Routers 2 and Edge Nodes 1 may have parent-child relationships, with Edge Nodes 1 being children of one or more Router 2 parents. Each Edge Node 1 may have a primary parent Router 2 and, if possible, a secondary parent Router 2 and even additional parent Router(s) 2 for redundancy. Similarly, Routers 2 may have parent-child relationships with other Routers 2 . Data Accumulators 3 and/or Gateways 4 may also act as parents.
WSNs in an Automated Meter Reading (AMR) Application
In this discussion, we use as an example a WSN 6 that is configured for automated meter reading (AMR), such as might be provided by a business billing customers for heat, electricity, or water usage. In an AMR application, for example, a Heat Cost Allocator may measure the temperature of a radiator and from that may estimate a customer's energy usage. Similar calculations may be performed with water usage, using a low-powered or self-powered water meter designed for that purpose. The calculation of energy or water usage may be accumulated on the device itself, and a cumulative reading may be reported periodically (such as daily). Readings may be transmitted to a central collection point and then may be sent to an enterprise application. Information may also be displayed locally, such as on an LCD, at the press of a button.
The SensiNet AMR design may be a variant of Sensicast's Distributed Frequency Spread Spectrum (DFSS) design, as described in PCT Application WO05/010214 Method and Apparatus for Wireless Communication in a Mesh Network. For power savings on the Router, a single frequency or small number of frequencies may be used, particularly for control channels used to advertise Router timing and availability.
Although a WSN 6 configured for AMR is used as an example in this discussion, descriptions within are purely illustrative and are not intended to be limiting.
For the AMR application example described herein, we assume a design goal for Routers 2 is to run on battery power, with 10 year battery life at 1000 mAh. A one-day reporting interval may be sufficient, as long as daily reporting is reasonably reliable.
For the AMR application example described herein, we illustrate the design with a hypothetical but typical RF transceiver with the following general characteristics:
An integrated microprocessor with 32 kb flash, 4 kb SRAM, and power/timer features similar to MSP430. Some of the flash and minimal SRAM may be used for specific applications, such as for AMR. 2 μA power consumption with radio & microphone asleep. 2 ms wakeup at 4 mA power consumption. 250 kbit/s radio bandwidth, such as can be found with 802.15.4 radios or various proprietary transceivers. 20 mA receive, 25 mA transmit power consumption.
The different types of devices in a WSN 6 are discussed in more detail below.
Routers
A Router 2 may participate in the formation and operation of the network backbone. It may normally include a sensor and/or actuator and may also relay data from nearby devices. Routers may work together to form a redundant tree topology leading to a Data Accumulator 3 . The tree may be redundant; each Router 2 may have multiple parents. Two parents per Router 2 are shown in FIG. 1 ; more than two parents per Router 2 may be supported by the software. The illustrative power calculations in this disclosure are based on three parents per Router 2 .
A Router 2 may transmit a beacon once each minute on a randomized but predictable schedule. This beacon may allow other nodes to find (e.g., by listening for) the Router 2 and synchronize their timing with the Router 2 . When a node becomes the child of a Router 2 , it may lock onto the Router 2 's beacon schedule, and may read the Router 2 's beacon every few minutes to stay synchronized. A node with multiple parents may stay time synchronized with all of its parents. Aspects of the invention related to clock synchronization or other time management techniques are discussed in more detail below.
After each beacon, the Router 2 may wait for a short period of time to allow its children to direct a message toward the Data Accumulator 3 . If a Router 2 receives a message from one or more of its children, it may repeat this message to all of its parents. Messages between a Router 2 and its children may be acknowledged. A child may send a message multiple times to its parent, within reason, until the message is acknowledged.
Router 2 memory may be very limited, so only a few messages may be buffered in Router 2 memory. A Router 2 may retain messages from its children only long enough to direct those messages toward the Data Accumulator 3 and/or Gateway 4 .
Messages may be sent from a child to a parent during a “contention access period” immediately following the parent's beacon, or at other times that may be scheduled at predictable times in relation to the beacon. The parent/child protocol for a contention access period may be similar to that described in the specification for the IEEE 802.15.4 MAC. With a beaconing interval of about once per minute, the system may have a latency of about one minute per hop.
Routers 2 may also buffer a limited number of messages from a Data Accumulator 3 and/or Gateway 4 to its children, constrained by the limited memory available in the Router 2 . A message may be addressed to a specific child device, or it may be addressed to all devices. Indicators of store and forward messages may be included in each beacon, or the message itself may be included in each beacon.
The power draw for a Router 2 is estimated in Table 1. The estimates in Table 1 utilize calculations from Tables 4 and 5 in the Appendix.
TABLE 1
Power estimates for Routers.
Activity
mAh/year
Comments/Assumptions
Sensor Power
10
Sensor Report
0.05
This assumes that sensor readings are
reported once per day, to all three
parents, with acknowledgements and
retries.
Route Child Messages
25.6
This power estimate assumes the worst
case scenario, wherein a Router must
relay messages from 500 descendents
once per day.
Sleep current
17.5
This estimate assumes a 2 μA power
draw when the device is asleep.
Beacon
5.9
This assumes one 30-byte beacon
transmitted each minute.
This calculation allows a short time
after each beacon to wait for incoming
message from children before going
back to sleep.
Keep-Alive
19.5
This assumes that Routers check for a
message from each of their parents
every two minutes. This also assumes
that Routers simultaneously resyn-
chronize their clock offset to each
parent and that parent-child clocks can
be cross-calibrated with 25 ppm
accuracy.
Network Scans
8.3
In order to join the network initially, a
node may run its receiver for a minute
to scan for beacons from all of its
neighbors. This may enable the node
to find and select the best parents.
Beacons may include a measure of link
quality from the Router back to the
Host, thereby enabling devices to pick
the best parents. Routers may rescan
for parents periodically. The power
estimate assumes that a scan is per-
formed every two weeks by each
device for the life of the network.
Total
86.9
This estimate corresponds to 11.5 year
battery life from a 1000 mAh battery.
The numbers in Table 1 incorporate very conservative assumptions. In particular, an average of three acknowledged transmissions (i.e., one message and two retries) to each of three parents for each link is assumed.
Sensitivity analysis shows that power consumption as shown in Table 1 may be particularly susceptible to the following variables:
Data Rate: For our calculations, a 250 kbit/sec radio is assumed. Power requirements may roughly double if the radio rate is reduced to 76 kbit/sec. Clock Skew: Clocks may be synchronized, with Routers 2 and their children waking up at (approximately) the same time. Drift in the clock crystal may require that child devices wake up earlier and listen longer, so that they may be sure of hearing a beacon at the appointed time. There may be small timing variations from crystal to crystal. In addition, crystal timing may change with temperature, age, and other effects, which may result in additional clock drift. Adjustments for each of these factors are discussed below. The power estimate assumes that crystals may be calibrated to within 25 ppm for each parent-child pair. This may involve tracking node temperature, as well as automatically calibrating clock skew between devices. If performance may be calibrated to within 10 ppm, Router 2 battery life may be increased by about 8%. Conversely, calibration to within 50 ppm may decrease Router 2 battery life by about 12%. Sleep Current: Sleep current may be capped at 2 μA so as not to decrease battery life. If sleep current is doubled, Router 2 battery life may be decreased by about 17%.
As noted earlier, a WSN 6 may be designed to support hundreds of devices reporting daily. Some Routers 2 may need to expend power passing traffic to and from a large number of more distant devices. For example, Routers 2 at the root of the network (near the Gateway 4 ) may pass messages to and from nearly every other node in the network, whereas Routers 2 at the edges of the network may need to pass messages to and from only a small number of descendents. Thus, Routers 2 nearer the root of the network may expend more power to service their descendents than may Routers 2 with a smaller number of descendents. Longer contention access periods may be needed for Routers 2 with more descendents. Thus, system capacity may be increased with larger batteries on Routers 2 with a large number of descendents.
Optimizations may be implemented to improve Router 2 battery life. For example, as noted in entry G 3 of Table 5 in Appendix A, messages may be combined on heavily used Routers 2 , thus decreasing the power required to service children by 50% (for example).
Clock Synchronization
Prior Sensicast specifications such as those described in PCT Application WO05/010214 describe how nodes may synchronize with their parents by listening for messages (called “beacons”) from Routers 2 (or Data Accumulators 3 ) that have already joined the network. A beacon may be a very short message (on the order of two milliseconds) that may signal the availability of a Router 2 for communication, broadcast a synchronized time base, and/or transmit scheduling information for future beacons so that other nodes may predict the availability of a given Router 2 for communication, so that sleep periods may be synchronized. With precise synchronization, nodes may lessen the amount of time they spend awake listening for beacons, and may thus improve their battery life.
Each Router 2 may transmit a beacon periodically, such as once per minute. New nodes may search for parents by listening for the full beacon interval (e.g., for one minute), and then may track the timing of those parents by listening periodically to subsequent beacons (e.g., every 15 minutes).
The beaconing strategy may be essentially as described in PCT Application WO05/010214. Beacon timing may be randomized to prevent repeated collisions, such as once per minute ±0.5 second (randomized). The randomization schedule may be known and anticipated by the Router's 2 children, based on information included with the beacon, so that children may predict when their parents may be available for communication. The beacon may signal a Router's 2 availability for communication. The beacon may include information about the time base of the WSN 6 , so that children may synchronize with their parents. The beacon may also include information about when to expect future beacons, so that child nodes can go to sleep and wake up based on when their parents are next expected to be available for communication.
A Router 2 may select the timing of beacons, as well as the channel on which they are transmitted at a given time, through a combination of user configuration and adaptive algorithms. The timing and channel of beacons may be regular and pseudorandom. For example, a Router 2 may be set to send a beacon every 60 seconds, with a randomized dither of plus or minus 0.500 seconds. The randomized dither may be calculated using a linear congruential generator of the form in Equation 1:
R n+1 =( a·R n +b )mod m (1)
The values a (the multiplier), b (the increment), and m (the modulus) are pre-selected constants. The choice of constants is well studied in the computer science literature.
Transmission of the value R n with each beacon may allow a node to “lock on” to the Router's 2 pseudorandom number sequence. This in turn may be used to forecast the timing of future transmissions, thus allowing the node to wake up and sample the channel at the time a transmission is expected.
Alternatively, and for less computational complexity, the dither may be derived from a lookup table that is shared across the network.
These two techniques may be combined, with a linear congruential generator used to generate a table of a sequence of x pseudorandom numbers. A device wishing to duplicate the table and synchronize with the Router 2 may need the pseudorandom seed used to generate the table, the table length, and the current offset into the table.
For example, a node may use a seed in a linear congruential generator to generate a table of 32 pseudorandom numbers. Each of the table entries may be taken as a dither amount. For example the low-order 10 bits may be used to set the dither in milliseconds, resulting in a dither of ±512 milliseconds (approximately ±0.5 seconds). Thus a Router 2 may send a beacon every minute±a randomized dither from the table. In this example, the true time period to cycle through a table of 32 entries would be 32 minutes±(sum of all 32 randomized dithers).
However, as noted earlier, drift in the clock crystal may require that child devices wake up earlier than the expected beacon time and listen longer, so that they may be sure of hearing a beacon at the appointed time. There may be small timing variations between crystals, and temperature changes may result in additional clock drift. It may be desirable to adjust for these effects, so as to minimize child device wakeup time and thus to prolong battery life. Adjustments for temperature effects and fixed clock skew are discussed below.
Adjusting for Temperature Effects
As noted earlier, power consumption may be fairly sensitive to the degree of time synchronization between the parent and child, which in turn relies on clock accuracy.
Temperature may change the timing characteristics of crystal oscillators. It is possible to buy TCXOs (temperature compensated crystal oscillators) that provide highly accurate timing across a range of temperatures; however, this may involve some cost and may use more power than is desirable. TCXOs may also provide more precision than may be necessary; as noted earlier, the power estimates for the SensiNet AMR design assume 25 ppm accuracy, and TCXOs may achieve much better than 25 ppm accuracy.
A design guide from chip manufacturer Microchip Technology Inc. (PICmicro Microcontroller Oscillator Design Guide AN588, available at http://ww1.microchip.com/downloads/en/AppNotes/00588b.pdf) provides an overview of the issues with various types of timers. The guide describes a formula that estimates how timing may change with temperature in a 32 kHz crystal of the type typically found in an inexpensive WSN 6 device. A formula for temperature-dependent frequency change (in ppm) is given in Equation 2 as:
0.04*((25-° C.) 2 ) (2)
A similar formula may be used by a WSN 6 device to compensate for timing that drifts based on the device's own temperature.
In accordance with one aspect of the invention, a baseline approach for a device with a 32 kHz clock (actually specified as 32.768 kHz in a typical crystal) may be as follows:
The device may be scheduled to wake up at some precise time (e.g., after the passage of a determined time period since a last wake up event), such as one minute plus a randomized fraction of a second. The wakeup time may be calculated based on the standard performance of the clock at 25° C. A device may use a method such as that shown in FIG. 2 to control its sleep/wake cycle, according to which a device may go into a deep sleep for 10 seconds in step S 1 . After a time period of 10 seconds elapses, the device may wake up in step S 2 , read its temperature S 3 , and adjust the planned wakeup time to account for temperature effects over the prior 10 seconds in step S 4 . While the formula in Equation 2 may be used to adjust the elapsed time measured by the clock in step S 4 , a more accurate result may be achieved by profiling a representative sample of devices and placing an appropriate offset value in a table for a given set of temperatures. Adjustment made in step S 4 may be to the elapsed time measured by the clock (e.g., by multiplying the elapsed time by a suitable factor, and then comparing the adjusted elapsed time to the time period over which the device is to sleep), or to the expected time period (e.g., by multiplying the expected sleep time period by a suitable factor and comparing the adjusted expected time to the elapsed time measured by the clock). After step S 4 , the device may set a deep sleep time for another 10 seconds (or longer or earlier if required to wake up for a beaconing event) in step S 5 , and may return to a deep sleep, allowing control to jump back to step S 1 .
For example, the following process may be used to adjust a device's wakeup time period, e.g., the time period between events of beacon transmission or reception:
A device at 50° C. may be expected to drift by 25 ppm specifically due to temperature effects, as calculated by formula or looked up in a table (as described above). A drift of 25 ppm corresponds to 250 microseconds every 10 seconds. Each clock tick at 32.768 kHz corresponds to approximately 30.5 microseconds per tick. Thus, an adjustment of approximately 8 clock ticks over the 10-second period may roughly compensate for the temperature effect of the clock drift. (8 ticks*30.5 microseconds=244 microseconds per 10-second period) Thus, if a device wakes up after 10 seconds and measures its temperature as 50° C., it may adjust all of its future 10 second sleep periods by 8 clock ticks (plus a fraction that may be accumulated, dependent on implementation).
In a table-driven approach, a mapping between temperature and clock adjustment may be determined empirically for a particular design. Multiple such tables may be used to account for a variety of device profiles. For example, an aged (older or more heavily used) device may have a different set of offsets than a new device, or a device that is experiencing an increase in temperature may have a different profile than a device experiencing a temperature that is stable or decreasing.
Using these techniques, each device on the network may compensate for clock drift as a function of the device's own temperature.
A node's sensor (such as a temperature sensor) may be read and results accumulated every few seconds, in conjunction with clock drift correction. Alternatively, or additionally, a node's sleep cycle may be interrupted by asynchronous sensor events such as the rotation of a water meter.
Adjusting for Fixed Clock Skew
In another aspect of the invention, adjustment may be made for a fixed clock skew that may vary from one device to another, more or less independent of temperature effects. Such adjustment may be performed in conjunction with adjustment for temperature effects, or in the absence of temperature effect compensation. In the SensiNet AMR design, a key purpose of time synchronization may be to ensure that a child node is listening at exactly the time that its parent is scheduled to transmit a beacon. For this limited purpose, it may not be necessary for a device to calibrate the skew of each individual device; rather, the relevant metric may be the sum of the fixed skew for each parent-child relationship, since a device may need to measure only how much its own clock has drifted in relation to its parent's clock drift. This may be measured by child (or parent) devices as described below.
For example, a child node may forecast that one of its parents will beacon in 15 minutes and 3.173 seconds (here noted in the form 15:03.173) in the parent's time base. If the child finds that the beacon actually occurs in 15:03.212 in the child's time base, then the child may calculate a relative clock skew between the parent and child of 0.039 seconds over a 15-minute period. If the next synchronization time is forecast in 15:07.263 in the parent's time base, then the child may apply a fixed offset of 0.039 seconds (or other suitable offset) to forecast a wakeup in 15:07.302 in the child's time base. Such offsets may be averaged, for example to account for the last ten readings. If the fixed clock skew changes with age, this may be accounted for automatically with an approach that is biased in favor of recent data.
Tables 4 and 5 in Appendix A show a calculation to account for Keep-Alive “listening.” This simplified calculation assumes that the maximum uncalibrated clock drift is 25 ppm, and also assumes that a node's receiver is always turned on early enough to hear the beacon. In practice, more adaptive approaches may be used.
Taking the example of the Edge Node 1 Keep-Alive, Table 5 assumes that a node wakes up for a time period of 23.46 ms each 15 minutes. This provides an estimate for making broad design trade-offs, but the actual algorithm that results in this average use of power may work as follows, as shown in the flow chart of FIG. 3 :
After reading a parent's beacon, a child may calculate the beacon time of the parent approximately 15 minutes from now based on the parent's randomized beaconing formula in step S 10 and initialize a listening time (a time period while awake that the child listens for the parent's beacon) in step S 11 . The child may adjust for previously measured fixed clock skew between child and parent (e.g., add or subtract an offset to an elapsed time period measured by the clock or to the expected sleep time period) in step S 12 . The child may sleep for the 15-minute period minus a fraction of the listening time in step S 13 , e.g., incrementally adjusting its internal clock periodically (such as every 10 seconds) to account for temperature as shown in FIG. 2 . At the end of the period, the child may listen for the parent for 10 milliseconds in step S 14 . If the parent is not heard, control flows to step S 19 in which the child increases the listening time (e.g., to 20 milliseconds) according to a lookup table or by using another technique. In step S 20 , a determination is made whether all values in the lookup table have been used, and if so, it is assumed in step S 22 that the parent is lost and the child will stop listening for the parent. If not, in step S 22 , a new wake up time is determined for the parent's next beacon, and control jumps back to step S 12 . If the parent is not heard in subsequent listening times, the child may continue increasing the listening time in step S 19 until the system falls outside of a previously determined “reasonable” range in step S 20 (e.g., values in the lookup table are exhausted). In the example shown in Table 2, a 50 ppm drift for 20 minutes may result in a 60 ms offset. If it is known (from empirical study) that ±50 ppm is the worst case drift, then failure to detect a parent multiple times on the expected schedule may be taken as reasonably compelling evidence that the parent has stopped reporting on schedule. In the case where all table entries have been used, then the child may assume that its parent is lost and may attempt to rejoin the network after step S 22 (not shown). The decision of whether to search for a replacement parent may depend on the quality of the links that remain; for example, if a node has three parents and loses one, it may not be necessary for the node to rejoin the network, as it may have two remaining parents available for communications.
TABLE 2
Example of reasonable listening range.
Time
Duration of listening
Offset from forecast
15 minutes
10 ms
−5 ms
16 minutes
20 ms
−10 ms
17 minutes
40 ms
−20 ms
18 minutes
80 ms
−40 ms
19 minutes
120 ms
−60 ms
20 minutes
120 ms
−60 ms
(This is only an example. If this kind of drift is possible in the worst case, a more frequent keep-alive scan may be a more appropriate power saving strategy. Actual parameters may be selected based on an understanding of device performance and application requirements.)
In step S 14 , if the parent is heard, the child may determine whether the beacon includes a message or message indicator for itself in step S 15 . If it does, then the child may process the beacon and/or request additional information from the parent in step S 16 . The child may then report data as required by the application in step S 17 .
Once the correct offset is found, the offset may be applied to the next expected beacon in step S 18 . For example, if an actual offset of +57 ms is detected at 19 minutes, this 3 ms/min offset may be incorporated into the skew calculation for the subsequent sleep period.
One technique that may be used to calculate the offset may be a formula of the form in Equation 3:
OffsetMovingAverage=((1 −X )*OffsetMovingAverage)+( X *OffsetNow) (3)
where X may be a value such as 0.25 and where the initial state of OffsetMovingAverage may be 0. With this approach, old values decay exponentially.
FIG. 3 shows an example of a child tracking a single parent. This may be extended to track multiple parents (or children) simultaneously, by essentially running the process in parallel for multiple parents (or other devices). Similarly, FIG. 2 shows the time adjustment for a single beacon event; this may be simultaneously applied to the beacon tracking process for each of a node's parents or children, along with the beacon timing for a Router's 2 own beacons.
Router Messages in SensiNet AMR
In the typical SensiNet WSN 6 implementation, Routers 2 may keep track of their children and may have various buffers reserved for each child. The SensiNet AMR design may not require that Routers 2 know the identities of their children; a Router 2 may simply pass any message from any child toward the Data Accumulator 3 . This simplification may dramatically reduce program size and memory requirements.
While the primary flow of messages may be toward a Data Accumulator 3 , there may be applications requiring messages (such as NACKs) originating from the Data Accumulator 3 be sent to a specific Router 2 or Edge Node 1 . If simplified Routers 2 lack a picture of the rest of the network, other methods are still available for sending messages to a node:
The Data Accumulator 3 may build a hierarchical picture of the network in its memory, and may use this picture to rout messages explicitly. The hierarchical picture may be based on periodic reports from nodes identifying their parents. Thus, the Data Accumulator 3 a in FIG. 4 may determine, based on periodic reports from the Routers 2 , that Router 2 a is a child of Router 2 d , 2 d is a child of Router 2 g , and 2 g is a child of Router 2 h . In this example, the Data Accumulator 3 a may then send a message to 2 a of the form 2 h ( 2 g ( 2 d ( 2 a ))). Router 2 h may remove the message header for 2 h and may pass on a message 2 g ( 2 d ( 2 a )), and so forth until the message reaches Router 2 a. If messages are infrequent, they may be broadcast so that they are referenced or included within the beacons for a period of time and eventually received by all nodes. A sequence number included with the beacon, and repeated in the receiving node's next sensor report, may serve as an acknowledgement.
Long addresses, such as 64 bits long, may be assigned to devices at manufacture, but short addresses, such as 16 bits long, may be desirable within the WSN 6 for shorter packets and thus higher power efficiency. When a Data Accumulator 3 first hears from a node with a long ID, it may respond by sending to the node a short ID for use within a particular session.
Forming the SensiNet AMR Network
When a node is powered on, a device may validate that it found the network, such as by flashing an LED. During normal network operation, it may take some time for a Host 5 computer to be notified that a node has joined the network. However, local feedback may be needed quickly, so that an installer may know within a short time, such as within a minute or so, that the node has found the network.
FIG. 5 shows a Router 2 structure that may form the backbone of a SensiNet AMR network as shown in FIG. 1 . Prior Sensicast specifications such as PCT Application WO05/010214 describe how this backbone may be built. First, the Data Accumulator 3 a may transmit beacons that may be heard by nearby nodes; these nodes may join the network with a hop count of 1 (that is, these nodes may be one hop from the Data Accumulator 3 a ), and then may send their own beacons.
In one implementation, all Routers 2 may be continuously powered. In that scenario, Routers 2 may be installed before the Data Accumulator 3 is installed, and Routers 2 may simply monitor control channels until they hear beacons from Routers 2 that are already connected to a Data Accumulator 3 .
Edge Nodes 1 that are battery powered may need to be more selective in their use of power. If they fail to hear beacons when they are first powered, they may go to sleep and may look for beacons only infrequently. The sleep interval may constrain startup time on battery powered devices.
In the SensiNet AMR implementation, Routers 2 may be battery powered, and it may not be realistic to expect that Routers 2 will always be installed at increasing distances from the Data Accumulator 3 . This may involve some changes to the method of SensiNet network formation in order to save power. Routers 2 and Edge Nodes 1 may be configured to form clusters of intercommunicating devices, thus sharing a time base and beaconing schedules for low-power operation. When Data Accumulators 3 attach to such clusters, these clusters may, at a future time, be reorganized to direct traffic toward the Data Accumulators 3 . In this way, Routers 2 may not need to search continuously for neighbors, and Edge Nodes 1 may attach efficiently to nearby Routers 2 even if a functional data collection network has not yet been formed.
FIG. 6 shows an alternative design in accordance with one aspect of the invention. For this example, assume that Router 2 e was the first Router 2 installed. When it starts, Router 2 e may seek beacons for one minute, and when it hears none, it may start beaconing itself. The beacon may essentially say, “I′m here, but I didn't find a network.”
Upon installation, as shown in FIG. 6 , Routers 2 b , 2 c , 2 d , 2 f , and 2 g may all hear these beacons and may become children of Router 2 e , forming a cluster. Routers 2 a and 2 h may also join this cluster upon installation. All of these devices may beacon their presence, with an indication that they have not joined a WSN 6 . This cluster of devices may not be a functional network yet in the sense that it may not be connected to a cluster head, such as a Data Accumulator 3 , and as such there may be no place to send data from the devices. However, the cluster may provide a means for newly introduced nodes to find nearby Routers 2 and for collections of such nodes efficiently to remain time synchronized to one another. Such devices may assign themselves random temporary short addresses. It may be quite unlikely that two nearby devices may share both a common random short address and a beaconing schedule, and since no information may be transmitted through these devices, no harm may be done by assigning themselves short addresses. A network address, for the purpose of identifying a node to the Data Accumulator 3 , may be assigned later by the Data Accumulator 3 when it forms a network from a cluster of devices.
As shown in FIG. 7 , when a cluster head, such as a Data Accumulator 3 a , is first powered on, it may listen for beacons from other devices. It may hear beacons from Routers 2 h and 2 f and may “join” the network as a child of 2 h and 2 f . (This step may be virtual.)
As shown in FIG. 8 , the Data Accumulator 3 a may then command its “parents” 2 h and 2 f to become its children with a hop count of 1. Routers 2 h and 2 f may in turn command their parents Routers 2 c , 2 e , and 2 g to become their children with a hop count of 2. Finally, Routers 2 c and 2 g may command their parents Routers 2 e and 2 d to become their children with a hop count of 3. (Note that, in this example, Router 2 e may receive requests from three parents. If a Router 2 receives too many such requests, it may have to refuse some of them.) Routers 2 a and 2 b , without changing parents, may eventually discover (through beacons that are read during their periodic Keep-Alive scans) that their parents have joined a network, and may adjust their hop counts and short addresses accordingly without changing parents.
This scheme has the potential to create circular references. A Router 2 may detect circular references by receiving the same message twice. A Router 2 may also detect a circular reference by detecting a path to the Host 5 that includes the Router 2 itself. The Host 5 may also detect circular references by noting when a Router 2 has itself as a descendent. When a Router 2 detects a circular reference, the Router 2 may attempt to rejoin the network.
Similarly, when the Host 5 detects a circular reference, it may instruct the Router 2 to rejoin the network. This may remove the Router 2 from the current path. The Router 2 may then become the child of another Router 2 , creating a new path that does not include a circular reference. To prevent the occurrence of circular references, Routers 2 may be instructed to reject paths that contain themselves (i.e., devices may include instructions not to become children of their own children).
Edge Nodes
An Edge Node 1 may essentially be the same as a Router 2 , except that it may not route traffic on behalf of other devices. Therefore, an Edge Node 1 may not need to expend power transmitting beacons or responding to its children. This may allow Edge Nodes 1 to run longer or to utilize smaller batteries.
The power draw for an Edge Node 1 is estimated in Table 3. The estimates in Table 3 utilize calculations from Tables 4 and 5 in the Appendix.
TABLE 3
Power estimates for Edge Nodes.
Activity
mAh/year
Comments/Assumptions
Sensor Power
10
Sensor Report
0.05
This assumes that sensor readings are reported
once per day, to all three parents, with
acknowledgements and retries.
Sleep Current
17.5
This estimate assumes a 2 μA power draw
when the device is asleep.
Keep-Alive
14.0
This assumes that Edge Nodes synchronize to
their parents every 15 minutes and
simultaneously resynchronize their
clock offset to each parent. This
also assumes that parent-child clocks
can be cross-calibrated with 25 ppm
accuracy.
Network Scans
8.3
This covers overhead to join the network, as
described in Table 1.
Total
49.9
This estimate corresponds to 20.0 year battery
life from a 1000 mAh battery.
As with Routers 2 , power consumption for Edge Nodes 1 may be particularly sensitive to data rate, clock skew, and sleep current. These factors may be adjusted for as previously described and as shown in FIGS. 2 and 3 .
Data Accumulators
As shown in FIG. 1 , Data Accumulators 3 may sit at the root of the network tree. A Data Accumulator 3 may act as the “final” Router 2 , and may consume a similar amount of power as a normal Router 2 . Data Accumulators 3 may perform the following functions for the network:
All data reports may be directed to the Data Accumulator(s) 3 , which may archive cumulative daily readings from all nodes within the constraint of available storage. A Data Accumulator 3 may note when a device has not reported as expected. If an expected report is missing, the Data Accumulator 3 may broadcast a “NACK” (negative acknowledgement, i.e., a notification that an expected message has not been received) through the network by exception, which may in turn be embedded in the network beacons. This may provide a low overhead form of end-to-end acknowledgement between an Edge Node 1 and the Data Accumulator 3 . Data reports may be forwarded from a Data Accumulator 3 to a Gateway 4 as required by an application.
In FIG. 1 , two Accumulators 3 , a main Data Accumulator 3 a and a Shadow Accumulator 3 b , are shown for redundancy, with a serial connection between them to enable data mirroring. This may provide redundancy in two ways:
During normal operation, a Shadow Accumulator 3 b may provide a redundant radio link. In most cases, both Accumulators 3 may hear identical messages. However, under some multipath conditions, a link to one or the other device may be lost temporarily. A Shadow Accumulator 3 b placed several wavelengths away may substantially reduce the rate and severity of such problems. A Shadow Accumulator 3 b may provide a data backup in the event of failure of the primary Data Accumulator 3 a.
System capacity may be limited by the battery capacity of Routers 2 that are a small number of hops away from a Data Accumulator 3 or Gateway 4 . Routers 2 with a large number of descendents expend energy transmitting information on behalf of other nodes, and more descendents may result in more traffic. To a certain extent, the system design may compensate by reducing the reporting frequency or combining reports into consolidated packets. But eventually, it will be necessary to transmit more data and/or to extend the Router's 2 contention access period to a point where the battery life goals cannot be achieved. For these situations, it may be necessary to provide larger batteries for Routers 2 that are near the Data Accumulator 3 or Gateway 4 .
While it is generally desirable for all Routers 2 to be identical, it may be useful in certain situations to allow certain Routers 2 to be equipped with larger batteries. For example, a network of heat cost allocators and water meters may be installed in an apartment building, with all nodes being configured as Routers 2 for simplicity of installation. These devices may be configured to only accept a certain number of children and descendents. In addition, dedicated Routers 2 with larger batteries may be installed in the hallways as a network backbone, and allowed to establish a working network through the building before any sensors are deployed in the apartments. Due to the routing constraints of the sensor/routers, routes will tend to be directed toward backbone routers with larger batteries.
Gateways
As noted earlier, Gateways 4 may be mechanically similar to Routers 2 , except that, instead of relaying messages, Gateways 4 may provide an interface to a different physical or logical network. Gateways 4 may terminate the WSN 6 protocol and may translate communications to a different protocol appropriate for the new network.
In FIG. 1 , the Gateways 4 are shown as separate devices from the Data Accumulators 3 , but in practice a Gateway 4 may be fully integrated with a Data Accumulator 3 .
The Gateway 4 may need to support a walk-by scenario, wherein a handheld device may communicate directly with the Data Accumulator 3 to extract the network's data. A different radio may be appropriate for WSN 6 operation vs. a handheld link. For example, in Europe, the 868.0-868.6 MHz band has desirable characteristics for this AMR network design, but devices in this band are limited to a 1% duty cycle due to regulatory constraints. A 1% duty cycle may reduce the available channel from 250 kbps to 2.5 kbps. At 2.5 kbps, data payload throughput (accounting for communications and packet overhead) may be in the range of tens of bytes per second; at that speed, it may take an unacceptably long time to download data for a sizeable network from a Data Accumulator 3 to a handheld device.
A reasonable alternative may be to include a 2.4 GHz IEEE 802.15.4 interface 11 within a Data Accumulator 3 as shown in FIG. 9 , enabling the Data Accumulator 3 to operate as a Mini-Gateway 10 at 250 kbit/sec. A Gateway 4 based on the Sensicast OEM200 module may be used for this purpose. The OEM200 includes an IEEE 802.15.4 radio amplified to 15 dBm, 128K programming flash, 128K memory for data storage, and numerous interfacing options as supported by the Atmel AVR family of processors. A flexible memory and programming model may enable the implementation of a Shadow Data Accumulator 3 , as well as potentially supporting a wide range of Gateway 4 interfaces. For a walk-by scenario, the built-in IEEE 802.15.4 radio may provide an inexpensive wireless interface to PDAs or other devices with 802.15.4 capability. In applications where an IEEE 802.15.4 radio is appropriate for the WSN 6 , a single radio module may be used for both purposes.
For the SensiNet AMR application, the Mini-Gateway 10 may be battery operated, but the battery may be larger than 1000 mAh to provide power for the additional functionality of a Mini-Gateway 10 .
In another configuration, the Mini-Gateway 10 may transfer data to another device that may provide Host 5 connectivity through cellular connection or other means. As in other configurations, the Mini-Gateway 10 may collect data, as a Data Accumulator 3 would, and may serve as an interface to a different physical or logical network, as a Gateway 4 would.
System Reliability
The illustrative power model used herein assumes an average of three acknowledged transmissions (the original transmission plus two retries) per link, with three parents per link. Each message may be sent to all three parents for redundancy. If a message does not get through to a Data Accumulator 3 (which may be an infrequent occurrence), the Data Accumulator 3 may notice that the node has not reported, and may send a NACK asking the message to be sent again. If the expected message does not arrive in response to the NACK, the Data Accumulator 3 may send another NACK, within reason. Due to memory constraints on the Routers 2 and other factors, there may be limited bandwidth upstream towards the nodes, but there may be enough capacity to NACK (for example) ten nodes per hour, in addition to periodic messages that are broadcast to all nodes. Ten nodes per hour may cover about 50% of a 500-node network over the course of a day. Thus, the system may provide the following levels of resiliency:
Three parents for each link for redundancy.
For each link, acknowledged communication with retries.
NACK from the Data Accumulator 3 when data is not reported on schedule, essentially providing end-to-end reliability.
Cumulative data reports, so that if one day's data is missed, it may be accumulated in the next day's report.
In this disclosure, we have described how data may be reported from device to device within a WSN. We have considered how data from a network of devices may be accumulated and passed to devices or applications outside the network. We have discussed some requirements for timely, low power communication within such WSNs, including methods of clock synchronization and network backbone formation. We have also addressed features that may be incorporated to improve system reliability. Again, the embodiments described herein are meant to be illustrative and are not intended as limiting. In addition, various features described above may be combined in any suitable way to form a system in accordance with the invention.
APPENDIX A
TABLE 4
Power calculations for WSN.
Model Parameters
Bit rate
250
kbit/sec
Transmit power
25
mA
Receive power
20
mA
Sleep current
2
uA
Warmup time
2
ms
Warmup current
5
mA
Crystal drift
25
ppm
Calibrated pairwise
Beacon size
30
bytes
Contention access period
10
bytes
Listen for children
Beacon interval
1
min
Annual resynchs
25
Periodically search for
new parents
Router battery capacity
1000
mAh
Edge node battery capacity
1000
mAh
Network capacity
500
nodes
Router keep alive interval
2
min
Check for parent
messages
Edge node keep alive interval
15
min
Synchronize clock to
each parent
Number of parents
3
Primary, secondary,
tertiary, etc . . .
Report interval
24
hours
Report size
32
bytes
Report retries
3
Average number of
retries per hop
Sensor power
10
mAh/year
Edge Node Power Draw per Annum (see Table 5 for detailed calculations)
Sensor power
10.00
mAh
Report
0.05
mAh
Table 5 cell A10
Sleep
17.52
mAh
Table 5 cell B2
Keep alive
13.99
mAh
Table 5 cell D8
Network resynch
8.33
mAh
Table 5 cell F4
Total
50.00
mAh
Battery life
20.00
years
Router Power Draw per Annum (see Table 5 for detailed calculations)
Sensor power
10.00
mAh
Report
0.05
mAh
Table 5 cell A10
Sleep
17.52
mAh
Table 5 cell B2
Keep alive
19.53
mAh
Table 5 cell E8
Service children
25.59
mAh
Table 5 cell G4
Periodic beacon
5.90
mAh
Table 5 cell C11
Network resynch
8.33
mAh
Table 5 cell F4
Total
70.00
mAh
Battery life
14.29
years
TABLE 5
Detailed power calculations for WSN.
Detailed Calculations
Comments and Formulas (using cell numbers on left)
(warmup_time & warmup_current taken from Table 4)
Edge Node Report
A1
Report interval
24
hours
A2
Report size
32
bytes
A3
Transmit per report
1.02
ms
(A2 * 8)/C1
A4
Transmit power
25
mA
A5
Ack time
1.02
ms
Copied from transmit time A3
A6
Receive power
20
mA
A7
Number of parents
3
A8
Average retries
3
A9
Average draw
0.00000584
mA
(A7 * A8) * ((warmup_time * warmup_current) +
(A3 * A4) + (A5 * A6))/(1000 * 60 * 60 * A1)
A10
Draw per annum
0.05117
mAh
Sleep
B1
Sleep draw
2
uA
B2
Draw per annum
17.52
mAh
B1 * 24 * 365/1000
Router Periodic Beacon
C1
Bit rate
250
kbps
C2
Beacon size
30
bytes
C3
Time per beacon
0.96
ms
(C2 *8)/C1
C4
Transmit power
25
mA
C5
Beacon interval
1
minute
C6
Average draw transmit
0.00056667
mA
((warmup_time * warmup_current) + (C3 * C4))/
(C5 * 60 * 1000)
C7
Listen window
10
bytes
C8
Listen time
0.32
ms
(C7 * 8)/C1
C9
Receive power
20
mA
C10
Average draw receive
0.000106667
mA
(C8 * C9)/(C5 * 60 * 1000)
C11
Draw per annum
5.90
mAh
(C6 + C10) * 24 * 365
Edge Node Keep-Alive
D1
Keep-Alive interval
15
min
D2
Crystal drift
25
ppm
D3
Crystal drift
1.5
ms/min
D2 * 60 * 1000/10000000
D4
Receive power
20
mA
D5
Receive time
23.46
ms
Accounting for crystal drift; C3 + (D1 * D3)
D6
Average draw
0.000532444
mA
((warmup_time * warmup_current) + (D4 * D5))/
(D1 * 60 * 1000)
D7
Parents to track
3
D8
Draw per annum
13.99
mAh
D6 * D7 * 24 * 365
Router Keep-Alive
E1
Keep-Alive interval
2
min
E2
Crystal drift
25
ppm
E3
Crystal drift
1.5
ms/min
E2 * 60 * 1000/10000000
E4
Receive power
20
mA
E5
Receive time
3.96
ms
Accounting for crystal drift; C3 + (E1 * E3)
E6
Average draw
0.000743333
mA
((warmup_time * warmup_current) + (E4 * E5))/
(E1 * 60 * 1000)
E7
Parents to track
3
E8
Draw per annum
19.53
mAh
E6 * E7 * 24 * 365
Network Synch
F1
Router beacon interval
1
min
F2
Receive power
20
mA
F3
Rescynchs per annum
25
F4
Power per annum
8.33
mAh
F1 * F2 * F3/60
Service Children
G1
Number of descendents
500
G2
Power draw for each
0.10
mAh
Rough estimate -- twice Edge Node report
(inbound and outbound); 2 * A10
G3
Optimization
50%
Combine messages on heavily used Routers
G4
Power per annum
25.59
mAh
G1 * G2 * G3
|
A method and apparatus for coordinating communication in a wireless sensor network may include a plurality of nodes, such as routers, edge nodes, data accumulators and/or gateways. Time management functions, such as determining an elapsed time, may be controlled based on a detected temperature, e.g., a temperature detected at a node, and/or based on a detected clock skew between two or more clocks in two or more different devices. Accurate time management may allow for devices to more accurately coordinate communication instances, e.g., communication that occurs at periodic wake up times. A cluster head, such as a data accumulator, may be associated with a network after its initial formation and cause nodes in the network to alter their hierarchy in the network, thereby making the cluster head accumulator a parent to nodes in the network. Nodes having a relatively lower hop count may have a higher battery capacity than nodes having a higher hop count.
| 7
|
BACKGROUND OF THE INVENTION
This invention relates to electric self-cleaning cooking ovens and more particularly to power control relay switching circuits for such ovens.
Electric self-cleaning ovens are typically provided with a broil heating element disposed proximate the top wall of the oven and a bake element disposed proximate the bottom wall of the oven. A typical relay switching circuit known in the art for controlling energization of these elements is illustrated in FIG. 1. In this circuit, relay contacts 1 and 2 switchably electrically connect one terminal of the bake element 3 and the broil element 4 respectively to L1. Relay 5 connects the other terminal of both heating elements to power source L2 via a thermal limit switch 6. Typically the bake element has a power rating which is roughly 75% of the broil element rating.
During normal operation the temperature in the oven is maintained within acceptable limits by cycling the relay switches. For example, energization of the broil element in the bake operating mode is typically cycled to operate at one-quarter power when the bake element is operated at full power, and in the broil mode, the bake element is switched to its open state and the broil element is operated at full power or duty cycled depending on the broil mode selected. Consequently under normal operating conditions, the maximum total power is applied in the broil mode and the oven is designed to keep the surface temperature of the oven cabinet within acceptable temperature limits under such conditions. However, an abnormal operating condition could arise in which the three relays fail closed. In this worst case condition both the bake and broil elements would be energized at full power simultaneously. Under such conditions the oven temperature may rise to a level which causes the cabinet surface temperature to exceed normal operating temperatures. The thermal limit switch 6 is mounted externally of the oven on the outer surface of the range cabinet to provide protection against such an occurrence. Switch 6 is operative to interrupt energization of the heating elements in the event the temperature of the oven cabinet proximate the switch exceeds its threshold temperature.
This arrangement works satisfactorily, however, the use of the limit switch and its associated wiring adds cost to the design. It would be desirable to provide a less costly circuit arrangement which protects against excessive temperature conditions in the event of worst case failures of the switching devices without adversely affecting heating performance.
It is therefore, a primary object of the present invention to provide an improved switching arrangement for use in self-cleaning ovens which provides reliable protection against excessive temperatures in the event of switching device failures and which uses fewer components and is less costly than arrangements known in the art.
SUMMARY OF THE INVENTION
An improved power switching arrangement is provided for a self-cleaning oven appliance of the type energized by the standard three wire domestic AC power supply, and having an oven cavity, with a bake heating element disposed proximate its bottom wall and a broil heating element disposed proximate its top wall.
The power switching circuit conventionally includes a first relay switching device which is operative when closed to electrically connect one terminal of the bake element and one terminal of the broil element to the first power line, L1. In accordance with the present invention the improvement comprises a unique arrangement of two double throw relay switching devices, each comprising a common terminal, a normally open terminal and a normally closed terminal. In a preferred form of the invention, these switches are arranged such that, one has its common terminal electrically connected to the second power line, L2, and its normally open terminal electrically connected to the other terminal of the bake element, and the other has its common terminal electrically connected to the other terminal of the broil element, its normally closed terminal electrically connected to the neutral line, N, and its normally open terminal electrically connected to the normally closed terminal of the one switching device.
The one switching device is switchable between a first operating state in which its common and normally open terminals are electrically connected thereby connecting the other terminal of the bake element to L2 to enable energization of the bake element across L1 and L2, and a second operating state in which the common and normally closed terminals are electrically connected to disconnect the bake element from the power circuit. The other switching device is switchable between a first operating state in which its common and normally closed contacts are electrically connected thereby electrically connecting the other terminal of the broil element to the neutral line to enable energization of the broil element across L1 and N, and a second operating state in which its common and normally open terminals are electrically connected to enable energization of the broil element across L1 and L2 through the normally closed and common contacts of the one switching device.
By connecting the bake and broil elements to the three wire power supply in this fashion, the bake element can be cycled and the broil element operated at one-quarter power in the bake cycle and the broil element can be operated at full power or cycled in the broil cycle, providing the same performance potential as does the prior art circuit of FIG. 1. However, both heating elements cannot be simultaneously energized at full power regardless of the failure mode of the switching circuitry. The only combination possible in this configuration for simultaneously energizing both elements at significant power levels is one in which the bake element is energized at full power across L1 and L2, and the broil element is energized at one-quarter power across L1 and N. Since in this arrangement no failure mode exists in which both heating elements can be simultaneously energized at full power, the need for a thermal limit switch to guard against excessive temperatures in the oven is eliminated.
BRIEF DESCRIPTION OF THE DRAWINGS
While the novel features of the invention are set forth with particularity in the appended claims, the invention both as to organization and content will be better understood and appreciated from the following detailed description taken in conjunction with the drawings, in which:
FIG. 1 is a schematic circuit diagram of a portion of a prior art power switching circuit arrangement for a self-cleaning oven;
FIG. 2 is a schematic fragmentary side elevational view of an electric self-cleaning range incorporating an illustrative embodiment of the power switching arrangement of the present invention;
FIG. 3 is a functional block diagram of a power control circuit for the range of FIG. 2;
FIG. 4 is a schematic wiring diagram of the power switching circuit for the oven heating elements in the range of FIG. 2, illustratively embodying the switching arrangement of the present invention; and
FIGS. 5A and 5B illustrate the relay switching sequences for the relays of FIG. 4 for operation in the bake and broil operating modes, respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and more particularly to FIG. 2, there is shown for illustrative purposes a free standing electric range 10. While a free standing range is described herein, it should be understood that the invention may be applied to other oven appliances as well. The range 10 generally includes an outer cabinet 12 which includes a top cooking surface or cooktop 14 with a plurality of surface units 16. A control panel (not shown) including user actuable controls, such as control knobs or touch pads, for selecting various operating modes for the surface units and the oven, and a visual display, may be mounted behind the backsplash 17. Positioned in the cabinet 12 is an oven cavity 18 formed by a box-like oven liner 20 having vertical side walls 22, top wall 24, bottom wall 26, rear wall 28 and a front opening drop door 30. The oven cavity 18 is supplied with two electric resistance elements, a bake element 32 positioned proximate the bottom wall 26, and a broil element 34 positioned proximate to the top wall 24. In the illustrative embodiment the bake element 32 is rated at 2500 watts and the broil element 34 is rated at 3400 watts. A standard temperature probe 36 is mounted to project into the oven cavity 18.
Operation of the oven of range 10 in various cooking modes including a bake mode, a broil mode and a cleaning mode is controlled by the microprocessor-based control circuit schematically represented in FIG. 3. The microprocessor 40 may be programmed in conventional fashion to receive input signals from the user actuable input control knobs or pads functionally represented as input means 42, representing the desired operating mode and operating temperature information, and from the oven temperature sensor circuit 44, representing the actual temperature in the oven, and to generate appropriate output signals for the visual display 46 and switching signals for the bake relay coil 48, the broil relay coil 50, and the double line break relay coil 52, via conventional relay driver circuitry 54 to control energization of the bake and broil heating elements 32 and 34, respectively. Power for the control circuit is provided by a conventional DC power supply 56.
As briefly described in the Background discussion, the prior art switching arrangement illustrated in FIG. 1 is vulnerable to a worst case failure condition in which both the bake and the broil relays fail to the shorted state causing both elements to be simultaneously energized at full power, potentially resulting in excessively high oven cabinet surface temperatures. The prior art solution protects against this worst case condition by providing a thermal limit switch mounted to the external surface of the oven cabinet to interrupt energization of the heating elements should the cabinet surface temperature exceed its threshold temperature.
In accordance with the present invention an improved power switching arrangement is provided which reliably protects against abnormally high temperature conditions in the event of a worst case switching failure, while eliminating the need for the limit switch and its associated wiring. Referring now to the diagram of FIG. 4, K1, K2 and K3 represent the switching contacts operatively coupled to the bake relay coil 48, the broil relay coil 50 and the double line break relay coil 52, respectively (FIG. 3). The bake and broil relays comprising coils 48 and 50 and contacts K1 and K2 respectively, are single pole double throw relays, each having a common terminal designated C, a normally open contact terminal designated NO and a normally closed contact terminal designated NC. The terms normally open and normally closed are used in the conventional sense, i.e., the relay is in its normally closed state, closed across its normally closed terminal when its coil is de-energized and in its normally open state, closed across its normally open terminal when its relay coil is energized. Contacts K3 are closed when relay coil 52 is energized and open otherwise. L1, L2 and N refer to the standard three wire domestic 240 volt AC power supply, with a nominal 240 volts across L1 and L2 and a nominal 120 volts across L1 and neutral line, N.
In accordance with the invention one terminal of the bake element 32 and one terminal of the broil element 34 are each electrically connected to power line L1 via contacts K3. The other terminal of bake element 32 is connected to normally open terminal NO of K1. The common terminal of K1 is electrically connected to power supply line L2. The other terminal of the broil element 34 is electrically connected to the common terminal C of K2. The normally closed terminal of K2 is connected to neutral power supply line N. The normally open terminal of K2 is electrically connected to the normally closed terminal NC of K1.
The switching states for K1, K2 and K3 for the bake, broil and clean operating modes are listed in Table A.
TABLE A______________________________________ Bake BroilMODE K1 K2 K3 Htr. Htr.______________________________________Bake Cycle NC Cycle 240 v 120 vBroil NC NO Cycle -- 240 vClean (1st NC NO Cycle -- 240 vcycle)Clean (after Cycle NC Cycle 240 v 120 v1st Cycle)______________________________________
In the Bake mode K2 is switched to its normally closed mode and K1 and K3 are cycled to provide the desired temperature in the oven cavity. In this mode the 240 volt supply via L1 and L2 is applied to the bake element 32 to operate it at 2500 watts when K1 is in its normally open state and K3 is closed. The 120 volt supply via L1 and N is applied to the broil element 34 operating it at one-quarter power or 850 watts. Maximum power to the oven in the Bake mode is 3350 watts. In the Broil mode, K1 is switched to its normally closed state, de-energizing the bake element 32, and K2 is switched to its normally open state connecting the broil element 34 across the 240 volt supply via L1 and L2 to operate it at 3400 watts. Maximum power to the oven in the Broil mode is 3400 watts. K3 is cycled to achieve the selected broil performance.
During the first cycle of the Clean mode, consisting of the first 30 minutes of operation in that mode, the relays are operated as in the broil mode to provide high initial heat proximate the top wall of the oven to enable the smoke eliminator (not shown) to come up to operating temperature before applying high heat to the more heavily soiled bottom area of the oven. For the balance of the self-cleaning operation after this first cycle, the relays operate as in the Bake mode with cycling to achieve and maintain the high self-clean temperatures in the oven.
By interconnecting the relay contacts with the bake and broil elements in this way to couple the elements to the three wire power supply, the bake element can be cycled and the broil element operated at one-quarter power in the bake cycle, and the broil element can be operated at full power or cycled in the broil cycle, providing the same performance potential as does the prior art circuit of FIG. 1. However, both heating elements cannot be simultaneously energized at full power regardless of the failure mode of the switching circuitry. The only combination possible in this configuration for simultaneously energizing both elements at significant power levels is one in which the bake element is energized at full power across L1 and L2, and the broil element is energized at one-quarter power across L1 and N. In this operating state the power to the oven is 3350 watts.
The only other combination of switching states which results in simultaneous energization of the heating elements occurs when K1 is in its normally open state and K2 is in its normally closed state with K3 open. In this case bake element 32 and broil element 34 are connected in series between L2 and N. However, the total power output to the oven for this combination would less than 400 watts.
Thus by the arrangement of the present invention the maximum power output to the oven is limited to 3400 watts which occurs when the broil element 34 is operated at full power. By contrast, the worst case condition of the prior art circuit in which both elements are operating at full power results in a maximum power to the oven of 5900 watts. By limiting the maximum power to 3400 watts, the need for the external thermal limit switch of the prior art is eliminated.
Representative switching sequences for initiating and terminating cycles in the Bake and Broil operating modes to minimize contact arcing for contacts K1 and K2 are illustrated in FIGS. 5A and 5B, respectively. As shown in FIG. 5A, each power on cycle in the Bake mode is initiated with K3 in its open state, K2 in its normally closed state and K1 in its normally closed state. The cycle is initiated by initially switching K1 to its normally open state, followed one second later by closing K3. The power on cycle is terminated by reversing this sequence. K3 is switched open, followed one second later by switching K1 to its normally closed state. The duration and frequency of the power on cycles in the Bake mode are determined by the selected bake temperature and the sensed oven temperature in conventional fashion.
In the Broil mode (FIG. 5B) the power on cycle is initiated by initially switching K1 to its normally open state. One second later, K2 is switched to its normally open state. After a delay of one more second K1 is switched to its normally closed state. During this transition period K3 remains in its open state. Beginning one second after K1 returns to its normally closed state, K3 is closed. Thereafter K3 is cycled at a duty cycle rate associated with the selected broil power setting. The Broil cycle is terminated by opening K3, switching K1 to its normally open state, switching K2 to its normally closed state, and returning K1 to its normally closed state, with a one second delay interposed between each step of the sequence. The switching sequence for the first cycle of the Clean mode is initiated and terminated in the same manner as for the Broil mode. Thereafter for the balance of the Clean mode, switching is accomplished as in the Bake mode.
While a specific embodiment of the present invention has been illustrated and described herein, it is realized that modifications and changes will occur to those skilled in the art to which the invention pertains. It is therefore to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit and scope of the invention.
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A power switching arrangement for a self-cleaning oven appliance incorporating a unique arrangement of two double throw relays in the oven power control circuit. The two relays are operatively interconnected to selectively couple the oven bake and broil elements to the three wire power supply to switch the bake element across L1 and L2 and the broil element across L1 and N when operating in the bake mode, and switch the bake element out of the circuit and the broil element across L1 and L2, when operating in the broil mode. The interconnection is accomplished in a manner which prevents both heating elements from being simultaneously energized at full power regardless of the failure mode of the switching circuitry, thereby eliminating the need for a thermal limit switch to guard against excessive temperatures in the oven resulting from worst case switching circuit failures.
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RELATED APPLICATIONS
[0001] This application is related to and claims priority to U.S. Provisional Application Ser. No. 61/754,332, entitled “Cooler Lock,” filed on Jan. 18, 2013, which application is herein incorporated by reference in its entirety for all that it suggests, discloses, and teaches, without exclusion of any portion thereof.
TECHNICAL FIELD OF THE DISCLOSURE
[0002] The disclosure is directed generally to enclosure locking mechanisms, and, more particularly, to an access control system that includes features for providing locking and access to a refrigerated cooler. The lock mechanism consists of a strike mounted on the door or cabinet, and a motor-controllable latch mounted on the other of the door or cabinet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1A is a simplified perspective view of a cooler structure within which aspects of the disclosure may be implemented;
[0004] FIG. 1B is a simplified perspective view of an alternative cooler structure within which aspects of the disclosure may be implemented;
[0005] FIG. 2 is an enlarged perspective view of a cooler locking structure in accordance with an aspect of the disclosure;
[0006] FIG. 3 is simplified interior view of the cooler locking structure of FIG. 2 in accordance an aspect of the disclosure;
[0007] FIG. 4 is a simplified exploded view of the lock structure of FIG. 2 in accordance with an aspect of the disclosure;
[0008] FIG. 5 is a further simplified exploded view of the lock structure of FIG. 2 in accordance with an aspect of the disclosure;
[0009] FIG. 6 is a further simplified exploded view of the lock structure of FIG. 2 in accordance with an aspect of the disclosure;
[0010] FIG. 7 is a further simplified exploded view of the lock structure of FIG. 2 in accordance with an aspect of the disclosure;
[0011] FIG. 8 is a further simplified interior view of the cooler locking structure of FIG. 2 in accordance with an aspect of the disclosure;
[0012] FIG. 9 is a further simplified interior view of the cooler locking structure of FIG. 2 in accordance with an aspect of the disclosure;
[0013] FIG. 10 is a further simplified interior view of the cooler locking, structure of FIG. 2 in accordance with an aspect of the disclosure;
[0014] FIG. 11 is a further simplified interior view of the cooler locking structure of FIG. 2 in accordance with an aspect of the disclosure;
[0015] FIG. 12 is a further simplified interior view of the cooler locking structure of FIG. 2 in accordance with an aspect of the disclosure;
[0016] FIG. 13 is a simplified circuit diagram in accordance with an aspect of the disclosure;
[0017] FIG. 14 is a simplified circuit diagram in accordance with an alternative aspect of the disclosure;
[0018] FIG. 15 is a process flow chart illustrating, a process executed by a cooler controller in an embodiment; and
[0019] FIG. 16 is a process flow chart illustrating a process executed by a lock controller in an embodiment.
DETAILED DESCRIPTION
[0020] A refrigerated cooler typically consists of a refrigerated cabinet to hold food and beverages and a glass door that swings outward via a hinge. Typically the door or the cabinet has a rubber gasket or other flexible sealing element (collectively “gasket”) along the edge to create a harrier between the cold air inside the cabinet and the warm air outside the cabinet. The gasket further serves to accommodate misalignments between the cabinet and the door, when for example the cooler is placed on a floor that is not level such that the structure is twisted, or when over time the door droops downward from the hinge and fads to maintain alignment with the cabinet. Typically the inner surface of the door will interface to the outer surface of the cabinet, and as such the door usually does not reside on the interior of the cabinet. Typically the door is held to the edge surface of the cabinet by a magnet. In addition, typically the door is hung and the hinge is aligned such that the door is naturally biased to swing toward the cabinet without applying an external force to a surface of the door.
[0021] When the door is opened, e.g., by a consumer in order to retrieve product, and is then released, the door will naturally swing toward the closed position. As the door reaches the closed position from the open position, its movement is accelerating slightly and needs to be stopped. The gasket will serve to absorb some of the energy released by the door as it abruptly stops. The magnet serves to some extent to maintain the door in the closed position and the magnet and the gasket together also serve to minimize the amount of bounce the door may exhibit as it moves to a stopped position.
[0022] FIG. 1A is a perspective view of a cooler 1 within which embodiments of the invention may be implemented. FIGS. 2 and 3 illustrate the lock mechanism 2 mounted to the cooler 1 , showing the lock 2 while the strike 3 is entering the latch 4 . The mechanism may be mounted in a door centered position on the vertical edge of the door/cabinet as shown in FIG. 1 , and it can be mounted at the top or bottom of the door/cabinet at the vertical edge or along either of the horizontal edges at the top or bottom of the door/cabinet in order to hide or protect the mechanism from the reach of customers. In an embodiment shown, the lock mechanism is mounted to the cooler cabinet and the strike is mounted to the door. In alternative embodiments, the lock can be mounted to the door and the strike mounted to the cabinet. In another embodiment, the strike unit or function can be provided by the outside surface of the door, or a surface provided by a slot within either the door or the cabinet.
[0023] As noted above, in an embodiment, the lockable enclosure is a freezer. Moreover, whether a freezer or a cooler, enclosures having sliding rather than hinged doors may also benefit from application of the disclosed principles. Referring to FIG. 1B , typically such enclosures 1 A include two doors mounted in tracks adjacent to but offset from one another, with one or both doors being slidable across the front of the cooler. In such coolers, each door may also include a casket on one or both of the door and the cabinet, used to seal the door and cabinet together when the door is closed. The sliding doors are typically biased to slide back to the closed position in the event that the user does not properly slide the door to the closed position. For sliding door coolers, the lock can be applied to either the door or the cabinet of each door, or, a lock can be applied to one door and the strike can be applied to the other door, such that when the lock and strike are engaged, neither door can slide open or parallel to the other door.
[0024] In any case, the lock mechanism consists of a number of components as labeled in FIG. 4 and as shown in different views in FIGS. 5-7 . The components include the mounting base 5 , latch base 6 , claw 7 , claw spring 8 , shaft 9 , circuit board 10 , manual release push rod 11 , slider 12 , slider spring 13 , cam 14 , cam sensor 15 , claw sensor 16 , and motor 17 . The components are primarily mounted to the latch base 6 and the mounting base 5 , which are stationary. The latch base 6 has a “Y” shaped opening and serves to help guide the strike to connect to the claw 7 properly when the door is closed. The claw 7 rotates clock-wise and against the force of the claw spring 8 as the door is closed and it receives the strike. The force of the claw spring 8 is ideally light enough so the force of the door closing will overcome the claw spring force and the claw 7 will receive the strike and rotate clock-wise.
[0025] In the strike received position of FIG. 9 , the claw sensor 17 will detect that the claw 7 has received the strike. The claw spring 8 is biased to push the claw 7 out so when the door is opened the claw 7 will rotate counter-clockwise to move to the receive position as in FIG. 8 . This cycle whereby the claw 7 rotates clockwise to counterclockwise while the door moves from closed to open repeats over and over again as food or other material is being vended from the cooler, as shown in FIGS. 8 and 9 .
[0026] The slider 12 when extended to the right acts to lock the claw 7 holding the strike in the clockwise rotated position during certain conditions while the door is closed, as shown in FIG. 10 . The slider 12 is biased to the locked extended position by the slider spring 13 when the door is intended to be locked. The cam 14 connected to the motor 17 will act to move the slider 12 via the inner surface of the slider 12 to the unlocked position upon being energized by the circuit board 10 as shown in FIG. 9 . A cam sensor 16 on the circuit board 10 senses the position of the cam 14 to determine the slider 12 has moved to the required position.
[0027] Once the slider 12 moves to the far right extended position behind the rear surface of the claw 7 , the claw 7 will no longer be able to rotate counter-clockwise as the door is attempted to be opened as shown in FIG. 11 ; the rear surface of the claw 7 is blocked from rotating counterclockwise by the right extended edge of the slider 12 . Thus, the claw 7 and extended slider 12 will serve to hold the strike in the position in FIG. 11 to keep the door closed or locked. Once the electronics determine the door should be unlocked, the motor 17 rotates and moves the cam 14 so that it applies a force to the slider 12 to make it retract, such that the slider 12 will no longer be in a position to hold the claw 7 in the full clockwise position as in FIG. 9 . The claw will then be free to rotate counterclockwise as the door is pulled opened as in FIG. 8 .
[0028] The manual release 11 serves to manually force the slider 12 from the rightward position to the leftward retracted position to release the slider interference from the claw 7 , and allowing the door to be opened. The feature is useful in the event that a person, for example a child, climbs into the cooler and the cooler door closes and locks. A person inside the cooler can push the manual release 11 , serving to apply a force to the inclined surface of the slider 12 so the slider 12 retracts by overcoming the force of the slider spring 13 and retracting to the left to release the lock. As an alternative to the push-rod method, a cable can be attached to, for example, the left end position of the slider 12 to pull the slider 12 to the retracted position to release the claw 7 and unlock the unit.
[0029] In this embodiment, the cooler controller 10 comprises sensors and inputs for measuring a temperature of the enclosure 1 it is locking and unlocking; see FIG. 13 . In one example, the cooler controller will control the actuator of an electronic lock mechanism based on the temperature of the enclosure. The cooler 1 has a refrigerator for maintaining products at a temperature around or below 42° F. As long as the temperature is maintained below the desired temperature of 42° F., the cooler can be opened by any patron who desires to open the door, so that the patron can select a product to be purchased.
[0030] When the door is closed, the strike mounted on the door is engaged with the latch mounted to the cabinet (or vice versa in an alternative embodiment). If the temperature is proper, for example 42° F. or less, and when the door is pulled open, the latch mechanism allows the strike to be released and the door will swing open. The temperature of the cooler can be communicated remotely over a local or wide-area network.
[0031] In the event that the temperature of the cooler exceeds a pre-determined limit for a period of time such as 45 minutes, there is a risk of spoilage of the food or beverage in the cooler. Thus, in an embodiment, when this occurs, the cooler controller proceeds to enable the lock controller and in turn the lock controller energizes the motor and latches the strike pro that the door is locked and cannot be withdrawn from the cabinet. The locking event can be communicated remotely over a local or wide-area network. If the temperature returns to a safe/proper temperature, it may be possible for the controller to determine the contents are safe to consume because the cooler temperature only stayed in the elevated range for a short period of time, i.e. too short for the food to spoil. In such a case, the controller may unlock the door.
[0032] In another example, the status of the sensors is communicated to a person remote to the cooler over a local or wide-area network, and this person may send a remote signal or command the controller to unlock the controller. As an alternative, the lock controller can also provide a local interface to an electronic or mechanical key or a keypad to signal the controller to unlock the door as shown in FIG. 13 .
[0033] The latch provides a sensor for detecting the strike releasing from the latch and thus the door swinging open. This door opening sensor can be useful by the controller for measuring the time the door remains open, and alerting someone either locally or remotely (and/or storing this data remote to the cooler) that the door is open for too long to avoid spoilage of food or other items in the cooler.
[0034] The latch also comprises a sensor for detecting the locked/unlocked position of the latch. As the motor controls the latch to change states from locked to unlocked, or from unlocked to locked, the sensor will detect the change of state so the lock controller can properly control the state of the latch and report the state of the latch to a device external to the cooler.
[0035] The controllers may be powered by AC line voltage and by a battery as a back-up for example. The advantage of the combination of both the AC power and the battery is that the lock controller will be powered primarily from the AC power while it is assumed the cooler will also have the same AC power for operating the refrigerator. Thus the refrigerator should normally be successful keeping the temperature at or below 42° F. If and when the AC voltage is lost for an extended time period, it is expected the temperature in the cooler will increase to a temperature and for a time period that could cause the food and/or beverages to spoil. In the event of lost power, the controller has the capability, in an embodiment, to control the lock actuator to lock the door, or to latch the strike so the door cannot be withdrawn.
[0036] During the time that AC power is lost, the controller may be configured to continue to monitor all the sensors, such as for example, the temperature sensor, and also to measure elapsed time. Thus by conducting these measurements during a power outage, the controller(s) can determine if the temperature has exceeded certain undesirable levels for an extended period of time, in order to determine if the cooler can be unlocked to allow products to be distributed once the AC power resumes. In addition, the controllers can communicate status of the power and the sensor measurements during the power outage event.
[0037] In the event of a temperature limit event, the controllers may also serve to control alternative devices related to the cooler, such as the lighting for the cooler. For example, if the temperature limit is exceeded, the controller may be configured to turn off the lights of the cooler, to discourage patrons from trying to access the cooler (a cooler without lights would visually indicate the cooler has a malfunction).
[0038] Another feature of the cooler lock is to lock the door based on a timer or a schedule regardless of cooler temperature. For example, if the cooler is in an office that is typically closed after 6 PM, the cooler may be automatically locked after 6 PM to discourage maintenance or cleaning crews from taking items from the cooler. If the office re-opens at 8 AM, the cooler would unlock at approximately that time.
[0039] In another example, the cooler lock can be in a default locked state. In this embodiment, the patrons can select which products they intend to purchase before opening the cooler door and removing the products. After the products are selected and payment is collected or authorized by credit or debit card, the cooler door can be unlocked for either a) a short period of time, or b) a single access event so the customer can remove the purchased products. In this example, in the event the cooler temperature exceeds certain limits or power is lost as described above, the cooler would remain locked and the customers would be discouraged from paying for products.
[0040] In another embodiment, the access control system further includes additional features for providing locking and access to a refrigerated cooler as in FIG. 1A . As shown in FIG. 14 , while the cooler door is open the slider can move from the unlocked position shown initially in FIG. 8 to the locked position shown in FIG. 14 . In FIG. 8 , the cooler door is open, the claw is rotated counter clockwise, and the slider is in the unlocked position and retracted from touching the claw. In the event the door is unlocked and a customer opens the door to select a product, it is possible the controller could send a locked signal to the lock. This situation could take place if, for example, the door is left open for too long of a period of time. In this situation, it is desirable to move the slider to the extended locked position while the claw is rotated counter clockwise and to rest on the curved surface of the claw before the door is closed and before the claw is rotated clockwise.
[0041] Once the door is closed and then after the strike rotates the claw clockwise, the slider will continue to move to the extended position and block the movement of the claw, and will maintain the claw in the locked counterclockwise position as shown in FIG. 11 . This feature provides for locking the cooler door upon closing the cooler door if a lock event is triggered while the cooler door is open. In another embodiment, if the cooler door is open and a lock event is triggered by a failed probe or an over temperature event, the lock delays the locking event until the cooler door is properly shut. This is accomplished by monitoring the door position, and if the door is open during the lock trigger event the lock, delaying going to the locked condition; later upon sensing the cooler door is closed, the lock then moves to the locked position and the door is locked.
[0042] In the embodiment, the lock controller can provide a reset signal to the cooler controller as described below. The reset signal source can come from another source, for example from a separate switch in a secured location (not shown) that is only reached via authorized access. In the event the cooler controller senses a cooler fault and sends the lock signal to the lock controller, and the lock controller locks the cooler door, the service technician must provide a system for repairing the equipment and resetting the lock and cooler controller. Once the lock controller has locked the cooler door, the lock controller is configured to sense a secured signal to indicate the cooler has been repaired and should be reset back to the unlocked condition. In this embodiment, the lock controller will sense a signal via, the keypad or the key sensor, and when this signal is received the lock controller will unlock the cooler door and send a reset signal to the cooler controller, and the cooler controller will release lock signal to the lock controller. In another embodiment, the lock or cooler controller will sense a reset signal from a mechanical switch accessible by a mechanical or electronic lock.
[0043] Upon either a power-up condition or upon receiving a reset signal from the lock controller, the cooler controller will wait for the cooler to begin cooling and the temperature to reach a low temperature, for example 37° F. before proceeding to the lock control measurement algorithm. Prior to reaching the lower temperature, e.g., 37° F., the cooler controller will continue to output the unlock signal. Once a tempera lure of 37° F. or below is attained, the cooler controller begins the lock control algorithm and continues to output the unlock signal since the temperature is proper. Once the cooler controller measures a higher than normal temperature for a certain time period (over-temperature time), for example 42° F. for 15 minutes, the cooler controller will send the lock controller the lock signal.
[0044] The cooler or lock controller may be powered by a battery and may be programmed to lock the cooler door after loss of AC power, regardless if the temperature has exceeded the temperature limit of 42° F. This will insure the cooler door will be locked before the back-up battery has depleted, and it would be too late to lock the cooler door.
[0045] In an embodiment a service mode of operation is provided, whereby the cooler and lock controllers are placed into an operation mode that will not provide for the cooler door to be locked for a period of time typically longer than the over-temperature trigger time (for example ½ hour), so that the cooler can stand open and be loaded with products. After the service mode time period, the cooler controller resumes monitoring for a temperature default. It is desirable to exit the service mode after one single service mode time period, and to restrict consecutive service mode time periods.
[0046] As an alternative to a manually-entered service mode, in an embodiment, the cooler controller intelligently controls the service mode of the cooler by measuring the temperature rate of change. For example, if the temperature of the cooler rises above 42 degrees this could be due to either a fault of the cooler, or due to the cooler being refilled or serviced. After being filled or serviced, the door is closed and the temperature should begin to decrease rapidly toward the proper level provided the cooler is functioning properly. In this embodiment, when the cooler temperature exceeds the over-temperature trigger time while it is in the process of rapidly cooling down, the controller logic refrains from locking the cooler because as the controller measures the rapid rate of temperature change it can determine that a service condition is in process and determine to not lock the door, since it has determined that he temperature variation is not a faulty cooler refrigeration condition.
[0047] The cooler controller may also sense for a failed temperature probe in an embodiment, and may communicate a cooler lock event with the lock controller. The time period that the cooler controller senses for the failed probe before the lock signal is communicated from the cooler controller to the lock controller is typically shorter than the over-temperature delay time as described above. It is desirable to quickly lock the door in the event of a temperature probe fault because the integrity of the entire cooler system is in question, and the risk of serving spoiled food is minimized by locking the door. The cooler locking system may also include a test switch (not shown, typically mounted in a location that is easily accessible without the use of tools) that will be used by an equipment technician or health inspector to simulate an over-temperature condition or a failed probe condition to determine if the lock if functioning properly. In a working system, when the test switch is activated, the controller will sense (erroneously) that there is a malfunction of the cooler or the probe and will send a lock signal to the lock, and the cooler will proceed to lock. The system will return to normal operation after the switch is deactivated or if the system receives another signal, such as an access signal from the key or a reset signal.
[0048] FIGS. 15 and 16 describe an example of the control logic of the cooler controller (CC) and the cooler lock (CL) in greater detail. Referring to FIG. 15 first, the cooler controller process begins at stage 25 , wherein the system powers up. Subsequently at stage 26 , the cooler is unlocked, e.g., the cooler controller outputs a 0V signal to the lock. The cooler controller then determines at stage 27 whether the internal temperature of the cooler is at or below a threshold value such as 38° F. If the temperature is determined to be at or below the threshold value, the process continues to stage 28 , wherein the cooler controller determines if the system is in service mode as described above. In the event that the system is in service mode, the process flows to stage 29 , wherein a 30 minute delay, or other suitable delay period, is imposed and the process flows back into stage 28 .
[0049] If instead it was determined that the system is not in service mode, the process flows to stage 30 , wherein the cooler controller determines whether there has been a power loss exceeding some time threshold, such as 2 minutes. If so, the process flows to stage 31 , wherein the cooler controller determines whether there is a probe fault, and if there is not, the process continues to stage 31 a . At stage 31 a , if the measured temperature is decreasing at a rapid rate, it is assumed the cooler is working properly and it may have been recently opened for service or re-filling, and thus it should remain unlocked and should not proceed to stage 32 . If the temperature is not decreasing at a rapid rate, the process flows to stage 32 . At stage 32 , the cooler controller determines whether the internal temperature has been above a second threshold temperature, e.g., 42° F., for greater than a predetermined period, e.g., 15 minutes.
[0050] In the event that the temperature has not been above the second threshold temperature for greater than the predetermined period, the process flows back to stage 28 . Otherwise, the process flows to stage 33 , wherein the cooler controller locks the cooler, e.g., by sending a 12V signal to the lock motor. From stage 33 , the cooler controller determines at stage 34 whether a reset signal has been received, and if such a signal has been received, the process returns to stage 26 . Otherwise, the process flows back to stage 33 .
[0051] Returning to the decision stages 30 and 31 , if either of these stages results in an affirmative determination (yes, probe faulted and/or yes power lost for greater than the prescribed period), then the process flows immediately to stage 33 . From there, the process continues as described above.
[0052] Turning to FIG. 16 , this figure shows the control process from the standpoint of the cooler lock controller. Starting at stage 40 , the cooler is unlocked. Next at stage 41 , it is determined whether a 12v (lock) signal is received from the cooler controller. If so, the cooler lock locks at stage 42 . Subsequently at stage 43 , the lock controller determines whether CC is set, whether it reads 12V. If so, the controller checks for a valid key access at stage 44 . If a valid key access is detected at stage 44 , the process continues to stage 45 , wherein the lock controller unlocks the cooler and sends a cooler controller reset signal.
[0053] If at stage 43 it is determined that CIF is not set, then the process flows to stage 46 to unlock the cooler and then returns to stage 41 . If at stage 44 it is determined that there is no valid key access, then the process returns to stage 43 .
[0054] If at stage 41 it determined that a 12v (lock) signal is not received from the cooler controller, the process looks for a valid key access at stage 47 , and if such access is not found, proceeds back to stage 41 . Otherwise, the process flows to stage 48 , and the cooler is locked. Subsequently at stage 49 , is again determined whether a valid key access has occurred. If so, the process moves on to stage 46 and continues thence as described above. If, however, no valid key access is found, the process loops at stage 49 .
[0055] As noted above, FIG. 13 is a simplified schematic of a control system usable to implement the processes described herein. The illustrated system includes primarily a cooler controller 50 and a lock controller 51 . Both controllers may be, for example, microcomputer or microprocessor-based controllers. In an alternative embodiment, the two microcomputers may be integrated together into a single microcomputer controller.
[0056] The cooler controller 50 includes inputs for power 52 and a temperature probe 53 . The cooler controller 50 also includes outputs, e.g., for light control 54 , lock control 55 , lock controller power 56 , as well as an Ethernet or other data connection 57 to access a LAN or a WAN, such as the Internet. The cooler controller 50 may also include a battery 58 for back-up purposes.
[0057] The lock controller 51 includes a clock 60 and a lock actuator 61 . The lock controller 51 also includes inputs for a key sensor 62 , a keypad 63 , a door sensor 64 , and a latch position sensor 65 , in an embodiment wherein a reset capability is included, the system also includes a reset line 66 providing input from the lock controller 51 to the cooler controller 50 , as shown in FIG. 14 .
[0058] It will be appreciated that a new and useful system for cooler lock function and control has been disclosed and described herein. However, while the foregoing detailed description has been given and provided with respect to certain specific embodiments, it is to be understood that the scope of the disclosure should not be limited to such embodiments, but that the same are provided simply for enablement and best mode purposes. The breadth and spirit of the present disclosure are broader than the embodiments specifically disclosed and are encompassed within the claims appended hereto.
[0059] While certain features are described in conjunction with specific embodiments of the invention, these features are not limited to use with only the embodiment with which they are described, but instead may be used together with or separate from, other features disclosed in conjunction with alternate embodiments of the invention.
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A cooler access control system locks a cooler when occurrence of an event is detected that requires limiting access to the inside of the cooler. Examples of such events include the loss of power to the cooler for a predetermined period of time, the opening of the cooler door for longer than an allowed time, the loss of functionality of a temperature probe and others. In an embodiment, a service mode is supported wherein the door is left unlocked despite the occurrence of such an event, to allow a stocker or other personnel to leave the cooler door open while stocking the cooler with product.
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TECHNICAL FIELD
[0001] Embodiments of the subject matter disclosed herein generally relate to methods and devices and, more particularly, to mechanisms and techniques for cooling internal components of a downhole device using a heat exchanger based on a Stirling cycle.
BACKGROUND
[0002] Like other manufacturing disciplines, well drilling technology has been integrated with electronics for measurements, computing, communications, etc. As well drilling capabilities have allowed drilling of deeper wells, the temperature of the well fluid, otherwise known as “mud” has increased to the point where insulation and/or cooling of the downhole electronics is required to keep the electronics operational. Attempts have been made to insulate the electronics but even if a truly adiabatic insulator was available, the heat generated by the electronics themselves would lead to overheating if a cooling mechanism was not incorporated into the design of the electronics system.
[0003] Attempts have been made to provide a coolant to the electronic systems but the depth of state of the art wells has made this task difficult. Typical wells can be many thousands of feet deep and can include bends in the well that make plumbing one or more coolant lines to the drill head difficult. Further, existing methods of chaining multiple measurement and data collection downhole tools together in a single well further complicates an already difficult task of cooling individual tools and their associated electronic components. Further, attempts have been made to insulate the electronic components from the heat associated with the external environment but these attempts have resulted in a fixed operational time based on the amount of time required for the heat source to overcome the insulator, combined with heat generated by the electronics, and raise the temperature of the electronic components to a temperature at which they cannot operate.
[0004] Many prior art systems and mechanisms have evolved to transfer heat from a higher temperature region to a lower temperature region or to perform mechanical work based on the aforementioned energy transfer. One such device for performing mechanical work based on the described temperature difference is a Stirling engine. A Stirling engine is a device that converts thermal energy into mechanical energy by exploiting a difference in temperature between two regions.
[0005] The Stirling engine operates on the principle of the Stirling cycle which consists of four thermodynamic processes acting on a working fluid. The Stirling cycle consists of an isothermal expansion, an isovolumetric cooling, an isothermal compression and a isovolumetric heating. The output of the Stirling cycle is the ability to perform mechanical work based on movement of the piston in the Stirling engine. Noteworthy in the theory of the Stirling cycle is the reversible nature of the Stirling cycle. Accordingly it is possible to provide the mechanical energy to the Stirling engine and create a heat exchanger capable of transferring heat from a region of lower temperature to a region of higher temperature.
[0006] Accordingly, it would be desirable to provide devices and methods that avoid the afore-described problems and drawbacks of cooling downhole electronics.
SUMMARY
[0007] According to one exemplary embodiment, there is a heat pump apparatus comprising a plurality of flexible barriers separating a location to remove heat from a location to add heat and enclosing a volume through which said heat transfers. Next in the exemplary embodiment, a heat transfer fluid, contained in the volume, for transferring heat based on an input of mechanical energy. Continuing with the exemplary embodiment, a plurality of mechanical agitators for imparting the mechanical energy as compressive and expansive force on the volume an alternating the location of the heat transfer fluid from a position adjacent to the location to remove heat to a position adjacent to the location to add heat.
[0008] According to another exemplary embodiment, there is a down-hole drilling apparatus including an inner canister encasing drilling components, an outer canister encasing the inner canister and creating a void between the inner canister and the outer canister and a heat pump apparatus disposed in the void between the inner canister and the outer canister. The exemplary embodiment continues with the heat pump apparatus comprising a plurality of flexible barriers separating a location to remove heat from a location to add heat and enclosing a volume through which said heat transfers. Next in the exemplary embodiment, a heat transfer fluid, contained in the volume, for transferring heat based on an input of mechanical energy. Continuing with the exemplary embodiment, a plurality of mechanical agitators for imparting the mechanical energy as compressive and expansive force on the volume an alternating the location of the heat transfer fluid from a position adjacent to the location to remove heat to a position adjacent to the location to add heat.
[0009] According to another exemplary embodiment, there is a method for cooling down-hole drilling components. The method includes encasing the drilling components in a first canister. The exemplary embodiment continues with encasing the first canister in a second canister and providing a void area between the first canister and the second canister. Next, the exemplary embodiment continues with inserting a plurality of flexible barriers in the void area between the first canister and the second canister. Further, the exemplary embodiment continues with adding mechanical energy by alternately compressing and expanding a heat transfer fluid, contained in a plurality of pockets created by the plurality of barriers, with agitators, wherein said agitators are moving approximately ninety degrees out of synchronization with each other. Next in the exemplary embodiment, shifting the position of the plurality of pockets alternately from a cooler position during expansion to a hotter position during compression to transfer heat from the cooler position to the hotter position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate one or more embodiments and, together with the description, explain these embodiments. In the drawings:
[0011] FIG. 1 is a prior art exemplary embodiment of a Beta Type Stirling Engine representing the four thermodynamic processes comprising the Stirling cycle;
[0012] FIG. 2 is an exemplary embodiment depicting the higher temperature and lower temperature regions of a radial cross-section typically associated with downhole electronics of a drilling apparatus;
[0013] FIG. 3 is an exemplary embodiment depicting the higher temperature and lower temperature regions of a radial cross-section typically associated with downhole electronics of a drilling apparatus including a plurality of beta type Stirling engines connected to the two regions across the void between the two regions with an exploded view of a Stirling engine;
[0014] FIG. 4 is an exemplary embodiment depicting the higher temperature and lower temperature regions of a radial cross-section typically associated with downhole electronics of a drilling apparatus including a moveable dual-barrier Stirling cycle heat exchanger located in the void between the two regions with an exploded view of the dual-barrier interacting radially with a plurality of pistons;
[0015] FIG. 5 is an exemplary embodiment depicting the higher temperature and lower temperature regions of a radial cross-section typically associated with downhole electronics of a drilling apparatus including a barrier ring Stirling cycle heat exchanger located in the void between the two regions with an exploded view of the barrier ring interacting tangentially with a working fluid;
[0016] FIG. 6 is an exemplary embodiment depicting the higher temperature and lower temperature regions of a radial cross-section typically associated with downhole electronics of a drilling apparatus including a barrier ring Stirling cycle heat exchanger located in the void between the two regions with an exploded view of the barrier ring interacting axially with a working fluid;
[0017] FIG. 7 is an exemplary embodiment depicting the higher temperature and lower temperature regions of a radial cross-section segment typically associated with downhole electronics of a drilling apparatus including a barrier ring Stirling cycle heat exchanger located in the void between the two regions with a support stud maintaining the annular gap between the inner and outer canister;
[0018] FIG. 8 is an exemplary embodiment depicting the higher temperature and lower temperature regions of a non-circular cross-section capable of supporting a barrier Stirling cycle heat exchanger located in the void between the two regions; and
[0019] FIG. 9 is a flow chart illustrating steps for operating a barrier type Stirling heat exchanger according to an exemplary embodiment.
DETAILED DESCRIPTION
[0020] The following description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following embodiments are discussed, for simplicity, with regard to the terminology and structure of turbo-machinery including but not limited to compressors and expanders.
[0021] Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
[0022] As shown in FIG. 2 , an exemplary embodiment depicts a cross-section of a typical canister arrangement for a downhole drilling apparatus. In the exemplary embodiment the inner canister 208 encloses the cooler region. In one aspect of the exemplary embodiment, it is desired to maintain the internal region 206 at a temperature low enough to permit uninterrupted operation of the electronics associated with the drilling operations, including but not limited to drill control, data collection and communications to external locations. In another aspect of the exemplary embodiment an outer canister 210 encases the inner canister 208 and provides a void area 204 between the inner canister 208 outer wall and the outer canister 210 inner wall. It should be noted in the exemplary embodiment that a support structure (not shown) maintains the predefined void area between the inner canister 208 and the outer canister 210 . Continuing with the exemplary embodiment, an external region 202 outside the outer canister 210 is at a temperature higher than the temperature of the internal region 206 inside the inner canister 208 and higher than the operational maximums of the electronics associated with the drilling operations. It should be noted in the exemplary embodiment that the external region 202 is a heat source with effectively unlimited capacity.
[0023] Looking now to FIG. 3 , an exemplary embodiment depicts another cross-section 300 of a typical canister arrangement for a downhole drilling apparatus. The cross-section 300 includes an inner canister 308 enclosing a cooler region 306 , with respect to a hotter region 302 , and an outer canister 310 encasing the inner canister 308 and provides a void area 304 between the outer wall of the inner canister 308 and the inner wall of the outer canister 310 . It should be noted that the hotter region 302 is effectively unlimited with regard to its heat capacity.
[0024] Continuing with the exemplary embodiment, a plurality of beta type Stirling engines are connected between the outer wall of the inner canister 308 and the inner wall of the outer canister 310 . In one aspect of the exemplary embodiment, the Stirling engines 312 serve as a support structure for maintaining the void area 304 between the inner canister 308 and the outer canister 310 . In another aspect of the exemplary embodiment, the Stirling engines 312 are constructed of an insulating material to prevent the transfer of heat from the hotter region 302 to the cooler region 306 . Further in the exemplary embodiment, mechanical energy is provided to the Stirling engines 312 to reverse the Stirling cycle forcing the Stirling engines 312 to operate as heat pumps for cooling the region inside the inner canister 308 .
[0025] As depicted in the exploded view of the Stirling Engines 312 , mechanical energy (not shown) is provided to a piston 314 to compress the working fluid in the compression zone 316 , therefore heating the working fluid and transferring heat energy through the outer canister 310 to the hotter region 302 based on the position of the displacer 318 moving the working fluid to the end of the Stirling engine 312 adjacent to the hotter region 302 outside the outer canister 310 . Next in the exemplary embodiment, as the piston 314 expands the volume, the working fluid cools and the displacer 318 forces the cooler working fluid to the end of the Stirling engine adjacent toward the cooler inner canister 308 therefore cooling the region inside the canister 306 .
[0026] Further, it should be noted in the exemplary embodiment that additional parallel planes of Stirling engines can be configured based on operational parameters and conditions dictating the amount of required cooling. It should be noted in the exemplary embodiment that the number of Stirling engines in a single cross-sectional plane is not limited to the number depicted in cross-section 300 and can be a larger or smaller number based on circumstances associated with the particular heat transfer and/or structural requirements.
[0027] Looking now to FIG. 4 , an exemplary embodiment depicts another cross-section 400 of a typical canister arrangement for a downhole drilling apparatus. The cross-section 400 includes an inner canister 408 enclosing a cooler region 406 , with respect to a hotter region 402 , and an outer canister 410 encasing the inner canister 408 and providing a void area 404 between the outer wall of the inner canister 408 and the inner wall of the outer canister 410 . It should be noted that the hotter region 402 is effectively unlimited with regard to its heat capacity.
[0028] Continuing with the exemplary embodiment, a flexible inner barrier 412 and a flexible outer barrier 414 , located in the void space 404 between the inner canister 408 and the outer canister 410 , separates an inner gas volume 416 from an outer gas volume 418 and encases a heat transfer fluid 420 between the inner barrier 412 and the outer barrier 414 . Next in the exemplary embodiment, a plurality of inner pistons 422 is attached to the outer surface of the inner canister 408 and exerts a radial force outward on the inner barrier 412 . Similarly in the exemplary embodiment, a plurality of outer pistons 424 is attached to the inner surface of the outer canister 410 and exerts a radial force inward on the outer barrier 414 .
[0029] Further in the exemplary embodiment, it should be noted that the inner canister pistons 422 and the outer canister pistons 424 are mounted such that they are diagonally across from each other as illustrated in the exploded view of FIG. 4 and oscillate approximately ninety degrees out of phase of each other. It should also be noted in the exemplary embodiment that the mechanical energy provided to the system to oscillate the inner barrier 412 and the outer barrier 414 can be provided, as illustrated in FIG. 4 , not only by pistons but also by electric motors, solenoids, piezoelectric ceramics, acoustic waves, etc.
[0030] The exemplary embodiment depicted in FIG. 4 illustrates the use of a series of radial force applications, by the exemplary pistons 422 / 424 , to oscillate the two barriers in such a manner as to input mechanical energy into the barriers and create a heat pump, based on a reverse Stirling cycle, for transferring heat from the cooler region 406 to the hotter region 402 and preserving a desired temperature of operation within the cooler region 406 inside the inner canister 408 . For example, an inner canister piston 422 acts as a compression piston in the hot cycle, compressing and heating the heat transfer fluid 420 while displacing the compressed and heated fluid toward the higher temperature outer canister 410 and allowing heat transfer from the heat transfer fluid to the hotter region 402 . Continuing with the example of the exemplary embodiment, approximately ninety degrees out of phase with the inner canister piston 422 , the outer canister piston 424 acts a compression piston in the cold cycle, moving an adjacent section of the heat transfer fluid 420 toward the lower temperature inner canister 408 while the inner canister piston 422 retracts to increase the volume occupied by the heat transfer fluid 420 and cools the heat transfer fluid 420 with the channel between the inner barrier 412 and the outer barrier 414 acting as a regenerator and allowing heat transfer from the cooler region 406 to the heat transfer fluid 420 .
[0031] Looking now to FIG. 5 , an exemplary embodiment depicts another cross-section 500 of a typical canister arrangement for a downhole drilling apparatus. The cross-section 500 includes an inner canister 508 enclosing a cooler region 506 , with respect to a hotter region 502 , and an outer canister 510 encasing the inner canister 508 and providing a void area 504 between the outer wall of the inner canister 508 and the inner wall of the outer canister 510 . It should be noted that the hotter region 502 is effectively unlimited with regard to its heat capacity.
[0032] Continuing with the exemplary embodiment, a plurality of saw tooth outer agitators 512 are paired with a plurality of saw tooth inner agitators 514 functioning as the hot cycle compression piston and the cold cycle compression piston as described in the example for FIG. 4 . In the exemplary embodiment, the saw tooth agitators 512 , 514 oscillate in an angular direction around the shared axis of the inner canister 508 and the outer canister 510 . Further in the exemplary embodiment, the barrier ring 516 acts as the regenerator described in the example for FIG. 4 . In a similar manner as described for the example of FIG. 4 , adding mechanical energy to the agitators 512 , 514 operates a reverse Stirling cycle heat pump and transfers heat from the cooler region 506 to the hotter region 502 based on compression and expansion of a heat transfer fluid located in an inner volume 518 and an outer volume 520 between inner canister 508 and outer canister 510 .
[0033] Looking now to FIG. 6 , an exemplary embodiment depicts another cross-section 600 of a typical canister arrangement for a downhole drilling apparatus. The cross-section 600 includes an inner canister 608 enclosing a cooler region 606 , with respect to a hotter region 602 , and an outer canister 610 encasing the inner canister 608 and providing a void area 604 between the outer wall of the inner canister 608 and the inner wall of the outer canister 610 . It should be noted that the hotter region 602 is effectively unlimited with regard to its heat capacity.
[0034] Continuing with the exemplary embodiment, a saw tooth outer barrier 612 is paired with a saw tooth inner barrier 614 functioning as the hot cycle compression piston and the cold cycle compression piston respectively, as described in the example for FIG. 4 . Further in the exemplary embodiment, the barrier ring 616 acts as the regenerator described in the example for FIG. 4 . In a similar manner as described for the example of FIG. 4 , adding mechanical energy to the saw tooth barriers 612 , 614 operates a reverse Stirling cycle heat pump and transfers heat from the cooler region 606 to the hotter region 602 based on compression and expansion of a heat transfer fluid located in an inner volume 618 and an outer volume 620 between inner canister 608 and outer canister 610 . It should be noted in the exemplary embodiment that the barriers 612 , 614 , 616 are oriented in an axial direction with regard to the common axis shared by the inner and outer canisters 608 , 610 and the oscillation of the barriers 612 , 614 is in the axial direction.
[0035] Looking now to FIG. 7 , an exemplary embodiment depicts the saw tooth agitators of FIG. 5 including a support mechanism for maintaining the angular void between the inner canister 708 and the outer canister 710 . Continuing with the exemplary embodiment, a support stud 712 is connected to the inner canister 708 and the outer canister 710 . In the exemplary embodiment, the stud is a component of the barrier 718 between the outer agitators 720 and the inner agitators 722 . Further in the exemplary embodiment, slots 714 , 716 are cut in the agitator mechanism to allow the stud 712 to be attached to the inner canister 708 and the outer canister 710 . Continuing with the exemplary embodiment, the studs 712 maintain mechanical integrity and dimensional consistency between the inner canister 708 and the outer canister 710 and protect the heat pump components from crushing associated dimensional change of the void area between the inner canister 708 and the outer canister 710 . It should be noted in the exemplary embodiment that other support mechanisms such as, but not limited to, ball bearings, rollers or axial end studs can be used as a support mechanism for maintaining the angular void between the inner canister 708 and the outer canister 710 .
[0036] Looking now to FIG. 8 , the exemplary embodiment illustrates that the hotter region 802 can be constrained by non-circular inner barrier 810 with a non-circular void between the inner barrier 810 and an outer barrier 808 . In another aspect of the exemplary embodiment, the cooler outer region 806 , as described for the hotter region in the previous examples, can have an infinite capacity to absorb heat. It should be noted that other shapes of barriers and voids between barriers are possible and should not be limited by these examples. In another aspect of the exemplary embodiment, movement of barriers acting as a reverse Stirling cycle power pistons can be in radial, angular or axial directions as previously described for the previous exemplary embodiments.
[0037] An exemplary method embodiment for cooling components of a down-hole well drilling apparatus is now discussed with reference to FIG. 9 . FIG. 9 shows exemplary method embodiment steps for using a cooling system based on a reverse Stirling cycle to cool down-hole drilling components by transferring heat from an area housing the down-hole drilling components and transferring the heat to the drilling mud surrounding the outer casing of the drilling system. The exemplary method embodiment includes a step 902 of encasing drilling components in an inner canister. In one aspect of the exemplary method embodiment, the inner canister is typically cylindrical in shape and is typically the cooler region of the heat transfer path i.e. heat is removed from the volume inside the inner canister. It should be noted in the exemplary embodiment that the drilling components can be, but are not limited to, electronic components for control, data acquisition and communications and can generate heat based on component power consumption.
[0038] Next at step 904 , the exemplary method embodiment continues by encasing the inner casing with an outer casing. The outer casing is typically has the same shape as the inner casing and creates a void between the inner casing and the outer casing. It should be noted that the inner casing and the outer casing share the same rotational axis i.e. the separation distance between the outer wall of the inner casing and the inner wall of the outer casing is maintained. It should further be noted that the region outside the outer casing is typically the hotter region of the heat transfer path i.e. the heat removed from the cooler region inside the inner canister is transferred to the hotter region outside the outer casing.
[0039] Continuing with step 906 , the exemplary method embodiment inserts a plurality of flexible barriers in the void between the inner canister and the outer canister. It should be noted that in one exemplary embodiment, the barriers can have a saw tooth shape and can be oriented in an angular or an axial direction. Further, it should be noted in the exemplary embodiment that one or more additional barriers can be sandwiched between the inner and outer barrier and the inner and outer barrier can oscillate while the sandwiched barrier(s) can remain fixed and/or rigid. In another aspect of the exemplary embodiment, studs for maintaining dimensional integrity between the inner canister and the outer canister can be integrated in the sandwiched barrier(s) and extended through slots in the inner and outer barrier for attachment to the inner canister and the outer canister.
[0040] Next at step 908 , the exemplary embodiment adds mechanical energy to the flexible barriers. In the exemplary embodiment, the mechanical energy is provided by agitators moving in a radial, angular or axial direction. It should be noted that the movement can be an oscillation of the agitators with the agitators configured as opposing pairs oscillating approximately ninety degrees out of phase of each other. In another aspect of the exemplary embodiment, the phase difference between the opposing pairs of agitators can vary by a phase selected based on design, maximizing efficiency or maximizing the economic value. It should further be noted that a heat transfer fluid is also inserted in the volume between the inner flexible barrier and the outer flexible barrier. Continuing with the exemplary embodiment, the agitator movement imparts compressions and expansions on the heat transfer fluid resulting in localized hot and cold volumes sufficient to provide a heat transfer path between the cooler region inside the inner canister and hotter region outside the outer canister.
[0041] Continuing with step 910 , the exemplary embodiment transfers heat from the cooler region inside the inner canister to the hotter area outside the outer canister. It should be noted in the exemplary embodiment that the localized volumes of hotter and colder heat transfer fluid created by the agitator oscillations are displaced to a hotter outer location and a colder inner location, respectively, by the agitator movement, allowing the transfer of heat in the desired direction.
[0042] The disclosed exemplary embodiments provide devices and a method for implementing Stirling cycle coolers and energy generators in a down-hole drilling operation. It should be understood that this description is not intended to limit the invention. On the contrary, the exemplary embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the exemplary embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.
[0043] Although the features and elements of the present exemplary embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein.
[0044] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements to those recited in the literal languages of the claims.
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Apparatus and method for cooling internal components of a down-hole well drilling apparatus. Components of the well drilling apparatus are encased in an inner canister that is further encased in an outer canister creating a void between the inner canister and the outer canister. Further, a plurality of moveable barriers is disposed between the inner canister and the outer canister and contains a heat transfer fluid. A plurality of agitators add mechanical energy to the plurality of moveable barriers compressing and expanding, while repositioning, the heat transfer fluid and creating a heat pump based on a reverse Stirling cycle to remove heat from the cooler inner canister and transfer the heat to the hotter environment outside the outer canister.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 11/118,958, filed on Apr. 29, 2005 now abandoned.
FIELD OF THE DISCLOSURE
The present disclosure generally relates to oral hygiene products and methods and, more particularly, to such products and method adapted for children.
BACKGROUND OF THE DISCLOSURE
The teaching and motivation of toddlers and young children is a subject of much attention in patent and general literature. In particular, numerous writings, devices, techniques, aides, and kits have been proposed to assist children, parents (or other caregivers), or both, with learning and performing oral hygiene tasks. A common challenge for a caregiver is to teach the child to perform a complete oral hygiene task, particularly where the task requires several steps. At the outset, a caregiver will often provide at least some assistance and instruction on how to complete the task. The ultimate goal, however, is for the child to be able to execute the oral hygiene task unassisted. The age at which a child will practice an oral hygiene task on his or her own is dependent upon many factors, some of which are psychological, some physiological, and some unique to each individual child.
Conventional oral hygiene products and methods are overly difficult for a child to use or perform. When performing tooth brushing, for example, current products typically require a child to simultaneously manipulate two separate items at some point in the process. When loading a brush with toothpaste, for example, the child must hold the toothbrush in one hand while dispensing toothpaste from a container with the other hand. Unfortunately, many children are unable to properly or efficiently perform this task, since they are at a stage of physiological development where muscle control and general coordination are limited. Consequently, oral hygiene apparatus and methods are needed that facilitate successful use by children.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a toothbrush adapted for use by children;
FIG. 2 is a perspective view of a toothpaste dispenser adapted for use by children;
FIG. 3 is a side elevation view, in cross-section, of the toothpaste dispenser of FIG. 2 ;
FIG. 4 is a side elevation view of the toothbrush of FIG. 1 positioned to receive toothpaste from the toothpaste dispenser of FIG. 2 ;
FIG. 5 is a perspective view of the toothpaste dispenser discharging toothpaste onto the toothbrush;
FIGS. 6A and 6B are a perspective view and a side elevation view, respectively, of an alternative embodiment of a toothpaste dispenser for use with a toothbrush;
FIGS. 7A-C illustrate a further toothpaste dispenser embodiment for use with a toothbrush;
FIGS. 8A and 8B illustrate yet another embodiment of a toothpaste dispenser for use with a toothbrush;
FIGS. 9A and 9B illustrate an additional embodiment of a toothpaste dispenser for use with a toothbrush;
FIGS. 10A and 10B illustrate yet another embodiment of a toothpaste dispenser for use with a toothbrush;
FIGS. 11A and 11B illustrate an additional embodiment of a toothpaste dispenser for use with a toothbrush; and
FIGS. 12A and 12B illustrate a further embodiment of a toothpaste dispenser for use with a toothbrush.
DETAILED DESCRIPTION
Combinations of a toothbrush and a toothpaste dispenser, as well as methods for using such combinations, are disclosed that are particularly adapted for use by a child. Specifically, the combinations and methods allow a child to apply toothpaste to a toothbrush using a single hand.
As used herein, the term “comprising” means that the various components, ingredients, or steps, can be conjointly employed in practicing the present invention. Accordingly, the term “comprising” is open-ended and encompasses the more restrictive terms “consisting essentially of” and “consisting of.” Other terms may be defined as they are discussed in greater detail herein.
As used herein a “caregiver” means a person other than the child, such as, a parent, babysitter, family member, teacher, day care worker, or other person who is able to provide sufficient assistance to the child to complete a personal hygiene task. For purpose of style and simplicity, the term “parent” will be used in this specification to refer generally to any caregiver and the use of this term is in no way intended to limit the scope of the aides described and claimed.
As used herein, a “compressing mechanism” includes any known manner of extracting toothpaste from a toothpaste container. Such compressing mechanisms may be manually or electrically operated. Known pump type compressing mechanisms include those disclosed in U.S. Pat. No. 6,345,731 to Bitton; U.S. Pat. No. 6,834,780 to Levy; U.S. Pat. No. 5,305,922 to Varon; U.S. Pat. No. 6,715,521 to Back, each of which is incorporated by reference herein. Known squeeze-type compressing mechanisms include those disclosed in U.S. Pat. No. 5,845,813 to Werner; U.S. Pat. No. 6,789,703 to Pierre-Louis; U.S. Pat. No. 6,474,509 to Prince et al.; U.S. Pat. No. 6,454,133 to Lopez et al; U.S. Pat. No. 5,810,205 to Kohen; and U.S. Pat. No. 5,897,030 to Stangle, each of which is incorporated herein by reference. Known types of electrically operated compressing mechanisms include those disclosed in U.S. Pat. No. 5,050,773 to Choi and U.S. Pat. No. 4,403,714, both of which are incorporated by reference herein.
FIG. 1 illustrates a toothbrush 20 adapted for use by a child. The toothbrush 20 includes a handle 22 having a proximal end 24 and a distal end 26 . An enlarged base 28 is coupled to the proximal end 24 . Tooth cleaning structure, such as bristles 30 , are coupled to the distal end 26 to form a brush head 32 . The brush head 32 defines a toothpaste receiving surface 33 , which in the illustrated embodiment is oriented at an angle with respect to the proximal end of the handle 22 .
In the illustrated embodiment, the handle 22 is contoured so that it may be comfortably gripped by a child. Accordingly, the handle 22 includes an enlarged section 34 and an angled portion 36 leading to the brush head 32 . In addition, the handle 22 and base 28 may carry graphics, icons, or other images to attract a child's attention. In the illustrated embodiment, the base 28 includes an image of a frog's hand 38 .
The base 28 may be shaped and or eccentrically weighted to maintain the toothbrush 20 in an angular orientation illustrated in FIG. 4 . In the illustrated embodiment, the base 28 is formed substantially as a sphere. The sphere, by using internal voids, weights, or other means for introducing non-uniform mass, has a center of gravity CG that is spaced from a geometric center C of the sphere. In the illustrated embodiment, the center of gravity CG is spaced farther away from the handle proximal end 24 than the geometric center C. The sphere further has a mass sufficiently greater than the handle 22 and brush head 32 , so that the eccentrically located center of gravity CG forces the toothbrush to rotate about an exterior of the sphere to an equilibrium state, in which the handle 22 extends from the base 28 at an angle with respect to a plane defined by a support surface 40 on which the toothbrush 20 rests. In this position, the brush head 32 is held above the support surface 40 . The center of gravity CG is preferably located such that the toothbrush receiving surface 33 is automatically oriented generally towards the orifice 54 . The center of gravity CG may further be located, and or the outer surface of the enlarged base 28 may be appropriately shaped, such that the toothbrush 22 has a second equilibrium position, like the substantially vertical orientation illustrated in FIG. 1 .
FIGS. 2 and 3 illustrate a toothpaste dispenser 50 adapted for use by a child. The dispenser 50 includes a housing 52 and a discharge orifice 54 extending therethrough. An activator 56 is positioned at a top of the housing 52 and is supported for reciprocating vertical motion between normal and actuated positions. A biasing element, such as spring 58 , extends between the housing 52 and a bottom of the activator 56 to apply a vertically upwardly directed biasing force to the activator 56 . A user may engage a top of the activator and apply a downward actuation force to overcome the bias force. A shroud 60 surrounds the spring 58 and extends between the housing 52 and the activator 56 to provide an attractive appearance. As best shown in FIG. 3 , a stem 62 is coupled to the activator 56 and extends into an interior of the housing 52 . The container 52 preferably includes a slip resistant base 64 to prevent movement of the dispenser along the support surface 40 during use.
In the embodiment illustrated at FIG. 3 , a toothpaste cartridge 70 is received within the dispenser housing 52 . Toothpaste cartridge 70 and dispenser housing 52 may be adapted to provide lock-and-key functionality such that only certain toothpaste cartridges will work with certain dispenser housings. The incorporation of lock-and-key functionality may utilize a variety of technologies including, but not limited to, mechanical and/or electrical means. The cartridge 70 is similar to the cartridge construction disclosed in U.S. Pat. No. 5,158383, which issued to Glover et al. on Oct. 27, 1992, the entirety of which is incorporated by reference herein. Accordingly, the cartridge 70 includes a sidewall 72 , a sliding lower piston 74 , a sliding upper piston 76 , and a fixed upper wall 78 . The lower and upper pistons 74 , 76 sealingly engage an interior surface of the sidewall 72 to define an interior reservoir 80 for holding toothpaste. The lower piston 74 is adapted to move only in the upward direction, as is known in the art. The upper piston 76 may be releasably connected to the stem 62 , such as by mating threads, and is adapted to slide along the interior surface of the sidewall 72 . Accordingly, the upper piston 76 will move when an actuating force is applied or removed from the activator 56 . The fixed upper wall 78 includes a frustoconical portion 82 defining a spout 84 . The upper piston 76 includes a portion 86 that nests within the upper wall frustoconical portion 82 and extends across the spout opening to close the spout. The spout 84 fluidly communicates with the discharge orifice 54 .
The activator 56 has a normal position which prevents toothpaste from passing through the orifice 54 , as best shown in FIG. 3 . In this position, the upper piston 76 is forced upward by the spring 58 (via the activator 56 and stem 62 ) so that it engages the fixed upper wall 78 . The portion 86 of the upper piston 76 is fully inserted into the frustoconical portion 82 of the upper wall 78 thereby to close off the spout and prevent toothpaste from flowing to the orifice.
To dispense toothpaste, a user applies a downward actuation force to the activator 56 , as illustrated in FIG. 5 . The actuation force must be sufficient to overcome the spring bias force to allow the activator to move in a downward direction. The downward direction of the activator 56 also forces the stem 62 and upper piston 76 to move downward. The lower piston 74 resists downward movement to remain in the same position, and therefore the volume of the reservoir is reduced. Simultaneously, the portion 89 of the upper piston 86 disengages the frustoconical portion 82 of the upper wall 78 to open the spout 84 . As a result, toothpaste from the reservoir is forced through the spout toward the orifice 54 .
When the activator 56 is subsequently released, it returns to the normal position under the force of the spring 58 . The stem 62 and upper piston 76 also move in an upward direction until the upper piston 76 again engages the upper wall 78 , thereby closing the spout 84 . The upward movement of the upper piston 76 draws toothpaste toward the piston 76 , which in turn pulls the lower piston 74 in an upward direction. With the lower piston 74 repositioned, the dispensing process may be repeated.
The dispenser may be designed so that the actuation force required to operate the activator 56 is within a child's physical capabilities. Accordingly, the actuation force is less than approximately 50 Newtons, and more preferably less than 25 Newtons.
When used together, the toothbrush 20 and dispenser 50 provide a combination particularly suited for use by children. As illustrated at FIG. 5 , the dispenser orifice 54 is positioned at an orifice height X above the support surface 40 . The enlarged base 28 supports the brush head 32 at a brush head height Y, which is above the support surface 40 but below the orifice height X, so that the head 32 remains adjacent and below the orifice 54 when the toothbrush 20 is released. The brush head height Y may be approximately 1 to 5 centimeters below the orifice height X to provide sufficient space for the discharged toothpaste.
The passive positioning of the brush head 32 allows the child to focus on operating one oral hygiene article at a time, thereby simplifying the process of loading a toothbrush with toothpaste. The child may grasp the toothbrush 20 and position it on the support surface 40 in close proximity to the dispenser 50 . The child may then release the toothbrush 20 , so that the head 32 is raised above the support surface 40 . If necessary, minor adjustments to the position of the toothbrush 20 may be made to make sure the head 32 is vertically aligned with the orifice 54 . Additionally, one skilled in the art would appreciate that a variety of alignment techniques may be used to align head 32 and orifice 54 . One such example of an alignment technique includes the use of magnets 963 and 964 which may be located in head 32 and recess 965 , respectively. The activator 56 may then be operated to dispense toothpaste onto the head 32 .
While a specific type of dispenser has been disclosed, it will be appreciated that various other types of dispensers may be used without departing from the scope of this disclosure. In general, the force that advances toothpaste to the orifice 54 may be supplied manually, electrically, pneumatically, or otherwise. Furthermore, if the toothpaste is provided in a flexible container, the dispenser may squeeze, roll, or otherwise compress the container to force the toothpaste from the container. The dispenser may be freestanding or mounted on a surface such as a wall. The following are specific alternative embodiments of the dispenser.
FIGS. 6A and 6B illustrate a dispenser 100 adapted for mounting on a wall 102 . The dispenser includes a housing 104 carrying a flexible container 106 of toothpaste. The housing 104 further includes an orifice 108 in fluid communication with an interior of the flexible container 106 . The housing 104 may be positioned above the support surface 40 on which the toothbrush 20 lies, so that the brush head 32 is positioned below and proximate to an orifice 106 . In operation, a user may press the flexible container 106 inwardly to discharge toothpaste from the orifice 108 .
FIGS. 7A-C illustrate a freestanding dispenser 110 that guides the toothbrush 20 to the appropriate position below an orifice. The dispenser 110 includes a base 112 defining a recess 113 sized to receive the brush head 32 and an orifice 114 positioned above the recess 113 . A hand pump/toothpaste cartridge 115 is releasably attached to the base 112 to place the toothpaste cartridge in fluid communication with the orifice 114 . In operation, the toothbrush 20 is guided by the recess 113 into position below the orifice 114 and the hand pump is subsequently operated to discharge toothpaste onto the brush head 32 .
FIGS. 8A and 8B illustrate a wall-mounted dispenser 120 having a peristaltic type pump. The dispenser 120 includes a housing 121 for receiving a container 122 of toothpaste. The container 122 includes an elongate tube 123 extending to a discharge orifice 124 of the housing. A rotatable handle 125 is coupled to rollers 126 positioned to engages and squeeze the tube 123 when rotated. The rollers 126 produce a peristaltic effect that draws toothpaste from the container 122 for discharge from the orifice 124 .
FIGS. 9A and 9B illustrate a freestanding dispenser 130 having a manual pump. The dispenser includes a housing 132 enclosing a flexible container of toothpaste. A depressible button 134 is provided that is movable between normal and depressed positions. The orifice further includes an orifice 136 in fluid communication with the container of toothpaste. In operation, the button 134 is depressed to compress the flexible container, thereby to discharge toothpaste from the orifice 136 .
FIGS. 10A and 10B illustrate two related dispenser embodiments resembling a frog head. The dispenser 140 of FIG. 10A includes a flexible pouch 142 defining an orifice 144 . When compressed, the flexible pouch 142 forces toothpaste out the orifice 144 . In FIG. 10B , a dispenser 146 is actuated by placing the brush head 32 into a recess and cranking the toothbrush in a downward direction to advance toothpaste out an orifice 148 .
FIGS. 1A and 1B illustrate a freestanding dispenser 150 . The dispenser 150 includes a base 152 defining an orifice 154 and a side receptacle 155 adapted to hold the toothbrush 20 . A flexible, ball-shaped container 156 of toothpaste is releasably coupled to the base 152 to place the orifice 154 in fluid communication with an interior of the container 156 . A user may directly engage and compress the container 156 to force toothpaste out the orifice 154 .
FIGS. 12A and 12B illustrate a freestanding, manual pump style dispenser 160 . The dispenser 160 includes a toothpaste cartridge, such as a pump tube 162 , having a base 164 . As best shown in FIG. 12B , the tube 162 includes a reciprocating upper portion 165 for pressurizing and advancing toothpaste within the tube toward an orifice 166 . A pump shroud 167 is disposed over a top portion of the tube 162 . The shroud 167 defines a recess 168 sized to receive the brush head 32 . Downward force applied to the shroud 166 will compress the upper portion 165 to discharge toothpaste from the orifice 166 .
While the foregoing examples illustrate manual compression mechanisms, it will be appreciated that dispensers having automatic or electrical compression mechanisms may be used without departing from the scope of this disclosure. Such electrical compression mechanisms may be similar to the prior art disclosures noted above.
The toothbrushes and dispensers disclosed herein may include images such as character graphics to encourage and motivate a child to brush his or her teeth. The character graphic may provide a source of entertainment and reassurance for the child and a buddy, or friend, who reduces stress and can be related to in a non-competitive fashion during the tooth brush learning period. The character may also provide positive reinforcement and encouragement to the child while the child is learning new skills and behaviors to clean themselves in a non-competitive or threatening manner.
Suitable character graphics can include animals, people, inanimate objects, natural phenomena, cartoon characters or the like, that may or may not be provided with human features such as arms, legs, facial features or the like. It may be desirable for the character graphic to be familiar to the child, such as an identifiable cartoon character. The character graphics should at least be a type that the child can relate to, examples of which could include animals, toys, licensed characters, or the like. Character graphics can be made more personable and friendly to the child by including human-like features, human-like expressions, apparel, abilities, or the like. In one optional embodiment it is desirable for a character to have a distinguishing feature or features, which in a pictograph can help in training, such as a frogs webbed hand. By way of illustration, an animal character graphic can be shown smiling, wearing clothing, playing sports, fishing, driving, playing with toys, or the like. In particular embodiments, the character graphic can desirably be created to project an appearance that could be described as friendly, positive, non-intimidating, silly, independent, inspirational, active, expressive, dauntless and/or persevering.
In one optional embodiment the indicia may optionally include a character graphic which is associated with a line of children's consumer products, especially personal cleansing products and the like. The character may be one of a family, group, team, or the like, each member of which is designed to be associated with, for example, a consumer product, a personal hygiene activity such as brushing teeth, an age group, stage of infant development and the like. Alternatively, all of the characters of a family, group, team, or the like, may be designed to be associated with the entire range of consumer products.
The association by the child of the character with the consumer product, hygiene activity etc., encourages and provides a way for the child to visualize through their imagination the character using the consumer product in the way intended. Furthermore, since this teaching is through the use of the child's imagination, there are none of the negative connotations associated with conventional parental instruction on how to use a consumer product. Instead of the child being subjected to parental nagging to do something the child really doesn't want to do, the child will actively use the consumer product as part of active learning play to interact with their new buddy, or friend, and imitate behavior. The interaction between the child and the character is only limited by the bounds of the child's imagination. The role of the caregiver or parent in then becomes one of actively encouraging imaginative play by the child with the character to use the consumer product correctly, instead of a being perceived by the child as a parent who stops play. Play is actively encouraged and new skills become part of play; “uninterrupted play”. Since the use of the product is essentially play, the child is eager to use the article of commerce and learn the skill.
A family or group of character graphics can be used to progress a child through a system of consumer products, especially personal cleansing products and the like. In this embodiment each character of the family or group, would be tailored to appeal to different groups of children. These groups may be based on age, development stages, regions, etc. Alternatively, a single character may be tailored for one particular group consumer products of line of consumer products which are different for children at different ages, development stages, etc. In this case the character may, for example, be of a different age depending on the consumer product and by which group of children the product is intended to be used.
The dispensers and toothbrushes illustrated herein include images depicting a frog character image. For example, the toothbrush 20 and dispenser 50 include frog hand images. Similarly, the dispensers 140 , 146 of FIGS. 10A and 10B , respectively, are shaped and include images that give the associated toothpaste containers the appearance of a frog head. While the graphics disclosed herein are related to a frog character graphic, it will be appreciated that other images may be provided, such as different animal character graphics, human character graphics, literary or popular character graphics, designs, or shapes, without departing from the scope of this disclosure.
Alternatively, or in addition to, the appearance, the toothbrush and dispenser may interact in more than one way with the child's senses. For example, actuation of the dispenser may cause initiation of a signal that, for example, causes the appearance of dispenser to change (e.g., a change in color or actuation of a light) or causes origination of a sound. In one alternative embodiment, once initiated, the signal may be maintained for a predetermined time so as to provide reinforcement of a desired behavior. For example, the predetermined time may be the time required for the child to thoroughly brush his or her teeth.
This embodiment is further illustrated by an audio assembly for generating a sound feature during or in response to certain operations, such as actuation of the activator or placement of the toothbrush near the orifice. As schematically illustrated in FIG. 5 , the dispenser housing 52 may include a speaker 170 connected to an audio circuit 172 . A sensor 174 may be adapted to detect movement of the activator 56 and/or stem 62 and forward a signal to initiate the audio circuit 172 , thereby causing speaker to generate the sound feature. For example, the activator 56 may be movable between extended and retracted positions, and the sensor 174 may be adapted to detect when the activator (or stem 62 ) is in a proximate position, which may generally correspond to the retracted position, and forward a signal to the audio circuit 172 to deliver sound. The audio assembly may be contained entirely within the dispenser to generate a sound feature whenever a certain activity is performed. Alternatively, the elements of the audio assembly may be provided in separate components that must be matched for the sound feature to be generated. For example, the dispenser housing 52 may carry the speaker 170 and sensor 174 while the toothpaste cartridge 70 provides the audio circuit 172 responsive to the sensor 174 .
The audio feature may be particularly suited to a child and preferably promotes enthusiasm for using the toothbrush and/or dispenser. For example, the audio feature may provide a positive reinforcement upon successfully operating the dispenser, such as verbal or tonal encouragement. Additionally or alternatively, the audio feature may be a simulated animal sound or cartoon character voice. The audio feature may correspond to a visual feature provided on the toothbrush or dispenser. In the current embodiment, where the toothbrush and dispenser include frog character graphics, the audio feature may be a simulated “ribbit” or other noise typically associated with a frog. The audio feature need not match the frog character graphic, but may instead be provided as a simulated human voice, a series of notes, or other composition. Furthermore, the audio circuit may generate more than one type of sound which may be generated sequentially or randomly upon successful actuations of the activator or other activity, as desired.
All documents cited in the Detailed Description are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present disclosure.
While particular embodiments of the present disclosure have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this disclosure.
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A combination toothbrush and toothpaste dispenser, and method, are adapted for use by a child. The dispenser provides an easily actuatable activator that, when operated, discharges a predetermined amount of toothpaste from an orifice. The toothbrush is adapted to automatically lift the toothbrush head off of a support surface to a height near that of the dispenser orifice. As a result, a child may focus on manipulating one item at a time when loading a toothbrush with toothpaste.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims benefit from U.S. Provisional Patent Application No. 60/336,360 filed on Nov. 15, 2001 in the name of Christopher James Evans, et al. for RAPID IN SITU MASTERING OF AN ASPHERIC FIZEAU WITH RESIDUAL ERROR COMPENSATION, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention generally relates to interferometry and more particularly to apparatus and methods by which aspheric surfaces and wavefronts may be rapidly and precisely measured.
Aspheric surfaces offer significant advantages to the designers of high performance optical systems, but their widespread adoption has been hampered by difficulties in manufacture and measurement. Next generation lithography systems, however, are being designed with aspheric surfaces with apertures approaching 0.5 meters, high numerical apertures, and tolerances on the surface shape of less than 1 nm. A large number of approaches to the measurement of aspheric surfaces and wavefronts have been described over the years, each with advantages and disadvantages.
Küchel, in U.S. Provisional Patent Application No. 60/299,614 filed on Jun. 20, 2001 (now U.S. patent application Ser. No. 10/160,672 filed on Jun. 3, 2002 and published on Jan. 2, 2003 as US-2003-0002049 A1), introduced new approaches to measuring aspheric optics in a scanning interferometer. This was extended in U.S. Provisional Patent Application No. 60/303,856 filed on Jul. 9, 2001 (now U.S. patent application Ser. No. 10/180,286 filed on Jun. 26, 2002 and published on Mar. 6, 2003 as US-2003-0043385 A1) to allow explicitly for the collection of the data (to be reduced in the manner taught in the 60/299,614 application, id.) using a Fizeau interferometer. Such scanning approaches described by Küchel and others (e.g. Tronolone, U.S. Pat. No. 5,416,586) tend to be slow, leading Zanoni in U.S. Provisional Patent Application No. 60/299,512 filed on Jun. 20, 2001 (now U.S. patent application Ser. No. 10/152,075 filed on May 21, 2002 and published on Jan. 2, 2003 as US-20030002048 A1) to propose the use of an interferometer with an aspheric reference surface which would be calibrated elsewhere, for example, following the method of Küchel. Measuring the reference surface on a separate instrument introduces issues of stability in the transfer from one instrument to another, as well as practical issues relating to the frequency of recalibration. These issues were addressed by Evans and Küchel in U.S. Provisional Patent Application No. 60/317,028 filed on Sep. 4, 2001 (now U.S. patent application Ser. No. 10/233,772 filed on Sep. 3, 2002 and published on March 13, 2003 as US-2003-0048457 A1), who proposed an approach in which the aspheric reference surface of a Fizeau interferometer is mastered by scanning with a reference sphere. The aspheric part to be measured is then inserted into the instrument (without dismounting the reference asphere). The approach of the 60/317,028 (10/233,772, id.) Application presumes that a reference sphere of sufficient, known quality is available and can be installed in the instrument without distortion.
Accordingly, It is the object of this invention to provide a measurement process which provides for traceable calibration of aspheric optics.
It is a further object of the invention to provide a procedure for continuous improvement of the uncertainty of the measurement made using interferometric instruments.
It is another object of this invention to provide a process with inherent quality assurance, allowing monitoring of the stability of the measurement process.
Other objects of the invention will, in part, appear obvious and will, in part, appear hereinafter when the following detailed description is read in connection with the accompanying drawings.
SUMMARY OF THE INVENTION
This invention provides apparatus and methodology for traceable measurement of aspheric optical surfaces or wavefronts with internal self-consistency checks through two parallel routes to part measurement. Apparatus comprises a Fizeau interferometer which can be configured with optics that produce either spherical or deliberately aspheric wavefronts and with means of scanning test surfaces along the optical axis. Algorithms and procedures requiring multiple measurements are provided to compensate measurement data for bias arising from error motions of the slideway. Provision is made for storing and frequently renewing instrument calibration data. Trend analysis of that frequently retaken calibration data is used to indicate and, hence, manage measurement system performance.
BRIEF DESCRIPTION OF THE DRAWINGS
The structure, operation, and methodology of the invention, together with other objects and advantages thereof, may best be understood by reading the detailed description in connection with the drawings in which each part has an assigned numeral that identifies it wherever it appears in the various drawings and wherein:
FIG. 1 is a diagrammatic elevational view of an interferometric system that can be used to perform high precision measurements of an optical element carrying a spherical or aspherical surface;
FIG. 2 is a diagrammatic elevational view of the interferometric system of FIG. 1 shown configured with an actuable optical sphere used in determining the actual deviations of the reference, nominally spherical, wavefront or surface delivered by the interferometer from its theoretical design;
FIG. 3 is a diagrammatic elevational view of the interferometric system of FIG. 2 now calibrated to measure an appropriate spherical artifact;
FIG. 4 is a diagrammatic elevational view of an interferometric system that has been provided with a transmission asphere and the measured spherical artifact of FIG. 3 to assist in calibrating the aspherical wavefront delivered by the transmission asphere;
FIG. 5 is a diagrammatic elevational view of the interferometric system of FIG. 4 now calibrated to measure an appropriate aspheric artifact;
FIG. 6 is a diagram showing the vertical movement of a spherical surface with respect to its nominal, on-axis, position and is included to aid in explaining one aspect of the invention;
FIG. 7 is a diagrammatic elevational view of a mounting arrangement by which a spherical artifact may be rotated to practice certain aspects of the invention; and
FIG. 8 is a high level flow chart illustrating the methodology of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Traceability is defined (ISO: International Vocabulary of Basic and General Terms in Metrology) as the “property of the result of a measurement . . . whereby it can be related to stated references, usually national or international standards, through an unbroken chain of comparisons all having stated uncertainties”. In the case of measurements of the departure of optical surfaces or wavefronts from their desired shape, the relevant international standard is length, which is defined in terms of the distance an electromagnetic wave propagates in a vacuum in a fixed period of time. That unit is realized in an interferometer through measuring (with appropriate uncertainty) the wavelength. Given the unit of length, a variety of techniques have been described for so-called “absolute testing” of spherical surfaces using an interferometer that generates a spherical wavefront (see for example Evans C. J, Hocken R. J., and Estler W. T., “Self-calibration: reversal, redundancy, error separation and “absolute testing”, CIRP Annals, Vol 45/2(1996), pp617-634). Recent improvements in the art are described in U.S. Provisional Patent Application No. 60/333,245 filed on Nov. 14, 2001 (now U.S. patent application Ser. No. 10/277,553 filed on Oct. 22, 2002). Thus, the departure of an artifact that is nominally a segment of a sphere from a mathematical best fit sphere can be measured with a stated uncertainty. Simultaneously, the departure of the interferometer wavefront is also measured with a stated uncertainty. Now the teachings of Küchel, et al. and Zanoni can be followed along two different paths (that should agree within their (different) stated uncertainties) to make traceable measurements of an aspheric surface or wavefront of interest.
1. The aspheric part can be measured using the previously calibrated spherical interferometer shown in previously mentioned U.S. Provisional Patent Application Nos. 60/299,614 (now U.S. patent application Ser. No. 10/160,672 published on Jan. 2, 2003 as US-2003-0002049 A1) and 60/303,856 (now U.S. patent application Ser. No. 10/180,286 published on Mar. 6. 2003 as US-2003-0043385 A1), the disclosures of both of which are incorporated herein by reference in their entirety; or
2. The spherical artifact can be scanned in front of an aspheric Fizeau of the type disclosed in previously mentioned U.S. Provisional Patent Application Nos. 60/299,512 (now U.S. patent application Ser. No. 10/152,075 published on Jan. 2, 2003 as US-2003-0002048 A1); 60/303,856 (now U.S. patent application Ser. No. 10/180,286 published on Mar. 6, 2003 as US-2003-0043385 A1); and 60/317,028 (now U.S. patent application Ser. No. 10/233,772 published on Mar. 13, 2003 as US-2003-0048457 A1), the entire disclosures of which are incorporated herein by reference, to measure its wavefront with a stated uncertainty. The aspheric Fizeau can now be used to measure the aspheric surface, again with a stated uncertainty.
These two procedures can be implemented in a single special purpose interferometer using a replaceable optical system (referred to as, respectively, a “transmission sphere” or “transmission asphere”) using the following 4 step approach, or any one of a number of variants on it, which will be immediately apparent to those skilled in the art.
FIG. 1 shows an interferometric system, which can be used to perform a high precision measurement of, for example, an optical element 15 carrying a spherical or aspherical surface 16 . In FIG. 1, a laser 1 is shown, which emits a beam 5 at wavelength λ. Beam 5 is redirected downwardly by a reflecting element 7 and is then focused to a small spot with the help of lens 6 and cleaned by a small pinhole 4 . The pinhole 4 is located in the focal plane of a well-corrected collimator lens 9 which is configured to produce a plane wavefront 10 at the operating wavelength.
The plane wavefront 10 enters an optical system (“transmission sphere”) 13 , which appears only very schematically as a “box”, not showing the details of the optical lay-out. This lay-out depends on the exact functionality of the lens for a given task and can differ considerably from case to case. For present purposes, the lens-system 13 produces a wavefront 14 , which is close to a spherical wave (nominally spherical, with deviations small enough to be measured with high accuracy).
The light reflected by a surface 18 serves as a reference wavefront, and the light transmitted by the system 13 , reflected by the surface 16 and again transmitted by the system 13 acts as the measurement wavefront. Both wavefronts travel back through the collimator lens 9 and a beamsplitter 8 after which they pass through an aperture 19 . A lens 20 images the surface 18 onto a CCD detector 21 , where an interferogram can now be seen. With proper phase-measurement techniques, which are well-known to those knowledgeable in the art, and which are therefore not described here, the optical path difference between the interfering wavefronts are measured and transferred to a computer 22 . It will be understood that computer 22 also may be programmed for performing other computational, logical, operational, and housekeeping tasks.
The preferred embodiment of the invention is a Fizeau interferometer and, hence, the final surface of lens system 13 is the reference surface 18 , which is concentric to the focal point of the spherical wavefront 14 . It will be immediately apparent to those versed in the art that the inventions described herein can equally be implemented with other interferometer configurations such as, for example, Twyman-Green.
The first step of the 4 step approach referred to above is to determine the actual deviations of the reference surface 18 (for a Fizeau) or wavefront 14 (Twyman-Green) from it's theoretical design value. One approach is to use the actuable ball 30 , preferably hollow and constructed of a ceramic material such as Zerodur®, described in U.S. Provisional Patent Application No. 60/333,245 filed on Nov. 14, 2001 (FIG. 2 ), now U.S. patent application Ser. No. 10/277,553 filed on Oct. 22, 2002 and published on May 15, 2003 as US-2003-0090798 A1, or one of the many self-calibration methods reviewed, inter alia, in Evans C. J, Hocken R. J., and Estler W. T. “Self-calibration: reversal, redundancy, error separation and “absolute testing”.”CIRP Annals, Vol 45/2(1996) pp617-634.
The second step in the 4 step approach referred to above is to use the now calibrated interferometer complete with its transmission sphere 13 to measure an appropriate spherical artifact 31 (FIG. 3 ).
The third step is to replace the transmission sphere 13 with a second optical system (referred to here as the “transmission asphere”) 41 which generates an aspherical wavefront. The preferred embodiment of the invention is as a Fizeau interferometer and hence the final surface of lens system 41 is an aspheric reference surface 40 designed following the teachings of Zanoni, 60/299,512 (now U.S. patent application Ser. No. 10/152,075 published on Jan. 2, 2003 as US-2003-0002048 A1). The spherical artifact is now scanned using slideway 42 along the optical axis (horizontally in FIG. 4 ), and data acquired and reduced following the teachings of Küchel, 60/299,614 (now U.S. patent application Ser. No. 10/160,672 published on Jan. 2, 2003 as US-2003-0002049 A1) and/or 60/303,856 (now U.S. patent application Ser. No. 10/180,286 published on Mar. 6, 2003 as US-2003-0043385 A1). Since the departures of the spherical artifact were established in the previous step, this step calibrates the aspheric wavefront produced by the interferometer and its transmission asphere 41 .
The final step uses the interferometric system as calibrated above to measure (FIG. 5) an aspheric surface 43 , or wavefront of interest, following the teachings of Zanoni, 60/299,512 (now U.S. patent application Ser. No. 10/152,075 published on Jan. 2, 2003 as US-2003-0002048 A1). Note that the spherical artifact 31 has not been removed from the system.
Measurement, with a stated uncertainty, of the wavelength λ produced by laser 1 introduces the unit of length into an unbroken chain of comparisons (Steps 1 - 4 above) for each of which it is possible to state the uncertainty of the comparison. Hence, the process provides a traceable measurement of the aspheric surface or wavefront.
It will be apparent to those skilled in the art that one source of uncertainty in the resulting measurement arises from pitch, yaw, and vertical and horizontal straightness errors in slideway 42 during the scanning motion of Step 3 illustrated by FIG. 4 . Three different approaches reduce the uncertainty in the final result from the error motions of the slide.
In the first approach, spherical artifact 31 can be mounted on an actuated sub-stage the position of which is measured with respect to stationary metrology reference surfaces. A servo control system then actuates a sub-stage 52 (FIG. 7) in such a manner that spherical artifact 31 moves solely along the optical axis. The sub-stage may use flexures, magnetic levitation, or air, liquid or solid lubrication to allow motions actuated by voice coils, piezoelectric, magnetostrictive or other devices and sensed by transducers such as laser interferometers, capacitance gages, or optical scales. A variety of implementations will be apparent to those conversant with the arts practiced, for example, in lithographic systems (see, for example, Galburt and O'Connor U.S. Pat. No. 5,285,142, 1994). Alternatively, if the error motions are measured, their effect on the measurement result may be computed and the data appropriately compensated.
To implement the second and third approaches, carriage 42 must be provided with means 51 to rotate the spherical artifact 31 (See FIG. 7) and/or test piece including surface of interest of element 43 . Also, to understand the second and third approaches, it is important to recognize that the contribution to the uncertainty can be considered in two components: those that arise from systematic (or repeatable) error motions and those that arise from non-repeatable motions of the slideway system.
In the second method of compensating for slideway errors, data is taken four times, with the spherical artifact 31 rotated 90 degrees between each data cycle—referred to here as M0, M90, M180, and M270, where M0 is data taken with a part in a “first” position, M90 after the part is rotated 90 degrees, etc. Now half the difference between the data file M0 and the data file M180 rotated by 180 degrees represents the contribution to the measurement data resulting from one direction of straightness error motion and the tilt in the same direction (from the principle of superposition, the origin is arbitrary). Similarly, half the difference between M90 and M270 rotated by 180 degrees represents the contribution to the measurement data resulting from errors in the orthogonal direction. Hence, the contribution to the measurement results arising from systematic error motions of the slideway may be computed and subtracted from each measurement. These errors can now be subtracted from each of the measurements which, after appropriate manipulation to ensure that the data sets are properly orientated, can be averaged to reduce by the square root of the number of measurements (i.e., {square root over (4)}=2) the influence of slide error motions arising from random sources. Further reduction in these uncertainties will be obtained from increased numbers of measurements.
The third approach is based on the idea that, for systems that are rotationally invariant about the optical axis 50 , reasonable amplitude error motions produce uncertainties that have reflection symmetry with opposite sign. This is shown schematically in FIG. 6 where the surface of spherical surface 31 in shown to move vertically (dotted lines) with respect to its nominal, on axis, position. In this case the apparent distance to 31 seen by the spherical wavefront with respect to two symmetrically positioned points a, b increase and decrease by very nearly the same amount; practically, they can be taken to be the same over a range determined by the required uncertainty in the measurement to be made of the optical surface or wavefront of interest. The effect of this motion can be treated in the data by two methods.
Now, step 3 can be used only to calculate the average radial profile of the part, following well-known methods. Azimuthally varying errors can be calculated by rotating part 43 using rotatable means 51 during Step 4 and averaging the data (Kestner and Evans (Applied Optics) 1996). This averaging process allows the calibration of the part and deduction of the rotationally varying errors in the instrument.
Note that when the part is mounted on carriage 42 (Step 4 ), the spherical artifact 31 is left mounted in situ. Thus, the spherical artifact 31 , unaltered by varying mounting stresses, etc, may be used periodically to repeat the scan of Step 3 . Equally, after the part 43 has been measured using multiple rotational positions, the resulting estimate of the error of the instrument may be stored and compared with future estimates made using other parts. Hence, this is the basis for a simple measurement quality improvement and quality assurance system. Every scan of the spherical artifact generates new data on the aspheric wavefront; averaging with previous results continues to improve the estimate of the wavefront by reducing the effect of uncertainties arising from random sources. Similarly, mathematical characterizations of the estimate (e.g., power spectrum, Zernike fit, etc) can be tracked and trends in that data over time used to decided when the first two steps of the process need to be repeated due to dimensional changes in the system, drifts, etc. Additionally, measurement data may be compensated using the mean of the apparent change of the instrument as identified by a calibration scan taken immediately before and immediately after the part measurement. The flow chart of FIG. 8 summarizes the general approach described above.
It should be apparent that data taken using the multiple modes of operation of the instrument and processes using the multiple methods of data reduction identified herein should be self-consistent when the instrument is performing the required operations properly. Control computers and associated data processing provide the internal consistency checks and can display comparisons or offer GO/NO GO recommendations based on preprogrammed limits on allowable variations.
Based on the foregoing disclosure and teachings, other variants within the scope of will occur to those skilled in the art and are intended to fall within the coverage of its claims.
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A method with a traceable calibration for reducing the uncertainty in the precision measurement of aspheric surfaces and wavefronts. A transmission sphere is mounted in an interferometer and its emergent wavefront is calibrated by comparing it to an optical sphere that is moved and sampled in a predetermined manner to make it act like a substantially “perfect” sphere mounted on a slideway. Afterwards, the calibrated wavefront from the transmission sphere is used to measure a spherical artifact mounted on the slideway to calibrate its surface. A transmission asphere is then mounted in the interferometer, and its emergent wavefront is calibrated by comparing it to the calibrated spherical artifact mounted on the slideway. The calibrated aspheric wavefront from the interferometer is then used to measure an aspherical artifact mounted on the slideway to determine is surface shape. The calibration of the wavefront emerging from the transmission asphere is periodically updated to provide historical data that is used as the basis for quality improvement and assurance.
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BACKGROUND OF THE INVENTION
The present invention relates to a machine for cutting cloth and for applying borders and a peripheral band to cloths used to manufacture spring mattresses.
It is known (see in particular FIGS. 1, 2 and 3 ) that a spring mattress is constituted by a rectangular prism-like metallic body 1 which is composed of a plurality of biconical springs 2 which are connected one another and are covered by one or more layers 2 a of insulating material such as felt, foamed rubber and the like.
The upper and lower faces of the body 1 are covered by two rectangular cloths or quilts 3 and 4 whose edges are joined by a band 5 which peripherally closes the mattress.
Each cloth or quilt 3 and 4 is constituted, for example, by a panel 6 of soft material which is covered above and below by sheets of fabric 7 , 7 a or the like, the panel and the sheets being joined by a more or less ornamental quilting. A band 10 is fixed to the inner edges of the quilts 3 and 4 by means of two parallel stitch lines 8 and 9 , so as to form a flap 11 which protrudes from the stitch lines 9 and is thus spaced from the stitch line 8 .
When the quilts 3 and 4 are applied to the opposite faces of the body 1 , the flaps 11 are first folded outwards and then under the first turn 12 of the springs 2 and finally fixed thereto with metal staples 13 .
In this manner, the quilts 3 and 4 are fixed to the body 1 , while their borders between the stitch lines 8 and 9 remain free so that they can be connected to the peripheral band 5 by an operation for final application of a border for closure, as shown in FIG. 3 .
Currently, the band 10 is fixed to the quilts 3 and 4 manually, at high cost, also because it requires additional operations for positioning and trimming the cloths or quilts.
SUMMARY OF THE INVENTION
The aim of the present invention is to provide a machine which allows to apply a peripheral band while the cloths are being cut and a border is being applied thereto.
Within this aim, an object of the present invention is to provide a machine which can be combined with an apparatus for forming a quilt constituted by one or more sheets unwound continuously from rolls.
This and other objects are achieved with a machine whose characteristics are defined in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the present invention will become better apparent from the following description of a preferred embodiment, illustrated only by way of non-limitative example in the accompanying drawings, wherein the invention has been applied to an apparatus disclosed in U.S. Pat. No. 5,913,277 by the same Applicant, which is highly effective in the manufacture of quilts for covering spring mattresses. In the drawings:
FIGS. 1-3 show the constructional structure of a prior art mattress;
FIG. 4 is a perspective view of the known apparatus and of the machine according to the invention associated therewith;
FIG. 5 is a side elevation view of the machine and of the apparatus of FIG. 4;
FIG. 6 is a sectional view of the lateral guides of the quilt;
FIG. 7 is a perspective view of the region of the apparatus where the machine for transversely stitching and cutting the quilt before cutting is arranged;
FIG. 8 is a view of the same region of FIG. 7 after cutting has been completed;
FIG. 9 is a perspective view of the means for transversely cutting and stitching the quilt;
FIG. 10 is a schematic view of a unit for cutting the transverse band.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 4 and 5, an apparatus according to U.S. Pat. No. 5,913,277 is disclosed comprising a framework, generally designated by the reference numeral 14 , which is composed of four vertical columns 15 , 16 , 17 and 18 arranged at the corners of a rectangle. The columns 15 , 16 and 17 , 18 are connected, at the top, by a pair of longitudinal beams 19 , 20 , while two additional transverse beams 21 and 22 connect one another the tops of the columns 15 , 16 and 17 , 18 .
Two longitudinal members 23 and 24 lie between the transverse beams 21 and 22 , are parallel to each other and to the beams 19 and 20 and constitute the track for the sliding of a carriage 25 that supports one or more sewing machines.
The carriage 25 is composed of a double pair of horizontal and parallel beams 26 and 27 which lie above and below the plane of arrangement of the cloth P to be quilted and have opposite ends which are rigidly connected to each other. The carriage 25 is suspended from a pair of shoulders 28 and 29 which rest on the track 23 , 24 by means of rollers 30 .
The carriage 25 , is movable along the track 23 and 24 in the direction X, actuated by means of an appropriate and conventional motor drive not shown in the drawings.
The heads for moving the needle of two sewing machines 31 are mounted on the pair of upper beams 26 and the corresponding hook assembly is mounted on the pair of lower beams 27 . It is also possible to provide a different number of sewing machines. In a known manner, by means of an additional motor drive, the sewing machines 31 are actuated in the direction Y, which is perpendicular to the direction X, so that by actuating the carriage 25 and the sewing machines 31 it is possible to trace the intended paths on the quilt.
Two guides 32 and 33 lie between the pair of upper beams 26 and the pair of lower beams 27 of the carriage 25 and are adapted to guide the lateral edges of the cloth P to be quilted. As shown in FIG. 6, each guide is composed of a U-shaped beam 34 which is longitudinal (i.e., lies in the direction X) and whose opposite ends are fixed on supports 35 , 36 located at the columns 15 , 17 and 16 , 18 , respectively. The beams 34 define supporting surfaces on which profiles 37 provided with a C-shaped cross-section and open onto each other are arranged. The C-shaped cross-section of the guide 32 lies opposite the C-shaped cross-section of the guide 33 .
Each profile 37 is movable between the outer vertical wing 38 and the inner vertical wing 39 of the beam 34 by means of pneumatic jacks 40 whose cylinders are flanged to the outer wing 38 of the beam 34 and whose stem is rigidly coupled to the profile 37 .
The jacks 40 that relate to the guide 32 are actuated in opposition to the jacks of the guide 33 , so that the profiles 37 of the guides are simultaneously moved towards and away from each other with respect to the longitudinal central plane of the apparatus.
The reference numeral 41 designates additional pneumatic jacks whose cylinders are mounted vertically above the profiles 37 . A bar 42 is coupled to the stems of the jacks 41 and extends inside the profile 37 . The bar 42 constitutes the movable jaw of a clamp which is designed to engage the longitudinal edge of the cloth to be quilted and to clamp it against the fixed jaw, which is constituted by the lower wing 37 a of the profile 37 that rests on the beam 34 .
In the illustrated example, the cloth P to be quilted is produced by superimposing a set of three sheets T 1 , T 2 , T 3 which, in a manner which is known and therefore not described in detail, are taken from respective rolls B 1 , B 2 , B 3 supported by a framework 43 . The number of sheets and their thickness can of course be any according to requirements.
The sheets T 1 , T 2 , T 3 unrolled from the rolls B 1 , B 2 , B 3 are joined between a pair of superimposed bars 44 and 45 which lie transversely to the direction X on the support 35 and are inserted in the guides 32 and 33 between the bars 42 and the wings 37 a of the profiles 37 .
The upper bar 44 is movable vertically with respect to the lower bar 45 by means of pneumatic jacks (not shown), so as to provide a transverse clamp which is adapted to transversely lock the cloth P to be quilted upstream of the guides 32 , 33 .
It is evident that the longitudinal clamps 37 a, 42 and the transverse clamp 44 , 45 delimit on three sides the quilting region, which is delimited on the fourth side by a pair of traction rollers 46 , 47 located at the output of the guides 32 and 33 . The rollers 46 , 47 , by means of respective motors, are actuated so as to rotate in opposite directions, so as to pull in the direction X the cloth P inserted between them.
Between the outlet of the guides 32 , 33 and the traction rollers 46 , 47 there are two laterally arranged stitching and cutting devices 48 and 49 , each of which comprises a sewing machine and a cutter in order to join, with stitch lines at the lateral edges of the quilted cloth, two respective longitudinal strips 10 a and in order to cut the borders of the cloth or quilt that lie outside the stitch lines.
The longitudinal strips 10 a are made of fabric or the like and are taken from respective rollers 10 b rotatably supported on brackets 10 c (see FIG. 5) which are fixed to the support 36 below the devices 48 and 49 . The sewing machines of the devices 48 , 49 have a double needle, so as to allow to fix the longitudinal strips 10 a to the cloth or quilt P with two stitch lines, as shown by 8 and 9 in FIG. 2, and provide flaps 11 which lie inside the lateral edges of the quilt. The cutters of the devices 48 and 49 are arranged downstream of the needles of the respective sewing machines, and each one is constituted for example by a rotating blade (not shown in the drawings but known in the art), which cuts the lateral edges of the quilt outside the longitudinal stitch lines 8 and 9 , forming two strips of waste P 1 , P 2 .
The stitching and cutting devices 48 and 49 are an integral part of the machine, which according to the invention performs the transverse cutting of the cloth or quilt P, stitches the edges upstream and downstream of the provided cut, and applies two additional strips 10 d (which lie transversely to the strips 10 a ), with which the edges upstream and downstream of the cut are provided.
As shown in FIGS. 7, 8 and 9 , the machine is generally designated by the reference numeral 50 and comprises a finishing unit 50 a composed of a box-like carriage 51 which, by means of four free wheels 52 , slides on a pair of parallel rails 53 whose opposite ends are fixed to side walls 54 , 55 (FIG. 4) of the framework of the machine 50 . A sewing machine 56 of the type with four needles 57 is fitted on the carriage 51 and can therefore produce four parallel stitch lines.
The sewing machine 56 is moved in the direction Y, which lies transversely to the direction X, by means of a movement system which comprises a chain 58 having a portion which is fixed to the carriage 51 and being closed in a loop on a pair of sprockets 59 , 60 which are fitted in a cantilever fashion on the sides 54 , 55 . The sprocket 59 is free, while the other sprocket 60 receives its motion from a gearmotor 61 which is flanged to the side 54 . The gearmotor 61 is controlled by a pair of stroke limit switches 62 and 63 which determine the points of inversion of the back-and-forth strokes. Two arms 64 cantilever out in front of the carriage 51 (FIG. 9) in order to rotatably support a roll 65 of a band 10 e which, cut longitudinally in half, provides the two strips 10 d which, at the output of the machine 50 , will be associated with the front and rear transverse edges of the finished quilt. The four transverse stitch lines are formed only during the outgoing stroke of the sewing machine 56 while the quilt is cut in the region between one pair of sewing lines and the adjacent one.
In order to produce the separation cut, there is a rotating circular blade 66 which is rotatably supported in the carriage 51 .
The rotating blade 66 is actuated by an electric motor being accommodated in the carriage 51 or, by means of an appropriate transmission, by the same motor that drives the sewing machine 56 .
The rotating blade 66 protrudes, with an upper sector, from the upper face of the carriage 51 through a slot formed in the latter.
A unit, generally designated by the reference numeral 67 in FIGS. 4, 5 , 7 , 8 and 9 , is further fixed on the sewing machine 56 ; said unit, as will become apparent hereinafter, is designed to cut the transverse band 10 e after it has been joined to the quilt P.
As shown more clearly in FIG. 10, the unit 67 comprises a frame which is composed of a post 68 which is rigidly coupled to the body of the sewing machine 56 and on which a sleeve 69 is slideable.
Another sleeve 70 is rigidly coupled to the sleeve 69 , is perpendicular thereto, and a first arm 71 is guided therein. A second arm 72 and an L-shaped element 73 for coupling the stem 74 of a jack, whose cylinder 75 is fixed to the sleeve 70 , are rigidly coupled to the end of the arm 71 .
The axis of the jack 74 , 75 is parallel to the axis of the sleeve 70 , so that by activating the jack it is possible to move the second arm 72 towards or away from the sewing machine 56 .
The second arm 72 is substantially normal to the first arm 71 , and a cutter 76 is supported at its lower end; said cutter is composed of an electric motor 77 which drives a rotating blade 78 below which there is a feeler 79 which is designed to collect the two strips 10 d that slide on the sliding surface 83 of the sewing machine 56 and to raise them against the blade 78 in order to produce cutting and thus separate them from the remaining band 10 e, which has not yet been cut in half by the blade 66 .
The stem 80 of a jack is further rigidly coupled to the sleeve 69 and its cylinder 81 is fixed to the top of the post 68 . Accordingly, by actuating both jacks 74 , 75 and 80 , 81 , the cutter 76 can perform perpendicular movements which allow to position it with respect to the sewing machine 56 . In particular, by moving the cutter 76 towards the sewing machine 56 the feeler 79 can engage in a slot 82 of the quilt sliding surface 83 which is located behind the blade 66 , so as to facilitate the insertion of the strips 10 d between the feeler and the blade 78 .
The operation of the described machine 50 and apparatus 14 is as follows.
Assume that the apparatus 14 is in an operating condition such as the one shown in FIGS. 4 and 5, in which the cloth or quilt P is locked upstream between the bar 44 and the beam 45 and downstream between the rollers 46 and 47 , while the lateral edges of the cloth are locked in the guides 32 , 33 by the bars 42 . In practice, the lateral guides 32 , 33 , the bar 44 and the beam 45 and the rollers 46 , 47 form a frame which keeps the cloth or quilt P stretched both transversely and longitudinally.
Assume also that the sewing machine 56 is in the lateral position shown in FIG. 7, with the cutter 76 in the inactive position, spaced from the sewing machine 56 .
With the cloth P in this condition, quilting is performed by moving the carriage 25 in the direction X and the sewing machines 31 in the direction Y.
As quilting proceeds, the machine 50 produces the four transverse stitch lines and transversely cuts the quilt downstream of the rollers 46 and 47 .
Due to the transverse stitching of the cloth or quilt P, the band 10 e is applied under said quilt and, by simultaneously performing the cutting operation by means of the blade 66 , is divided into two transverse strips 10 d upstream and downstream of the cut. When the carriage 51 has crossed the quilt, thus moving from the position of FIG. 7 to the position of FIG. 8, the two stitch lines upstream of the cut close the front edge of the quilt P which is locked peripherally between the lateral bars 42 and the wings 37 a, the bar 44 and the beam 45 and the rollers 46 and 47 , while the two stitch lines located downstream of the cut close the rear edge of the previously quilted quilt, which is now designated by the reference letter M in FIG. 8 .
At this point, by actuating the jacks 74 , 75 and 80 , 81 , the cutter 76 is made to approach so that the feeler 79 enters the slot 83 below the strips 10 d that the blade 66 has already formed by cutting the band 10 e in half. By causing the advancement of the cutter 76 under the body of the sewing machine 56 , the strips 10 d are cut. Then the jacks 74 , 75 and 80 , 81 are actuated so as to disengage the feeler 79 from the slot 82 and move the cutter 76 into the inactive position.
Once the quilting of the stretched cloth P has been completed, the two longitudinal bars 42 and the transverse bar 44 are raised and, by releasing the lateral edges and the upstream edge of the quilt, allow the rollers 46 , 47 to unroll from the rolls B 1 , B 1 , B 3 new portions of sheets T 1 , T 2 and T 3 and form a new quilt P.
It should be noted that during unrolling, the two devices 48 and 49 sew the lateral edges of the quilt that leaves the guides 32 , 33 and cut the strips of waste P 1 , P 2 . In order to remove the strips of waste P 1 , P 2 (see FIGS. 4 and 5) a transfer roller 84 and two smaller rollers 85 and 86 are provided being actuated so as to rotate in opposite directions; the waste is guided between said smaller rollers. The actuation of the smaller rollers 85 and 86 can be derived from the actuation of the traction rollers 46 , 47 .
Once the rear edge of the quilted cloth, which was located below the bar 44 , has arrived at the stitch line of the sewing machine 56 , the rollers 46 , 47 are stopped and the jacks 41 that lower the bars 42 and the jacks that lower the bars 44 are actuated sequentially, locking the lateral and rear edges. Then, by actuating the jacks 40 , the lateral edges of the quilt P are spaced so as to subject the quilt to transverse traction, while longitudinal traction is determined by continuing the rotation of the rollers 46 , 47 after the bar 44 has transversely locked the cloth P against the beam 45 .
At this point, quilting is performed and the steps of the process are repeated in the manner described above.
It is evident that the described invention fully achieves the intended aim and objects. In particular, it is noted that the machine allows to automate the application of the transverse strips 10 d and longitudinal strips 10 a, thus providing a considerable cost saving.
The disclosures in Italian Patent Application No. BO2000A000033 from which this application claims priority are incorporated herein by reference.
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A cloth cutting and border applying machine for manufacturing mattresses starting from a roll wound sheet, comprising a framework, a cloth moving device, two sewing machines arranged upstream of the moving device to form longitudinal stitch lines for stitching a strip supported on a roll support along lateral edges of the cloth, a cloth finishing assembly arranged downstream of the moving device and having a sewing machine with at least two needles for providing parallel transverse stitch lines and mounted on a carriage slideable on guides to join a band to the cloth along transverse stitch lines, a cutter for cutting between the parallel stitch lines to separate a cloth portion lying downstream of the assembly from one lying upstream, a carriage actuator, and a band cutter to cut the band and the cloth transversely between the two stitch lines.
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FIELD OF THE INVENTION
[0001] The present invention relates to a process for removing carbon dioxide from a process gas, for example fumes of a reformer or stack emissions of a fossil fuel plant. The invention relates to a process based on temperature-swing adsorption of carbon dioxide on a solid adsorbent.
PRIOR ART
[0002] Removing carbon dioxide from the fumes of a combustion process or other oxidative process is desirable for environmental concerns and/or for use of carbon dioxide as a raw material of another industrial process. In the field of ammonia and methanol synthesis, the reforming of methane or other light hydrocarbons such as natural gas, LPG (liquefied petroleum gas), naphtha, etc. is a common source for ammonia or methanol make-up synthesis gas, and there is a need to remove at least part of the carbon dioxide contained in the fumes of the reforming process.
[0003] The so-called “wet” processes involve scrubbing of the process gas with a CO2-selective solution. However they suffer the drawbacks of degradation of the scrubbing solution, for example due to oxidation or reaction with sulphur and nitric oxides leading to salts or harmful compounds. The scrubbing solution needs to be replaced thus involving costs and/or maintenance is required to remove salts or harmful compounds.
[0004] Another known processes make use of a solid adsorbent and operate according to principles of pressure swing adsorption (PSA) or temperature swing adsorption (TSA). The capture and subsequent release of the CO2 are governed by a change of pressure in a PSA system and by a change of temperature in a TSA system. More in detail, the amount of CO2 that can be retained by the adsorbent is a function of pressure or temperature. Hence the captured CO2 can be removed at a later stage by an appropriate change of pressure or temperature. Removing adsorbate (such as CO2) from a solid adsorbent is called regeneration of the adsorbent. In a TSA system, adsorption takes place usually at a lower temperature and regeneration takes place at a higher temperature. This means that the adsorbent material of a TSA system needs a heat source for regeneration and usually must be cooled after regeneration.
[0005] EP-A-1249264 discloses a process for the recovery of carbon dioxide from waste gas, comprising the steps of: letting the waste gas flow permeate into a semi-permeable material such as TSA molecular sieve or activated carbon, in such a way to adsorb at least a relevant portion of the carbon dioxide in the waste gas, and to obtain a permeated gas flow with low carbon dioxide content, and desorbing the carbon dioxide from said semi-permeable material, thus obtaining a gaseous flow comprising high concentrated carbon dioxide.
[0006] The present invention is aimed to improve the known technique of CO 2 removal with TSA adsorption. In particular, the TSA process requires alternate phases of heating and cooling the solid adsorbent in order to carry out the adsorption and regeneration (desorption), respectively. This can be made with direct heat exchange or indirect heat exchange.
[0007] A direct heat exchange involves that the solid adsorbent is directly contacted with a heating medium or a cooling, medium. Direct heating has the advantage that the heating medium provides a carrier for the desorbed carbon dioxide, but the same heating medium dilutes the carbon dioxide. Hence there is the need of an additional system to remove CO2 from the heating medium, especially if pure or substantially pure CO2 is desired.
[0008] Indirect heat exchange involves that the solid adsorbent and heating/cooling medium are not in contact and remain separate by heat exchange surfaces, for example the heating/cooling medium is flowing in a tube bundle immersed in the bed of adsorbent. This method does not dilute the CO2 but, has a drawback in that, during the heating phase, it does not provide a carrier to sweep out the CO2 from the bed. In some cases an additional purge flow is passed through the bed, in order to remove the desorbed carbon dioxide, but this causes the same disadvantages of the direct heating process.
SUMMARY OF THE INVENTION
[0009] The invention provides a process for removing carbon dioxide from a process gas and with a solid adsorbent and temperature swing adsorption, by means of at least two beds or groups of beds of solid adsorbent. The process alternates two modes of operation. In a first mode, the first bed(s) are regenerated by indirect heat exchange with the incoming process gas, and then the CO2 is captured in the (previously regenerated) second bed(s). Once the second bed(s) are saturated with CO2, the process switches to a second mode, now regenerating the second bed(s) by the indirect heat exchange with the incoming hot process gas, and then capturing the CO2 in the first beds. The bed adsorbing CO2 can be continuously cooled during the adsorption phase, in order to remove the adsorption heat, increasing the amount of CO2 being adsorbed.
[0010] In a greater detail, the invention discloses a process where:
carbon dioxide removal from said process gas takes place alternately in at least a first bed of said solid adsorbent and at least a second bed of said solid adsorbent, the first bed being regenerated while carbon dioxide contained in the incoming process gas is adsorbed in the second bed and vice-versa, so that the adsorbent of first bed and of the second bed is alternately loaded with carbon dioxide, the incoming process gas is cooled by an indirect heat exchange with the CO2-loaded adsorbent material of either the first bed or the second bed, thus heating and regenerating said CO2-loaded adsorbent, and carbon dioxide is then removed from the process gas while contacting said process gas with adsorbent material of the other bed.
[0014] In a particularly preferred embodiment, the bed(s) of CO2-loaded adsorbent are kept in a closed environment during the regeneration step. As a consequence, the heating of the CO2-loaded adsorbent take place in a closed volume (iso-volumic condition), which means that pressure inside said closed volume increases while the carbon dioxide is progressively released. This preferred embodiment has the notable advantage that the carbon dioxide, or a carbon dioxide-containing gas, is made available under pressure and this pressure helps to evacuate the carbon dioxide without the need of a carrier or the need of a compressor.
[0015] More preferably, the heating of the adsorbent is maintained while the CO2 released by the adsorbent leaves said closed environment, in order to keep a substantially constant temperature of said closed environment while the pressure is being reduced.
[0016] According to preferred embodiments, the adsorbent beds are hosted in the shell side of respective vessels. A shell side of a vessel can form said closed environment, upon the closure of the related connections with the outside (e.g. valves). More preferably, each vessel includes heat exchange bodies such as tubes or plates immersed in the bed. Said heat exchange bodies define a path separated from the outside adsorbent bed. The indirect heat exchange between the process gas and CO2-loaded adsorbent is effected by feeding the gas to heat exchange bodies, for example inside tubes or hollow plates.
[0017] While regeneration of a bed is in progress, any connection of the shell side is closed, in such a way that the shell side defines a closed volume and released carbon dioxide accumulates under pressure. Once the regeneration is complete, a discharge line can be opened and carbon dioxide in pressure leaves the shell side of said bed, while the hot process gas on the tube or plate side continues to flow to maintain the temperature of the adsorbent while the pressure is dropping. Accordingly, heating of the adsorbent is maintained while the released CO2 is being removed from the shell side of the vessel, in order to keep a stable temperature in the shell side, while the pressure is being reduced due to CO2 leaving the vessel.
[0018] Optionally, the process gas is subject to a second cooling process, after said indirect heat exchange with the CO2-loaded adsorbent, and before contact with the previously regenerated adsorbent for CO2 removal. This second and additional cooling may be effected with cooling water or air and typically serves to cool the process gas to ambient temperature or slightly above ambient temperature, which is suitable for CO2 removal. Preferably said temperature is less than 50° C. and more preferably 20-40° C. Condensed water may also be removed during this second cooling.
[0019] Once a bed is regenerated, the bed is at a high temperature, for example 200° C., and is preferably cooled before it can receive the CO2-containing process gas. This cooling of the regenerated bed can be made by feeding a cooling medium in the aforesaid heat exchange bodies. Even more preferably, said cooling medium is a stream of de-carbonated gas previously obtained by means of the CO2 removal in the other bed. During CO2 adsorption the adsorbing bed can be indirectly cooled to remove the adsorption heat.
[0020] It shall be understood that any references to a bed or a vessel may equally apply to a group or array of beds or vessels, for example in parallel. The term of CO2-loaded adsorbent is used to denote the adsorbent which has captured some CO2 or is saturated with CO2. The term decarbonated gas denotes the process gas after CO2 capture and which has a lower CO2 content than the incoming gas; in some embodiments and according to the degree of removal of the carbon dioxide, said decarbonated gas is substantially a CO2-free gas.
[0021] The incoming process gas is generally a hot gas and may come from a combustion or oxidation process, including fumes of a reformer, waste gas of a furnace, fumes of a power plant, etc. Usually the temperature of the gas current available to the CO2 removal process of the invention is at least 80° C. and preferably in the range 100-300° C., more preferably 150-250° C. Waste gas or fumes at a higher temperature are normally cooled during previous steps like heat recovery, filtering, removal of pollutants, etc. The term process gas in this description may refer to combustion gases which are processed in order to remove carbon dioxide. Said process gas can be for example the flue gases from the stack of a primary reformer in an ammonia or methanol production plant.
[0022] An object of the invention is also an equipment for carrying out the process. Said equipment preferably comprises at least a first vessel for carbon dioxide removal, containing a first bed of solid adsorbent material and first heat exchange bodies immersed in said first bed, at least a second vessel for carbon dioxide removal, containing a second bed of solid adsorbent material and second heat exchange bodies immersed in said second bed. The heat exchange bodies define an inside path for a heat exchange medium, and each of said vessel has a shell side and a heat-exchanger side, so that a medium flowing in the shell side being in direct contact with the adsorbent material, and a medium in the heat-exchanger side being separated from the adsorbent material. The equipment also comprises means for selective direction of an incoming stream of a process gas containing carbon dioxide either:
according to a first path where the incoming process gas passes first in the heat-exchange side of the first vessel for regeneration of the adsorbent material in the first vessel, and afterwards in the shell side of the second vessel for CO2 removal, or according to a second path where the incoming process gas passes first in the heat-exchange side of the second vessel for regeneration of the adsorbent material in the second vessel, and afterwards in the shell side of the first vessel for CO2 removal.
[0025] The main advantages of the invention are that the process can run continuously, because regeneration of a first bed or a first group of beds can take place while, at the same time, the CO2 of the process gas is captured in a second bed or group of beds. Another advantage is the efficient exploitation of heat: the incoming hot process gas is the heat source for regeneration of saturated beds, while in some embodiments the cold, decarbonated gas leaving the adsorption process can be used to cool the bed after regeneration, and hence recover part of the heat of the bed. Yet another advantage, as stated before, is that released CO2 is available at a certain pressure and can be discharged without a carrier such as steam or purge gas. Moreover, CO2 is not diluted and available with high purity, which is a significant advantage whenever the CO2 is directed to a further use.
[0026] The advantages of the invention will be elucidated with the help of the following description of preferred and non-limiting embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a block diagram of a CO2 removal section according to a preferred embodiment of the invention.
[0028] FIGS. 2 and 3 disclose modes of operation of the equipment of FIG. 1 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0029] Referring to FIG. 1 , the main items of the CO2 removal section are a first vessel V 1 , a second vessel V 2 , a cooler C and a separator S. Vessels V 1 and V 2 contain beds B 1 and B 2 of adsorbent material suitable for removal of CO2 from a gas phase with a TSA process. Each of vessels V 1 , V 2 also contains a heat exchange tube bundle T 1 , T 2 immersed in the adsorbent bed.
[0030] Hence the vessels V 1 , V 2 have a tube side (inside tubes) and a shell side (inside the vessel and outside tubes). The shell side contains the adsorbent bed and the tube side defines a path for a heating or cooling medium. The shell side and tube side are not in communication inside the vessels.
[0031] Lines 11 , 12 are in communication with the tube side of the vessel V 1 (i.e. with the inside of tubes T 1 ), while lines 13 , 14 are in communication with the shell side. In a similar way, lines 21 , 22 are in communication with the tube side of the vessel V 2 , namely with inside of tubes T 2 , and lines 23 , 24 are in communication with the shell side of vessel V 2 .
[0032] A hot process gas containing CO2 is denoted as G. The incoming gas G can be directed either in the tube side of the first vessel V 1 via line 11 , or in the tube side of the second vessel V 2 via line 21 . The process gas flowing inside tubes T 1 or T 2 provides heat for regeneration of the respective adsorbent bed B 1 or B 2 . Regeneration follows the TSA principle, since the amount of CO2 adsorbed in bed depends on temperature. At the same time the process gas is cooled, for example from a typical inlet temperature of 150-200° C. to an intermediate temperature of 60-80° C.
[0033] Temperature of the process gas leaving the tubes of vessel V 1 (or V 2 ) is further lowered in the cooler C and condensed fluid, containing mainly water, W can be separated in the separator S. The process gas leaving the top of separator S, at around ambient temperature, enters the shell side of the other vessel V 2 (or, respectively, V 1 ) where it is contacted with the adsorbent bed for removal of CO2.
[0034] In other words, the CO2 is removed from the process gas in one bed, while the other bed is being regenerated with heat furnished by the same process gas. Hence the CO2 removal section has two modes of operation. The incoming gas G can be directed to line 11 or line 21 , which means to tube side of vessel V 1 or V 2 . Accordingly, after passage in one or another tube bundle, the process gas can reach the input line 15 of the cooler C via line 12 or via line 22 . The process gas leaving the head of separator S via line 17 can be directed to line 13 or 23 , hence to side shell of V 1 or V 2 . A number of valves (not shown) allow a selective direction of the flow.
[0035] The related two modes of operation are elucidated in FIGS. 2 and 3 where the thicker lines show the path of gas G during the treatment.
[0036] In FIG. 2 , the adsorbent bed B 1 of vessel V 1 is already saturated with CO2 and the adsorbent bed B 2 of vessel V 2 is ready to capture CO 2 , e.g. having been regenerated in a previous step. Hence, the incoming process gas G is directed via line 11 in the tube bundle T 1 , in order to regenerate the bed B 1 . The indirect heat exchange has the double advantage of heating the bed for regeneration, and cooling the process gas G to a lower temperature for contact with the bed B 2 .
[0037] As long as the hot process gas passes through tubes T 1 , carbon dioxide is released by the bed B 1 . In this stage, any connection with the shell side of vessel V 1 , such as lines 13 and 14 , is closed. Hence the CO2 is released in a closed volume and the pressure inside vessel V 1 increases. Once the regeneration of bed B 1 is complete, a CO2-rich gas is available in the shell side of V 1 at a certain pressure, for example 1.5 bars if starting pressure is 1 bar. Said CO2-rich gas may contain the released carbon dioxide plus some residual gas from a previous step of CO2 capture. Said pressure is the driving force for the recovery from the vessel; the line 14 can be opened to easily discharge said CO2-rich gas for a further use, the process gas continues to flow on the tube side until the pressure on the shell side has been completely released, in order to maintain the temperature on the shell side, otherwise the temperature would drop together with the pressure, on the process side, causing at least some of the CO2 to be re-adsorbed on the adsorbent.
[0038] The process gas G, still with the full content of CO 2 , leaves the tubes of vessel V 1 via line 12 and passes through the cooler C for a further cooling, preferably to ambient or near-ambient temperature (e.g. 30-40° C.). Line 18 denotes a cooling medium such as air or water, which does not come into contact the process gas. After a passage in separator S (line 16 ), the cool process gas now enters the shell side of vessel V 2 via line 23 . Here, the process gas is contacted with bed B 2 , the CO2 is adsorbed and decarbonated gas is obtained at line 24 .
[0039] Said decarbonated gas at line 24 can be used to cool the previously regenerated bed B 1 . In fact, the bed has a high temperature (e.g. 200° C.) after regeneration; use of the decarbonated gas as cooling medium is advantageous because it avoids the need of external cooling means such as air or water. Of course the temperature of decarbonated gas will also increase; in some cases, the availability of the decarbonated gas at a certain temperature may be an additional advantage, e.g. if said gas is directed to a further use.
[0040] Once the first bed B 1 is regenerated and/or the second bed B 2 is saturated, the CO2 removal section is switched to mode of FIG. 3 . In this mode the incoming gas G is directed via the line 21 inside tubes T 2 , i.e. in the tube side of vessel V 2 , and leaves said tubes via line 22 . Then the cooled gas passes through cooler C and separator S, and enters the shell side of vessel V 1 via line 13 for contact with the bed B 1 and CO2 removal. The decarbonated gas now exits at line 14 , while CO2 will be recoverable by means of line 24 .
[0041] It has to be understood that the figures show one vessel V 1 and one vessel V 2 but equivalent embodiments are possible with multiple vessels in parallel. Moreover, tube bundles T 1 and T 2 may be replaced with heat exchange plates or other heat exchange bodies arranged inside the vessels, provided they define a path for a heating or cooling medium isolated from the shell side.
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A process and equipment for removing carbon dioxide from a process gas (G), with a solid adsorbent and temperature swing adsorption, where the carbon dioxide is removed from process gas in either a first bed (B 1 ) or a second bed (B 2 ) of adsorbent, while the other bed is regenerated with heat furnished by the incoming hot process gas; the beds are contained in vessels (V 1, V 2 ) with heat exchange tubes or plates (T 1, T 2 ), so that the removal of CO2 takes place by contacting the process gas with the bed in the shell side, and regeneration of a bed takes place by passing the hot process gas inside the tubes.
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FIELD OF THE INVENTION
This invention relates to a conduit and continuos coiled tubing system for operating and deploying a powered device in a well.
BACKGROUND OF THE INVENTION
Coiled or continuous reel tubing has been used in the oil industry for the last 20-30 years. The fact that a continuous single tube is used provides several advantages when entering a live oil or gas well which could have anything up to 7,000 psi well head pressure. This means the well does not have to be killed, (i.e. a heavy fluid does not have to be pumped down the production tubing to control the oil or gas producing zone by the effect of its greater hydrostatic pressure). Continuous tubing has the advantage of also being able to pass through the tubing through which the oil and/or gas is being produced, not disturbing the tubing in place.
Since its introduction, the uses and applications for coiled tubing have grown immensely, and now, rather than just being used to circulate various fluids in a well bore, it is not uncommon for coiled tubing to be used for conveying various hydraulically powered tools and more recently electrically powered tools on its end into the well. This has resulted in conventional electrical wire-line logging cables or small hydraulic conduits being inserted into the inside of the reel of tubing so that these more sophisticated tools can be used and services can be performed.
A disadvantage which has resulted from this practice is the capstan effect of the smaller diameter wire-line or hydraulic tube tending to be pulled very tightly to the inner surface of the continuous reel of tubing. When considering the effect this has on the geometry, it will be appreciated that the wire-line or small hydraulic conductor will have a slightly smaller pitch circle diameter to that of the larger reeled tubing. The consequence of this is that for each complete 360 degrees of a turn the wire-line or hydraulic tube will be slightly shorter in length than the larger reeled tubing, so if this is added up over its total length of 12,000 ft (3657 m) or usually longer the difference in lengths could be as much as 200 ft (61 in).
This problem has been recognized due to the operational problems encountered. Either one end of the wire-line or hydraulic tube has been pulled out of its connection, or else the reeled tubing itself develops a low frequency wave form caused by the tension in the conduit inside the reeled tubing, which prevents the reeled tubing from being lowered any deeper into the well without the risk of damaging it.
Also the effect of increasing the weight of the conduit and for conduits having a certain length has resulted in the conduit being prone to stretching or creep when installed in the well in particular when it is considered that the conduit is intended to remain in position for a relatively long period of time for production of the well. The type of conduit for which stretching is a problem depends upon the weight per unit length of the conduit, the material of the conduit and the expected working life of the conduit. Stretching and slippage of the conduit is frequently a serious problem.
OBJECT OF THE INVENTION
It is an object of the present invention to provide a conduit, coiled tubing system which avoids this problem of stretching and overcomes the other disadvantages of present known systems mentioned above.
SUMMARY OF THE INVENTION
According to the invention there is provided a conduit and coiled tubing system for deployment in a well, in which the conduit is arranged internally of the coiled tubing which comprises a wall and an internal bore, and one end of the coiled tubing is attached to a powered device such as a motor or a drill which is to be installed in the well by a first attaching means arranged between the wall of the coiled tubing and the powered device, and wherein the conduit is connected at one end to a power supply at the surface and connected at the opposite end to the powered device and that fluid is provided in the annular space between the conduit and the internal wall of the tube and which provides an upwards buoyancy force to support at least in part the downward force due to the weight of the conduit.
Preferably the specific gravity of the fluid is greater than the average density of the conduit so that a buoyancy force is provided. The specific gravity of the fluid is preferably greater than 1 g/cm 3 .
The fluid in the annular space may be a concentrated salt solution such as calcium chloride solution, or alternatively an oil or water based gel. Such heavy fluids provide a buoyancy force on the conduit which supports the weight of the conduit along the whole of its length and this prevent the stretching or breaking of the conduit.
The conduit alternatively may comprise at least one buoyancy means. The buoyancy means may be arranged in-between the conduit and the internal wall of the coiled tubing and attached to the coiled tubing or the conduit.
The at least one buoyancy means may be a single buoy extending along a substantial part of the length of the conduit or alternatively arranged co-axially around the conduit.
Preferably the at least one buoyancy means is activatable between a "neutral" state in which the at least one buoyancy means does not act to support the weight of the conduit and an "active" state in which the at least one buoyancy means is buoyant and acts to support the weight of the conduit.
The at least one buoyancy means may be a plurality of buoys arranged in spaced relationship along the length of the conduit.
The at least one buoyancy means may be filled with a relatively lighter fluid such as air or another gas such as nitrogen and is preferably in the form of a flexible bladder which expands to fill at least a part of the concentric space between the conduit and the internal wall of the coiled tubing when said buoyancy means is filled with the relatively lighter fluid, or gas.
Alternatively the at least one buoyancy means is in the form of a rigid chamber or series of chambers and may also be in the form of a rigid cellular foam-like material.
The cellular foam-like material may fill the concentric space between the conduit and the internal wall of the coiled tubing and can provide an adhesive grip on the internal wall of the coiled tubing which aids the support of the conduit to the coiled tubing.
Alternatively the at least one buoyancy means is in the form of a longitudinal buoy arranged axially on the external wall of the conduit and having a width which corresponds in dimension to a section of the circumference of the conduit.
The at least one buoyancy means may be activated by the ingress of air into the at least one buoy.
The at least one buoyancy means engages the internal bore of the tube and prevents lateral movement of the conduit relative to the tube in the "active" state in one or both directions. The buoyancy means may be activated by means of a reagent.
The length of the conduit may exceed the length of the tube, the excess of conduit causing the conduit to form at least one curve or wave within the tube; the excess length of conduit may cause a curve to be formed in the conduit between each buoy.
The conduit may alternatively comprise a casing which comprises buoyancy means such a glass beads which provide the desired combination of low weight and sufficient strength to support long lengths of the cable. These beads may be included in the sheathing used to protect the transmission leads of the cable, being the electric wires, fibre optic lines, hydraulic lines. The glass beads will be such as to provide the desired pressure resistance as well as buoyancy and have a specific gravity of between 0.6 and 1.0 and a collapse pressure of between 2000 and 10000 psi and have a mesh size between 10 and 80 micrometers.
BRIEF DESCRIPTION OF THE DRAWINGS
The following is a more detailed description of some embodiments of the invention by way of example, reference being made to the accompanying drawings, in which:
FIG. 1 shows a side view of a coiled tubing reel showing a conduit lying inside the coiled tubing on its inner surface;
FIG. 1a is a longitudinal section which shows the conduit and coiled tubing system installed in a well;
FIG. 1b is a section which shows the attaching and connecting with a powered device;
FIG. 2 shows a cross section of a first embodiment of the conduit and coiled tubing system of the invention;
FIG. 3 shows a cross section of the system of FIG. 2 in the active state;
FIG. 4 shows a longitudinal cross section of the conduit and coiled tubing system of a further embodiment of the invention;
FIG. 5 shows a cross-section taken along the line A--A of FIG. 4, through a conduit having a coaxial cable set in the middle of the conduit;
FIG. 6 shows a cross-section taken along the line A--A of FIG. 4, through a conduit having a multi-conductor set in the middle of the conduit;
FIG. 7 shows a similar view to FIG. 5, in which the conduit is a fiber optic cable;
FIG. 8 shows a similar view to FIG. 5, in which the conduit is a steel tube for transmitting hydraulic pressure, or for acoustic transmissions;
FIG. 8A shows a similar view of FIG. 5 in which the conduit is a multi-use member;
FIG. 9 shows a cross section of a further embodiment of the system of the invention;
FIG. 10 shows the embodiment of FIG. 9 in the active state;
FIG. 11 shows a cross section of a further embodiment of the system of the invention;
FIG. 12 shows, in transverse section, the embodiment of FIG. 11 in the active state;
FIG. 13 shows a longitudinal cross section of a further embodiment of the system of the invention;
FIG. 14 shows in longitudinal section the embodiment of FIG. 13, in the active state;
FIG. 15 shows a longitudinal cross-sectional view of a further embodiment of the system of the invention;
FIG. 16 shows a longitudinal cross-section of the embodiment in FIG. 15 in the active state;
FIG. 17 is a cross section of a further embodiment of the buoyancy means; and
FIG. 18 is a longitudinal section of the embodiment of FIG. 17.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1, there is shown a side cross-sectional view of one wrap or turn of coiled tubing 1, with a conduit 2, lying on the inside wall 3 of the coiled tubing. A first dot-dash line shows the diameter center line of the coiled tubing 1 while a second dot-dash line shows the diameter center line of the conduit 2. It will be appreciated that because they have different center line diameters, their lengths per wrap will be slightly different with the coiled tubing being slightly longer. Multiplying this difference in length by the total number of wraps enables the difference in overall length to be determined, which can be in excess of 100 ft (30 in). The conduit is therefore preferably arranged so as to have a wavy profile to accommodate this.
Referring to FIGS. 1a and 1b the assembly of the conduit 2 and the coiled tubing 1 can be connected to a powered a device 7 which is deployed in a well. The conduit is arranged internally of the coiled tubing which comprises a wall and an internal bore, and one end of the coiled tubing 1 is attached to the powered device by a first attaching means 8 arranged between the wall of the coiled tubing 1 and the powered device 7. The powered device 7 may be a pump or a drill or other down-hole powered machine.
In FIGS. 4 to 8 several examples of the conduit function are shown; viz., an electrical signal via a coaxial cable 11, an electrical signal/electrical power via a multi-conductor cable 12, a fiber optics data transmission 13, a hydraulic conduit 14 or a combination of any of the above in a multi-conductor conduit 15 (FIG. 8A). In this last example two multi-conductor conduit comprises two hydraulic lines 16, an electrical line 17 and a fibre optic line 18. The signal line inside the conduit could also have a wavy profile, which could be important if the signal line is fiber optic.
The conduit 2 is connected at one end (the upper end in the installed position shown in FIG. 1a) to a power supply at the surface and connected at the opposite end to the powered device 7 by a first connection means 9 which is located within the wall of the coiled tubing 1 and within the first attaching means 8 so that the conduit 2 is prevented from contact with the outside of the coiled tubing 1 at all times.
The conduit may be pre-installed inside the coiled tubing and attached to the powered tool at the surface and the system lowered down the well together to the desired location. Alternatively the conduit and the powered device 7 may be lowered to the desired location first and then subsequently the conduit 2 is lowered and connected to the powered device 7 by means of a remote auto-locking mechanism 20 as shown in FIG. 1b. The conduit is effectively "stabbed" into the auto-locking mechanism 20 by permitting the conduit to drop into it and the auto-locking mechanism which permits the end of the conduit to engage it and then locks it in position. The auto-locking mechanism 20 may comprise a spring biased over center arrangement 22 which locks the end of the conduit after it is pushed in to it to a certain pre-defined extent. The connection means 9 of the powered device 7 preferably includes guides 21 to ensure that the end of the conduit is guided into the auto-locking mechanism.
The auto-locking mechanism will preferably included a dual auto-locking means so that both the transmission line of the conduit , for example the electric cable, can be connected automatically to provide the required electrical contact and also and separately the sheathing of the conduit is locked automatically to a corresponding mechanical gripping means.
Referring to FIGS. 4 to 8 a fluid is provided in the annular space 6 between the conduit and the internal wall 3 of the tube. In this embodiment the fluid is a concentrated solution of calcium chloride which is made using 22 lbs of calcium chloride (94%-97%) pure, mixed together with 34 gallons of water which makes one US barrel of the required calcium chloride solution. The solution has a specific gravity of 1.439. The fluid is preferably pumped in after the conduit has been installed in the tube and one end sealed but the fluid may be pumped simultaneously with the conduit and the ends sealed when installation is complete.
It will be appreciated that alternative fluids may be used which have a sufficiently high density to provide the desired buoyancy force on the conduit. Water based gels may be used in which the base fluid is water and the gelling agent is a water soluble polymer such as guar gum. This can produce a significantly viscous gel which can be used to support weighting agents such as barite or hermatite or sand, so the final specific gravity of the gel can be made as high as 2.0 specific gravity. Polymeric cross liking agent scan be used to make the gel last for a sufficiently long time to last for the life of the tube and conduit system.
Also oil-based gels may be used, formed by adding gelling agents to oil based fluids such as aluminium salts of organic acids to raise the viscosity of hydrocarbon fluids. Again similar weighting agents can be used to get the specific gravity as high as 2.0. Cross linking agents can be used in these gels also to improve the durability.
An example of a suitably dense fluid is Fluorinert (a trade mark of the 3M company), which has a specific gravity of 2.0 and which is a dieletrically stable at high operating temperatures.
In FIGS. 2, 3 and 9 to 16 various embodiments of the conduit and coiled tubing system of the invention are shown in which the conduit 2 is installed internally of the coiled tubing 1 which comprises an internal bore, wherein the conduit and coiled tubing system comprises at least one buoyancy means 5 arranged in-between the conduit and the internal wall of the coiled tubing. The at least one buoyancy means 5 is attached securely to the conduit 2. This may be by means of a suitable adhesive or by grip means arranged concentrically around the conduit, not shown.
In one embodiment of the conduit and coiled tubing system shown in FIGS. 15 and 16 the at least one buoyancy means 5c is a single buoy extending along a substantial part of the length of the conduit. In the embodiment shown in FIGS. 11 and 12 the at least one buoyancy 5a means is arranged co-axially around the conduit.
The at least one buoyancy means 5, 5a, 5b, 5c is activatable between a "neutral" state in which the at least one buoyancy means 5, 5a, 5b, 5c does not act to support the weight of the conduit which is shown in FIGS. 9, 11 and 13 and an "active" state in which the at least one buoyancy means 5, 5a, 5b, 5c is buoyant and acts to support the weight of the conduit 2, as shown in FIGS. 10, 12, and 14.
In a further embodiment of the conduit and coiled tubing system according to the invention the at least one buoyancy means 5b is a plurality of buoys arranged in spaced relationship along the length of the conduit. The buoys 5b are spaced corresponding to the waves formed in the conduit to give it a slightly greater length than the coiled tubing.
The activation of the buoyancy means 5, 5a, 5b, 5c takes place either immediately after installation of the conduit within the coiled tubing or alternatively when the conduit and coiled tubing system is first deployed in a well so that it is essential vertical and the weight of the conduit is required to be supported to prevent stretching or breakage. In order to activate the system the buoyancy means 5, 5a, 5b, 5c are filled with a relatively light fluid such as air or another gas such as nitrogen.
The buoyancy means 5, 5a, 5b, 5c is in the form of a flexible bladder which expands to fill at least a part of the concentric space 6 between the conduit 2 and the internal wall 3 of the coiled tubing when said buoyancy means is filled with the relatively lighter liquid, or gas. Preferably the buoyancy means is activated by the ingress of air into the at least one buoy.
The buoyancy means 5, 5a, 5b, 5c expands to fill annular space 6 and this volume of the gas provides buoyancy to the conduit to support its weight. The buoyancy means 5, 5a, 5b, 5c will also engage the internal wall of the coiled tubing 2 which will also resists the downward forces acting on the conduit and serve to reduce the effect of the downward weight of the conduit. It will be appreciated that although the buoyancy means 5, 5a, 5b, 5c are referred to as such it is not essential that they provide sufficient buoyancy to effectively float the conduit in the coiled tubing. They may merely assist in supporting some of the weight of the conduit 2. The object of the invention is to reduce the effect of stretching and this can be achieved by just reducing the downward force on the conduit by a certain critical amount. This extent of the required buoyancy effect of the buoyancy means will therefore depend upon a number of other factors relating to the type and function of the conduit itself. The conduit may just need a little support to reduce the effect of its weight slightly, or alternatively the conduit may need to be supported to the extent of all or nearly all of its weight. Or the extent of the support required may be anywhere in between these two extremes.
Rather than being entirely concentric the buoyancy means 5 in FIGS. 9 and 10 is in the form of a longitudinal buoy arranged axially on the external wall of the conduit and having a width which corresponds in dimension to a section of the circumference of the conduit.
With reference to FIG. 2 and 3, there is shown a buoyancy means 5d which is firmly attached to the conduit 2 inside the coiled tubing 1. The buoyancy means 5c has a plurality of interconnected chambers or cells which are affixed to and contact the outer surface of the conduit, buoying the conduit 2 reduce the down ward force of its weight in use. The buoy 5d may also be connected to the inside surface 3 of the coiled tubing. This makes use of the coiled tubing 1 to carry the weight of the conduit 2 until the next buoying apparatus 20, some distance further along the coiled tubing in the case that the buoyancy means is separate buoys. It will be appreciated that because the conduit 2 does not have to support its entire length when hung vertically in an oil well, its dimensions and weight may be significantly reduced. It will also be appreciated that because the conduit 2 is buoyed to the coiled tubing 1, no movement of the conduit is possible and the conduit remains in the same position regardless of pump rate and gravity effect. This also prevents any "bird nesting" or bunching at the extreme end of the coiled tube string which is common with existing wire-line installation and which causes cables to be pulled away from an electrical socket at the surface, which may cause the cable to crimp, resulting in a short circuit and disable the cable. In addition fibre optics may also be exploited, as the conduit is buoyed to the coiled tubing, and it has a built-in slack due to its wavy form, both in the fiber optic cable inside its conduit, and in addition to the conduit itself having a wavy form, so that the fiber optic cable is not subjected to any stretching whatsoever.
So that the conduit 2 may be installed inside the coiled tubing 1 the buoyancy means 5, 5a, 5b, 5c, 5d must be retained close to the conduit surface 4, which is achieved by the buoyancy means being in an un-inflated state and/or by using a wrapping material. This may be made from any material which can be removed once the conduit 2 has been installed inside the coiled tubing 1. The conduit 2 might be installed at the time of manufacture, or installed some time after manufacture. It will be appreciated that if it is installed some time after manufacture it will have to withstand the effects of friction, because the conduit 2 might have to be installed by pumping it through the coiled tubing 1 which could be many thousands of feet long. It is necessary that the buoyancy means is therefore in its neutral state so that the conduit 2 may be installed in the coiled tubing 1.
In FIGS. 2 and 3 the conduit and coiled tubing system according to the invention comprise a buoyancy means in the form of a cellular foam-like material which provides an adhesive grip on the internal wall of the coiled tubing which aids the support of the conduit to the coiled tubing. The foam like material is of the expandable form which can be provided on the external 4 surface of the conduit 2 or alternatively on the internal wall of the coiled tubing, in the un-expanded state before installation of the conduit inside the coiled tubing. After installation the foam-like expandable material is activated to expand and fill the concentric space 6 between the conduit 2 and the coiled tubing 1. The foam-like expandable material may be any suitable material which can be activated to expand. Such materials are likely to be polymeric and activated by the application or a reagent which causes the expansion process and the reagent is pumped through the coiled tubing after the conduit has been installed. Alternatively the expandable material may be activated by temperature or by time in contact with air.
Referring now to the embodiment of FIGS. 17 and 18, the conduit 32 alternatively comprises a casing or sheathing 33 which comprises buoyancy means such a glass beads 35 which provide the desired combination of low weight and sufficient strength to support long lengths of the cable 32. These beads 35 may be included in the sheathing 33 used to protect the transmission leads 34 of the cable, being the electric wires, fibre optic lines, hydraulic lines. The glass beads 35 are uniformly arranged in the sheathing of the conduit and this is advantageously achieved by including the glass beads granular plastic feed before the extrusion process of the sheathing.
Such glass beads 35 are hollow spheroids with air inside which provides the low specific gravity and hence buoyancy effect as well as high strength. They are typically made by allowing small droplets of molten glass to fall from a height in a tower though air. The droplets cool as they fall and also form the required hollow spheroids.
The type of glass beads 35 can be chosen such as to provide the desired pressure resistance as well as buoyancy. Preferably the beads will have a specific gravity of between 0.6 and 1.0. It has been found that the ideal specific gravity is 0.7. The collapse pressure of the beads 35 is also an important property because at lower depths the sheathing may be subject to high pressures and this is therefore required to be between 2000 and 10000 psi. It has been found that the ideal collapse pressure of 6000 psi is sufficient for most applications. The size of the glass beads is also a factor which is also interdependent with the specific gravity and pressure difference but also has an effect on the strength properties of the sheathing which is an important consideration in the support of the weight of the conduit. The beads 35 may have a mesh size between 10 and 80 micrometers. It has been found however that the ideal mesh size is between 20 and 40 micrometers. It will be appreciated that the beads 35 need not be glass beads but may be made of any material provided these important properties are met.
Thus by means of these buoyancy means associated with the conduit buoyancy may be provided when a conventional fluid is used in the annular space 6 such as water or a dielectric oil having a specific gravity of 1 or less.
Alternatively the buoyancy means associated with the conduit could be used in combination with a heavy fluid in the annular space 6 so that a maximum buoyancy effect may be achieved.
Whatever the embodiment of the chosen buoyancy means of the invention the buoyancy means may engage the internal bore of the tube and prevents lateral movement of the conduit relative to the tube in the active state.
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A coil tube and conduit system for feeding into a well has the coiled tube form an annular space closed at its top and herein a relatively dense liquid while the conduit is provided with buoyancy means so that within that coiled tube the conduit can be buoyed up by the confining liquid and hence the weight of the conduit relieved.
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[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/545,903, filed on Feb. 20, 2004.
FIELD OF THE INVENTION
[0002] The present invention relates to the general field of spinal surgery and, more particularly, to a computerized or automated method for the accurate sizing and placement of pedicle screws in spinal surgery.
BACKGROUND OF THE INVENTION
[0003] Placement of screws into the human spine is a common surgical procedure to allow for a multitude of spinal surgeries to be performed. Screws are typically placed into the pedicles of individual vertebra in the lumbar and sacral spine. Given their biomechanical advantages over other modes of fixation, surgeons are expanding the areas of the spine in which pedicle screws are placed. However, adjacent to the spine are numerous vital structures and organs, in particular the cervical and thoracic spine regions, which have very low tolerance for surgically created injuries that may ultimately lead to significant morbidity and/or mortality. For this reason the majority of research focus on placement of pedicle screws is centered on improving accuracy to maintain a screw within a bony (intraosseous) environment.
[0004] Image guided systems are evolving which are increasingly user friendly to assist a surgeon in accurately placing a screw. The critical parameters for placing a pedicle screw into the human spine are diameter, length, trajectory and then actual placement of the screw. To date many of the image guidance systems allow for manual determination of these parameters to improve a surgeon's manual performance in screw placement. Up to the present time, no system is available which will automatically determine ideal pedicle screw diameter, length and trajectory for accurate placement of pedicle screws. The present invention provides this capability akin to a pilot who flies an airplane with computer controlled aviation capabilities, and allows for placement of pedicle screws using either an open or percutaneous technique.
[0005] Patent Application Publication No. US 2004/0240715 A1, published on Dec. 2, 2004, relates to methods and computer systems for determining the placement of pedicle screws in spinal surgery. It discloses a method wherein the minimum pedicle diameter is first established for determining the optimum screw trajectory and then the maximum screw diameter and length using the optimum trajectory for each pedicle. Two dimensional transverse slice data is stacked to form three dimensional data points to determine optimum trajectory by linear least squares solution to fit the data, requiring the solution to go through the overall minimum transverse pedicle widths. A disadvantage of this method is that it allows for eccentric trajectory determination, particularly for distorted pedicle anatomy, with consequent smaller maximum diameter and length screw determinations resulting in biomechanically inferior constructions. In contrast, the new and improved method of the present invention always places the trajectory concentrically through the pedicle by the determination of optimum trajectory by using the center point of the smallest cross sectional area (isthmus) and projecting with a computer a line normal to this circumscribed area in opposite directions, as described more particularly hereinafter. The new and improved methods of the present invention allow for maximum screw diameter and length determinations for intraosseous placement.
SUMMARY OF THE INVENTION
[0006] The present invention utilizes three dimensional images and a computer or similar device to generate a table providing the maximum allowable pedicle screw diameter and length, summary data on trajectory, and also generates a schematic diagram illustrating this data for individual vertebral pedicles. The numerical data can be utilized by the surgeon for actual intraosseous pedicle screw placement by one of the following methods: 1. Manual screw placement by the surgeon's preferred method; 2. A pedicle base circumference outline method combined with intraoperative fluoroscopy; 3. Automated screw placement; or 4. Any commercially available registration software (e.g., computed tomography/fluoroscopy, etc.) The present invention also allows for extraosseous or extrapedicular pedicle screw placement if a surgeon should so desire based on a trajectory beginning at the same starting point from the anterior cortex but angled tangentially any distance or angle to the surgeon's desired preference.
[0007] The invention also facilitates safe and reliable access to any vertebral body through a transpedicular or peripedicular approach, such as during a vertebroplasty, kyphoplasty or vertebral body biopsy.
[0008] Furthermore, the invention forms a novel research tool for developing smaller or larger diameter or custom sized pedicle screws throughout the spine.
[0009] One method of the present invention generally comprises the following steps:
1. A computed tomography scan (CT), magnetic resonance image (MRI), CT capable fluoroscopy or similar two dimensional imaging study of the spine area of interest may first be obtained. 2. A dimensionally true three dimensional computer image of the bony spine is generated from the CT, MRI or other studies, or in any other suitable manner. 3. The computer generated three dimensional individual vertebra are then hollowed out by a computer or other device similar to an eggshell transpedicular vertebral corpectomy to the specifications desired by the surgeon, e.g., thickness of cortical wall remaining in the vertebral body cortices or pedicle walls. The individual vertebra can be visualized as a structure which has been cored or hollowed out and the resulting remaining vertebral body is “electrified” or highlighted throughout its walls. 4. A computer then automatically determines the maximum allowable diameter screw to be placed by determining the narrowest diameter or smallest cross sectional area (isthmus) within any given pedicle based on surgeon pedicle cortical wall diameter preferences. 5. A computer then generates an elongated cylinder by starting at the center of the isthmus as a straight line which determines the ideal trajectory and extends in opposite directions e.g., perpendicular to the plane of the isthmus so that it is positioned concentrically as much as possible within the pedicle without touching the remaining “electrified” or highlighted cortex. This line is allowed to penetrate the dorsal or posterior pedicle cortex so that it can extend beyond the skin of a patient to any desired length. The line terminates inside the vertebral body to within a surgeon's predetermined distance from the predefined anterior inner cortical wall so that it cannot penetrate it. 6. A computer then builds the line concentrically in radial directions to a final maximum diameter which will not exceed the narrowest defined pedicle diameter based on surgeon preference pedicle cortical wall thickness. This concentric building grows into a visible cylinder which stops building when any point on its outer surface comes into “contact” with the “electrified” or highlighted inner cortical wall. This rule, however, does not apply to the posterior cortex adjacent to the exiting straight trajectory line generated from the isthmus. 7. A computer then determines the length of the screw by measuring the length of the cylinder starting at the predefined anterior inner cortex up to its intersection with the dorsal/posterior cortex. To facilitate the placement of screws in accordance with one of the automated methods described hereinafter, the cylinder may be extended beyond its intersection with the dorsal/posterior cortex. 8. A computer then provides a data summary table which displays the ideal pedicle screw diameter, length and trajectory for each individual vertebra pedicle and an idealized schematic drawing of same. 9. The tabulated data can then be utilized to determine the viability of using pedicle screws based on maximal pedicle screw diameter and length, and also for placement of screws by a surgeon's preferred method, such as one of the methods described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIGS. 1 a and 1 b are three dimensional computer images of the side and back, respectively, of the bony spine made from CT, MRI or other studies of the spine area of interest;
[0020] FIG. 2 illustrates three dimensional computer images of individual vertebra undergoing a manual eggshell corpectomy from the spine area shown in FIGS. 1 a and 1 b;
[0021] FIG. 3 is a computer image of a hollowed out individual vertebra showing the narrowest diameter or cross sectional area (isthmus) within the pedicle;
[0022] FIG. 4 is a computer image view of a hollowed out individual vertebra showing the generation of the straight line through the center of the isthmus and extending in opposite directions through the posterior pedicle cortex and toward the anterior inner cortex;
[0023] FIG. 5 is a schematic drawing showing the generation of the cylinder by building the line extending through the center of the isthmus concentrically in radial directions;
[0024] FIGS. 6 a and 6 b are schematic images of hollowed out individual vertebra that are of symmetrical and irregular shape, respectively;
[0025] FIGS. 7 a and 7 b are schematic views showing the isthmus of straight and curved pedicles, respectively;
[0026] FIG. 8 is a schematic view of a hollowed out vertebra showing the length of the cylinder for determining pedicle screw length;
[0027] FIG. 9 is a schematic side elevational view of the individual vertebra labeled by a surgeon for pedicle screw installation;
[0028] FIG. 10 a is a data summary table generated by a computer of maximum pedicle screw diameter and length, and also of the trajectory angle of the pedicle screw with respect to the sagittal and transverse planes;
[0029] FIG. 10 b is a schematic side view of a vertebra showing the sagittal plane and the nature of the trajectory angles in FIG. 10 a; and
[0030] FIG. 10 c is a schematic plan view of a vertebra showing the transverse plane and the nature of the trajectory angles in FIG. 10 a;
[0031] FIG. 10 d is a schematic rear view of a vertebra showing the coronal plane and the nature of the trajectory angles in FIG. 10 a;
[0032] FIG. 11 is a computer generated schematic view of the ideal pedicle screw placements as identified in the data summary table of FIG. 10 a in AP plane demonstrating coronal trajectory;
[0033] FIG. 12 is a table of maximum available screw size parameters corresponding to the data in the summary table of FIG. 10 a and pedicle base circumference outlines (coronal planes) and pedicle distance points A-B;
[0034] FIG. 13 is a computer generated schematic view of the screw placements as identified in the table of FIG. 12 ;
[0035] FIG. 14 a is a schematic side elevational view of a vertebra showing the isthmus and the pedicle base circumference;
[0036] FIG. 14 b is a schematic plan view of a vertebra showing the computer generated pedicle cylinder extending through the pedicle base circumference in the transverse and coronal planes;
[0037] FIGS. 14 c , 14 d and 14 e are plan views of vertebra in the lumbar, thoracic and cervical regions, respectively, showing the relationship between the isthmus and the pedicle base circumference in each vertebra;
[0038] FIGS. 14 f and 14 g are schematic rear elevational views of a vertebra showing the positioning of an awl for creating the pedicle screw pilot hole in the vertebra;
[0039] FIG. 14 h shows schematic and aligned plan and rear elevational views of a vertebra with a manually determined pedicle screw directional line extending through the center of the pedicle base circumference;
[0040] FIGS. 15 a, 15 c and 15 e show schematic rear elevational views of a vertebra in different orientations with a computer generated pedicle screw cylinder extending through the pedicle base circumference thereof;
[0041] FIGS. 15 b, 15 d and 15 f show schematic side elevational views of the vertebra illustrated in FIGS. 15 a, 15 c and 15 e, respectively;
[0042] FIG. 16 shows CT transaxial views through the center of pedicles T 1 , T 2 , T 4 and T 5 demonstrating pedicle morphology, isthmus and determination of pedicle pilot hole entry points correlating with intraoperative AP fluoroscopic images of each respective vertebra;
[0043] FIGS. 17 a and 17 b are side elevational views of different embodiments of an adjustable awl of the present invention;
[0044] FIG. 18 a is a schematic view of an intraoperative AP fluoroscopic image of individual vertebral and pedicle base circumferences;
[0045] FIG. 18 b is a schematic view of computer generated three dimensional images of vertebra with computer placed pedicle cylinders and pedicle base circumferences;
[0046] FIG. 18 c is a schematic view of the registered images of FIGS. 18 a and 18 b;
[0047] FIG. 19 a is a schematic side elevational view of a dual ring pedicle screw aligning apparatus constructed in accordance with the present invention;
[0048] FIG. 19 b is a front elevational view of the apparatus shown in FIG. 19 a;
[0049] FIGS. 19 c and 19 d are schematic plan views of a vertebra showing the use of the dual ring pedicle screw aligning apparatus in a percutaneous environment and an open surgical environment, respectively;
[0050] FIG. 20 is a front elevational view of a modified dual ring pedicle screw aligning apparatus;
[0051] FIGS. 21 a and 21 b are side and front elevational views of the end portion of a first embodiment of a drilling cannula member for the dual ring aligning apparatus shown in FIGS. 19 a and 19 b;
[0052] FIGS. 22 a and 22 b are side and front elevational views of the end portion of a second embodiment of a drilling cannula member for the dual ring aligning apparatus shown in FIGS. 19 a and 19 b;
[0053] FIG. 23 a is a perspective view of a slotted outer cannula for use with the dual ring aligning apparatus of FIGS. 19 a and 19 b;
[0054] FIG. 23 b is a front elevational view of the slotted cannula shown in FIG. 23 a with an aligning ring disposed therein;
[0055] FIG. 24 is a schematic view of a hollowed out vertebra showing different pedicle screw trajectories in a centered or ideal trajectory and an extraosseous or extrapedicular trajectory that is offset tangentially from the centered trajectory; and
[0056] FIG. 25 is a schematic plan view of a vertebra showing the installation of a pedicle screw in accordance with the method of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0057] The methods of determining pedicle screw size and placement in accordance with the present invention are set forth in more detail hereinafter.
[0000] Step 1
[0058] A computed tomography scan (CT), magnetic resonance image (MRI), CT capable fluoroscopy or similar two-dimensional imaging study of the spine area of interest may first be obtained. Thin cut sections are preferable to increase accuracy and detail.
[0000] Step 2
[0059] A dimensionally true three dimensional computer image of the bony spine is made from the CT, MRI or other studies or in any other suitable manner, as shown in FIGS. 1 a and 1 b.
[0000] Step 3
[0060] The three dimensional individual vertebra as shown in FIG. 2 are then hollowed out by a computer, similar to an eggshell transpedicular vertebral corpectomy, to the specifications desired by the surgeon (i.e., thickness of cortical wall remaining in the vertebral body cortices or pedicle walls). These specifications allow for asymmetric thicknesses, such that, for example, anterior vertebral body cortex could be five millimeters thick, lateral vertebral body wall seven millimeters thick and the pedicle walls only one millimeter thick; or body cortical wall uniformly five millimeters thick and pedicle walls only one millimeter thick or the like. The individual vertebra can be visualized as a structure which has been cored or hollowed out and the resulting remaining vertebral body is “electrified” or highlighted in a suitable manner throughout its walls.
[0000] Step 4
[0061] A computer then automatically determines the maximum allowable diameter screw to be placed by determining the narrowest diameter or cross sectional area (isthmus) X within any given pedicle based on surgeon pedicle cortical wall diameter preferences, as shown in FIG. 3 .
[0000] Step 5
[0062] A computer then generates an elongated cylinder by starting at the center of the isthmus X as a straight line 10 in FIG. 4 which determines the ideal axis/trajectory and extending in opposite directions, e.g., perpendicular to the plane of the isthmus of the pedicle so that it is positioned concentrically as much as possible within the pedicle without touching the remaining cortex with the center of the isthmus being the fulcrum. This line is allowed to penetrate the dorsal or posterior pedicle cortex so that it can extend beyond the skin of a patient to any desired length. The line terminates inside the vertebral body to within a predetermined distance (e.g. 5 mm) from the predefined anterior inner cortical wall, as selected by the surgeon, so that it does not penetrate the anterior outer cortex and also maximizes screw diameter as described hereinafter.
[0000] Step 6
[0063] A computer then builds the line 10 concentrically in radial directions as shown schematically in FIG. 5 to its final maximum diameter which will not exceed the narrowest defined pedicle diameter based on surgeon preference pedicle cortical wall thickness. This concentric building ultimately grows into a visible cylinder 12 which stops building when any point on its outer surface comes into “contact” with the highlighted inner cortical wall with the exception of the posterior pedicle cortex. The cylinder formed has at its center the beginning line 10 which may be identified in a different color or pattern than the concentrically built cylinder 12 . As described hereinafter, the cylinder 12 may be extended beyond its intersection with the dorsal/posterior cortex to facilitate the placement of screws in accordance with one of the automated methods described hereinafter.
[0000] Step 7
[0064] The maximal diameter allowed may actually be less than that determined by the narrowest diameter method for those pedicles which have irregular anatomy, as shown in FIG. 6 b, such as curved pedicles ( FIG. 7 b ) or a similar deformity. This prevents cortical pedicle wall breach.
[0000] Step 8
[0065] A computer then determines the length of the screw by measuring the length of the cylinder 12 starting at the point D in FIG. 8 adjacent to the predefined anterior inner cortex up to its intersection A with the dorsal/posterior cortex.
[0000] Step 9
[0066] A computer then provides a data summary table as shown in FIG. 10 a which displays the ideal pedicle screw diameter, length and trajectory (measured as an angle shown in FIGS. 10 b and 10 c with respect to the transverse and sagittal planes with corresponding superior end plate 20 as the reference plane) for each individual vertebra pedicle, and also provides idealized schematic drawings as shown in FIG. 11 . Individual vertebra are labeled by having the surgeon identify any specific vertebra as shown in FIG. 9 and then the computer automatically labels the remaining vertebral bodies with the surgeon confirming accurate vertebral body labeling.
[0000] Step 10
[0067] This tabulated data can then be utilized at this juncture for determination of the viability of using pedicle screws based on maximal pedicle screw diameter and length, as shown in FIG. 12 , and also for placement of screws by a surgeon's preferred method. FIG. 12 also provides the individual pedicle base circumference outlines (coronal trajectory) from points A to B and their respective lengths. Actual screw sizes utilized will be based on surgeon selection of commercially available screws. A computer can automatically determine and generate this table once the surgeon provides the available screw size ranges in the selected pedicle screw system and can concomitantly generate an idealized schematic AP (coronal), lateral and transverse drawing with the data as shown in FIG. 13 . Furthermore, this system provides surgeon override capabilities to choose a diameter different than the maximum available one on an individual vertebra basis and incorporates these override modifications into the summary data and diagrams.
[0000] Step 11—Manual Pedicle Screw Placement
[0068] The surgeon may then use the idealized schematic diagram and summary data for pedicle screw placement based on his or her preferred method.
[0000] Step 12 a —Pedicle Base Circumference Outline Method—Manual Determination
[0069] This method takes advantage of radiographic vertebral body anatomical landmarks to match the ideal pedicle screw trajectory in the coronal plane as shown in FIGS. 10 d and 11 . Specifically, the radiodensity circular lines seen on standard anteroposterior x-ray or fluoroscopic images correspond to the pedicle base circumferences. The pedicle base circumference B is defined as the cortical junction between the pedicle wall and its transition into the vertebral body. This pedicle base circumference is distinctly different from the pedicle isthmus, but can in some instances be one and the same or super imposable for individual vertebra as seen in FIGS. 14 a - 14 e.
[0070] For manual utilization of the pedicle base circumference technique, first the ideal trajectory through the pedicle isthmus X is manually determined using the corresponding transverse radiographic image through the pedicle as seen in FIG. 14 b. The pedicle isthmus X is then measured to determine the maximum diameter pedicle screw. The trajectory is utilized for determination for the maximum pedicle screw length. The pedicle base circumference B is then determined by identifying the transition of the pedicle wall into the vertebral body as seen in FIG. 14 b. Finally, the length A-B which corresponds to the starting point on the posterior cortex A up to the intersection with the pedicle base circumference B is measured and utilized for the calibration of a suitable tool such as a variable length awl to be described hereinafter. Point A and point B should be centered with respect to the pedicle base circumference from the top (cephalad) and bottom (caudad) edges of the pedicle base circumference, as shown in FIG. 14 h. The ideal trajectory and pedicle base circumference are then combined to determine where the point A lies with respect to the anteroposterior projection of the pedicle base circumference and where the point B lies within the pedicle base circumference. This pedicle base circumference outline will have a circular configuration to resemble the anteroposterior radiographic image for each individual vertebra.
[0071] For manual placement of pedicle screws, a standard fluoroscopy unit can be used to align the superior endplate of the respective vertebral body parallel to the fluoroscopic imaging. Furthermore, the vertebral body is centered when its superior end plate is fluoroscopically visualized by symmetric disc space with the cephalad vertebral body, and when the vertebral body is equidistant from each pedicle by having the pedicle base circumference outlines visually identical on the fluoroscopic AP image. This centering can still occur when there are other than two pedicles per vertebral body, such as congenital anomalies, tumors, fractures, etc. An appropriately calibrated variable length awl or other suitable tool T is then placed onto the posterior cortex of the corresponding vertebral body at pedicle pilot starting hole point A under fluoroscopic imaging and advanced into the pedicle up to point B as seen in FIGS. 14 f and 14 g. This placement is confirmed fluoroscopically and represents two points A and B on a straight line that co-aligns with the ideal trajectory. The tool T can be readjusted to lengthen and further advance into the vertebral body to point D or exchanged for another pedicle probing awl or similar tool. The pedicle is then sounded for intraosseous integrity, the hole tapped and the appropriate diameter and length pedicle screw is placed transpedicularly into the vertebral body.
[0072] In accordance with Step 12 a, CT transaxial views through center of pedicles T 1 , T 2 , T 4 , T 5 , as shown in FIG. 16 , demonstrate pedicle morphology, isthmus and manual determination of pedicle pilot hole entry points correlating with intraoperative AP fluoroscopic images of each respective vertebra. Pedicle screw length, diameter and trajectory have already been determined. The pedicle base circumference outline is represented as the circle on the bottom right hand corner and is utilized as a consistent intraoperative marker for identifying pedicle pilot hole starting points. For example, the starting points A for both T 1 and T 2 pedicles are approximately 2 pedicle base circumferences and 1.25 pedicle base circumferences, respectively, as seen on the AP fluoroscopic pedicle base circumference seen intraoperatively (indicated by the dot within the circle). The T 4 and T 5 pedicle pilot holes are 0.9 and 0.8 pedicle base circumferences, respectively.
[0000] Step 12 b —Pedicle Base Circumference Outline Method—Semi-Automated
[0073] This method is similar to Step 12 a except that points A and B and pedicle base circumference outline is determined by a computer after building the computer generated pedicle cylinders concentrically. This data is then summarized as in FIG. 12 . This data also includes the sagittal and transverse trajectory angles measured in degrees with respect to the superior endplate and midline vertebral body. A variable length awl or other tool, for example, may then be appropriately adjusted to specific pedicle length A-B summarized in FIG. 12 and screws placed with standard fluoroscopy as described in Step 12 a.
[0000] Step 12 c —Pedicle Base Circumference Outline Method—Fully Automated
[0074] This method further expands the present technique to allow for real-time imaging and multiple vertebral body visualization for pedicle screw placement. The data generated is the same as in FIG. 12 except that the pedicle base circumference outlines and identified points A and B are dynamic and do not require the vertebral body to be centered or have the superior end plate parallel to the fluoroscopic imaging as in Steps 12 a and 12 b. The fluoroscopically imaged vertebral bodies are registered by any suitable method to the computer generated vertebral bodies with their corresponding computer generated pedicle cylinders. The points A and B are then visualized as seen in FIGS. 15 a, 15 c and 15 e and displayed as in FIG. 12 as updated real-time imaging. A variable length awl or other tool, for example, may then be adjusted to appropriate length for starting at point A and advancing to point B for each respective vertebra. It is noted that any suitable tool, such as a nonadjustable awl, may be used other than an adjustable awl in accordance with the methods of the present invention.
[0000] Step 13—Adjustable Variable Length Awl
[0075] The distance from point A to point B ( FIG. 14 b ), posterior cortex to intersection with pedicle base circumference, is utilized to set the length A-B on an adjustable variable length awl constructed in accordance with the present invention. This awl is used to establish the pedicle pilot hole under fluoroscopic imaging. The pedicle pilot hole forms the first step in a series of steps for actual placement of a pedicle screw. The pilot pedicle hole is started at the identified starting point A indicated by the computer generated pedicle cylinders and advanced to point B once it is fully seated.
[0076] Referring to FIG. 17 a, the awl 100 comprises a cannulated radiolucent housing 102 with an open end which movably supports a radio opaque awl member 104 . The awl 100 is fully adjustable for variable lengths to correspond to length A-B and also configured to prevent advancement of the awl further than any distance A-B as seen in FIG. 14 b and other drawing figures.
[0077] A surgeon can adjust the awl to any length from point A to point D, the final screw length, in FIG. 14 b once the distance A-B has been radiographically confirmed. The awl 100 preferably is of such construction to tolerate being struck with a mallet or the like and is of a diameter narrow enough to be used percutaneously. To facilitate visualization of depth, the awl member 104 may be marked in color or otherwise at fixed increments 106 , such as 5 mm or 10 mm.
[0078] The awl 100 may be provided with a solid head 108 at its outer end for striking, and with any suitable locking mechanism 110 , such as a locking screw mechanism, for locking the awl member 104 in a desired position relative to the housing 102 . The awl may also be provided with a window 112 or other indicia for indicating the position or length of the awl member 104 . FIGS. 14 f and 14 g show an awl being advanced into the pedicle to create the screw pilot hole.
[0079] FIG. 17 b illustrates a modified adjustable awl 300 which comprises a cannulated or hollow awl member 304 and a head 308 with a central aperture 309 such that a guide wire 311 may extend through the head and through the awl member 304 to its inner end. After the pilot hole is formed by the awl 300 , the guide wire 311 may be left in position in the pilot hole to facilitate its location during subsequent steps leading to the installation of the pedicle screw.
[0000] Step 14—Dual Ring Co-Aligned Technique
[0080] For automated intraoperative pedicle screw placement the dimensionally true three dimensional spine model with computer automated placed pedicle screw cylinders defining length, diameter and trajectory is utilized. In addition, the pedicle base circumference outline data is utilized to facilitate registration with intraoperative imaging.
[0081] Real-time intraoperative fluoroscopy is utilized for accurate registration with the three dimensional model on an individual vertebral basis. This fluoroscopic vertebral body image is centered on the monitor and identified by the surgeon for its specific vertebral body identifier (i.e., T 2 , T 3 , etc.). The corresponding dimensionally true three dimensional individual vertebral model is registered to this fluoroscopic image as shown schematically in FIGS. 18 a, 18 b and 18 c. This can be performed on either surgically exposed spines or percutaneously.
[0082] The registration occurs by utilizing internal vertebral body bony landmarks. These landmarks are the pedicle base circumferences seen on the fluoroscopic image which arise from the confluence of the pedicle cortical walls joining the vertebral body. As hereinbefore explained, these pedicle base circumferences form either circular or elliptical shapes which can change configuration and square area based on vertebral body rotation with respect to fluoroscopic imaging.
[0083] The intraoperative fluoroscopic and computer spine generated pedicle base circumference outlines are then registered. Precision of registration is obtained by assuring outlines are superimposed and measured square areas are equal and by assuring distance between pedicles is equal. This method of registration eliminates the requirement of having a radiographic marker anchored to the patient's skeleton, which is particularly disadvantageous for percutaneous applications. This method also allows for free independent movement of one vertebral body to another demonstrating compliance of this computer generated model, which is particularly useful in spines with instability. The surgeon confirms adequacy of registration of pedicle base circumferences intraoperatively in order to proceed with screw placement. This method allows for magnification or reduction of the computer generated model to match the intraoperative fluoroscopic image.
[0084] The full three dimensional image which now includes the computer generated pedicle base circumference and pedicle cylinder is then projected superimposed on the intraoperative fluoroscopic image. As shown in FIGS. 19 a and 19 b, the computer pedicle screw cylinder 200 is then projected out of the patient's body through the posterior cortex and is intercepted by and extends through two separate and collinear rings 202 , 204 . The rings are mounted on a suitable support frame 206 anchored to the patient's bed or other support (not shown) and are sized to allow interception of the computer cylinder image and to allow placement of drilling cannulas. The first ring 202 intercepts the computer pedicle screw cylinder near the posterior cortical region 208 or just outside the body and the second ring 204 intercepts the computer pedicle screw cylinder at any desired distance from the first ring 202 . The longer the distance between the two rings the greater the accuracy of screw placement. The interception of the computer pedicle cylinder by the rings 202 , 204 is displayed on a computer monitor which demonstrates movement of the rings with respect to the computer pedicle cylinder 200 .
[0085] FIGS. 19 c and 19 d illustrate the computer generated cylinder 200 and line 210 projecting out from a vertebral body VB through the rings 202 , 204 in a surgically open environment and a percutaneous environment, respectively.
[0086] Interception of the pedicle cylinders occurs on two levels. The computer pedicle cylinders 200 are comprised of a central line 210 with surrounding cylinder. First, the rings 202 , 204 need to be centered to both the central line 210 and pedicle cylinder 200 . Second, the rings are registered to the vertebral body so their movements can be followed on the computer monitor such as through LED devices. Third, the rings are constructed to have inner diameters to allow matching of diameters corresponding to the diameter of the computer generated pedicle cylinders 200 . A variety of removable rings with different diameters may be provided to allow utilization of any pedicle screw system desired by the surgeon. Fourth, the rings can be constructed to be adjustable in any suitable manner to allow for variable diameters to allow matching of diameters corresponding to the diameter of the computer generated pedicle cylinder as shown in FIG. 20 where the ring 202 is formed of movably connected sections 212 that can be rotated to vary the ring diameter. Registration of the rings with the computer pedicle cylinder is identified and confirmed on the computer monitor.
[0087] The two co-aligned rings 202 , 204 now form the conduit in which to place a drilling cannula 214 ( FIGS. 21 a and 21 b ) which is also secured to the frame 206 anchored to the patient's bed or other support. Inside this drilling cannula 214 is placed a solid cannula member 216 ( FIGS. 21 a and 21 b ), or a specialized inner cannula member 218 ( FIGS. 22 a and 22 b ) may be used which has multiple narrow movable and longitudinal metal parallel pins 220 therein and is open centrally to allow for drill placement. The multiple pins 220 allow for the inner cannula member 218 to rest evenly on an uneven surface. This feature provides additional stability at the posterior cortex drilling area to avoid toggling of the drill bit. Additionally, the specialized inner cannula member 218 allows for retraction of the multiple parallel pins to allow fluoroscopic visualization of drilling within the pedicle. Either method may be used by the surgeon.
[0088] The pedicle is then drilled to its desired precalibrated depth and not exceeding the predetermined pedicle screw length. The pedicle is then sounded with a pedicle probe to assure osseous integrity.
[0089] For actual screw placement, a specialized slotted outer cannula 230 ( FIGS. 23 a and 23 b ) is placed collinear and onto the co-aligned two rings 202 , 204 which are removably mounted on the support frame. This specialized cannula 230 is also secured to the support frame or other anchoring device. The rings are then removed by rotating them approximately ninety degrees (not shown) and withdrawing them from the cannula 230 . The slotted cannula's adjustable inner diameter is sufficient to accommodate any pedicle screw diameter threaded and variable head size. The appropriate pedicle screw (not shown) is placed into its holding screwdriver, placed into the slotted cannula and then placed into its respective pedicle.
[0090] For the modified adjustable coaligned rings shown in FIG. 20 , the slotted cannula 230 in FIG. 23 a can be used or alternatively, the rings 202 , 204 may be left in position and adjusted to a fully open position to accommodate a screwdriver placed into and through the rings.
[0000] Step 15
[0091] There are currently commercially available software packages capable of producing intraoperative registration of intraoperative fluoroscopy images with preoperative three dimensional images of a patient's spine. Such capabilities can be integrated with the methods of the present invention to provide summary numerical data and idealized illustrated diagrams. The latter information will provide the basis for actual screw placement as described herein or by a surgeon's preferred choice.
[0000] Step 16
[0092] For surgeons who prefer to place screws extraosseous or extrapedicular because the pedicle screw sizes are too small to accommodate available screw sizes, planned eccentric screw placement in large pedicles or planned straight ahead versus anatomic axis screw placement, the present invention allows this capability. It accomplishes this by obtaining all idealized data and then allows a surgeon to offset the pedicle pilot hole entry placement at any desired distance tangentially from the ideal trajectory, i.e., the anterior screw position is the pivot point D from which a computer pedicle cylinder 12 is generated, as shown in FIG. 24 . Furthermore, these changes will be automatically recorded to generate new idealized AP, lateral and transaxial schematic diagrams incorporating these changes. This data can be used for placement of screws by either the pedicle base circumference method, an automated aligning method or a commercially available CT/fluoroscopy registration method. For the pedicle base circumference method, new pilot hole lengths are determined to allow for proper length of an awl or other tool.
[0093] As an illustrative embodiment, FIG. 25 shows schematically the installation of a pedicle screw 20 by a screwdriver 22 or the like through the center of the isthmus X in accordance with the present invention.
[0094] While many of the steps of the methods of the present invention are described as being computer-generated, it is noted that any suitable apparatus or device may be utilized to accomplish these steps in accordance with the methods of the present invention.
[0095] The invention has been described in connection with what is presently considered to be the most practical and preferred embodiments. It is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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An adjustable awl for forming a hole for the insertion of a screw or other device in a pedicle or other body part. The awl comprises an elongated housing having an open end, and an elongated awl member movably mounted in the housing and being extendable beyond the open end to vary the length of the awl. The awl comprises means for locking the awl member in a selected position relative to the housing. The awl member is provided with markings thereon to indicate its position relative to the housing.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to the following provisional patent applications all filed on Jul. 16, 2001: U.S. Ser. No. 60/305,730, and U.S. Ser. No. 60/305,729.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates to a system, and process for use thereof, for inspecting wafers and other semiconductor or microelectronic substrates, and specifically for inspecting three dimensional (3D) surfaces or features thereon such as bumps. Specifically, the present invention relates to a confocal optical system for inspecting bumps and other 3D features on wafers or like substrates, and a process of using such system.
[0004] 2. Background Information
[0005] Over the past several decades, the microelectronics and semiconductor has exponentially grown in use and popularity. Microelectronics and semiconductors have in effect revolutionized society by introducing computers, electronic advances, and generally revolutionizing many previously difficult, expensive and/or time consuming mechanical processes into simplistic and quick electronic processes. This boom has been fueled by an insatiable desire by business and individuals for computers and electronics, and more particularly, faster, more advanced computers and electronics whether it be on an assembly line, on test equipment in a lab, on the personal computer at one's desk, or in the home via electronics and toys.
[0006] The manufacturers of microelectronics and semiconductors have made vast improvements in end product quality, speed and performance as well as in manufacturing process quality, speed and performance. However, there I continues to be demand for faster, more reliable and higher performing semiconductors.
[0007] One process that has evolved over the past decade plus is the microelectronic and semiconductor inspection process. The merit in inspecting microelectronics and semiconductors throughout the manufacturing process is obvious in that bad wafers may be removed at the various steps rather than processed to completion only to find out a defect exists either by end inspection or by failure during use. In the beginning, wafers and like substrates were manually inspected such as by humans using microscopes. As the process has evolved, many different systems, devices, apparatus, and methods have been developed to automate this process such as the method developed by August Technology and disclosed in U.S. patent application Ser. No. 09/352,564. Many of these automated inspection systems, devices, apparatus, and methods focus on two dimensional inspection, that is inspection of wafers or substrates that are substantially or mostly planar in nature.
[0008] One rapidly growing area in the semiconductor industry is the use of bumps or other three dimensional (3D) features that protrude outward from the wafer or substrate. The manufacturers, processors, and users of such wafers or like substrates having bumps or other three dimensional desire to inspect these wafers or like substrates in the same or similar manner to the two dimensional substrates. However, many obstacles exist as the significant height of bumps or the like causes focusing problems, shadowing problems, and just general depth perception problems. Many of the current systems, devices, apparatus, and methods are either completely insufficient to handle these problems or cannot satisfy the speed, accuracy, and other requirements.
SUMMARY OF THE INVENTION
[0009] The inspecting of semiconductors or like substrates, and specifically the inspection of three dimensional surfaces or features, such as bumps, is accomplished by the present invention, which is a confocal sensor with a given depth response functioning using the principle of eliminating out of focus light thereby resulting in the sensor producing a signal only when the surface being inspected is in a narrow focal range. The result is an accurate height determination for a given point or area being inspected such that the accumulation of a plurality of height determinations from use of the confocal sensor system across a large surface allows the user to determine the topography thereof.
[0010] In sum, this system and process creates multiple parallel confocal optical paths whereby the out of focus light is eliminated by placing an aperture at a plane which is a conjugate focal plane to the surface of the sample. The result is that the sensor produces a signal only when the sample surface is in a narrow focal range.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Preferred embodiment of the invention, illustrative of the best mode in which applicant has contemplated applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.
[0012] [0012]FIG. 1 is a drawing of one embodiment of the present invention.
[0013] Similar numerals refer to similar parts throughout the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] The three dimensional (3D) inspection system of the present invention is indicated generally at 120 as is best shown overall in FIG. 1 and is used in one environment to view, inspect, or otherwise optically measure three dimensional features or surfaces. One example is the measurement of bumps on wafers or like substrates. The 3D inspection system includes a light source 122 , an optical subsystem 124 , and a camera 126 . The optical subsystem includes an intermediate focal assembly and a pair of imager or reimagers. The intermediate focal assembly in one embodiment includes an optional critical baffle 129 , a beamsplitter 130 , a photon motel 131 , and an array mount including an aperture array 132 , while the imager/reimagers in one embodiment include an object imager 134 , and a camera reimager 136 .
[0015] The light source 122 is any source of light that provides sufficient light to illuminate the sample S, and the light source may be positioned in any position so long as it provides the necessary light to sample S to be viewed, inspected or otherwise optically observed. Examples of the light source include, but are not limited to white light sources such as halogen or arc lights, lasers, light emitting diodes (LEDs) including white LEDs or any of the various colored LEDs, fluorescent lights, or any other type of light source.
[0016] In the preferred embodiment, the light source 122 is an incoherent light source, preferably of an incandescent type, that includes a filament, a condenser lens and a heat absorbing glass. In one embodiment, which is most preferred and is shown in the Figures, the light source is an incoherent, optimally baffled, lamp. It is also preferred in certain embodiments that the light source is spatially uniform and of a quasi-telecentric or preferably telecentric design. The system also needs bright light which is typically provided by a broadband or broad-spectrum style light source. It is also very desirable to define the light source as one of a matched numerical aperture design with the object imager to reduce stray light and improve efficiency.
[0017] One style of incoherent light source is an incandescent lamp such as a halogen lamp such as a 12 volt, 100 watt quartz-style halogen lamp with a color temperature in the 3000-3500 Kelvin range. Halogen provides a very consistent, stable light output that is broadband or over many wavelengths and is cost effective and readily manufacturable. It is highly preferred that the light source is incoherent to avoid or reduce spatial non uniformity and/or speckle.
[0018] The light source is of a Köhler design such as a simple or reimaged Köhler design, and most preferably a reimaged Köhler design which includes additional lenses beyond the condenser lens, which effectively matches the telecentric properties of the optical subsystem thereby matching the numerical aperture and field properties needed by the system 120 to produce accurate height measurements of bumps on the surface of the sample S. One of the embodiments to create such a Köhler or reimaged Köhler system uses an aspheric condenser lens.
[0019] One of the advantages of our Köhler or reimaged Köhler design is that every field position or spot in our field “sees” all of the filament so the system has a very uniform irradiance.
[0020] The spatial extent of the source coupled with the numerical aperture of the condenser lens plus the focal length and the conjugate provides a combination of field of view and numerical aperture that is optimized. The system optimizes the AΩ where the A is the size of the area of the field and Ω is the solid angle of the cone of light. This provides a very uniform field. The Köhler illumination design (1) maps pupil of light source onto spatial extension of aperture array, and (2) maps spatial extension of filament in light source into numerical aperture or angle space of reimaging system. The reimaged Köhler design differs from a standard Köhler design in two ways: (1) reimaged Köhler designs have a filament that is reimaged to a circular aperture that very precisely defines a constant numerical aperture over an entire field, and (2) in between the filament and the sample there is a focal plane that is conjugated to our aperture array, and at that focal plane the light is baffled and masked so that light outside of the desired range at the aperture array never enters the system. One baffle defines the numerical aperture and another baffle limits the light that passes through to only light within the desired field of view.
[0021] In one embodiment, the filament length, width and packing density are optimized. The filament length, width and packing density are adjustable to scale the system to inspect significantly larger or smaller bumps or the like.
[0022] In one embodiment, the light source is also broadband which provides significant light to the system, and avoids laser-based system speckle problems. The broadband concept provides light across many wavelengths versus a single or small range of wavelengths. This broadband is provided by mercury-type, incandescent-type or other broadband light sources.
[0023] In the telecentric environment of one of the embodiments, it is optional to provide an intermediate numerical aperture stop and intermediate field stop that provides improved stray light elimination.
[0024] In the quasi-telecentric environment of one of the embodiments, the system has an illuminator interface in the light path adjacent to the illuminator or light source 122 . This illuminator interface provides optimal baffling to better match the illuminator cone of light with the field of view cone of light, i.e., in effect improving the quasi-telecentricity to as close as possible to complete telecentricity. In various embodiments, from one to multiple baffles are provided in front of the illuminator, and optimally sized and shaped. These baffles are basically windows that are sized and shaped to allow desirable light through while eliminating stray, peripheral or other undesirable light. This provides the optimal signal to noise ratio. Additionally in a non-preferred embodiment, an optical filter may be used in conjunction with baffling within the illuminator interface. This removes unwanted wavelengths of light.
[0025] A thermal barrier may optionally also be provided to reduce the heat transfer of the light from the light source to other components of the system. This reduces or eliminates thermal expansion which causes distortions. The thermal barrier is preferably placed between the lens and the baffle.
[0026] This light source provides sufficient energy to illuminate the sample S. The light emitted from the light source 122 is directed into the optical subsystem 122 . Specifically the light is directed toward beamsplitter 130 .
[0027] In more detail and in the embodiment shown in the Figures, the optical subsystem 124 includes the intermediate focal assembly including the critical baffle 129 , beamsplitter 130 , photon motel 131 , and array mount with aperture array 132 , and the system further includes object imager 134 , and camera reimager 136 .
[0028] Critical baffle 129 is an optional additional baffle that is positioned as close as possible to an intermediate focal surface as possible. The critical baffle is positioned in between the light source and the beamsplitter and is preferably as close as possible to the beamsplitter. The critical baffle reduces stray light entering the intermediate focal assembly as well as removing stray reflections off of the beamsplitter.
[0029] Beamsplitter 130 in the embodiment shown is a pellicle beamsplitter. A pellicle beamsplitter has several advantages since it is achromatic, has very low polarization effects, and less variation with angle and color issues, and more uniformly provides light even after beam splitting effects than a polarized beamsplitter. A pellicle beamsplitter also allows for an optical system that does not need a ¼ waveplate.
[0030] Another important feature is the design, setup, alignment and configuration of the light source 122 , pellicle beam splitter 130 and the aperture array 132 as is shown in the FIG. 1. The light or illumination source 122 provides reflected light to the beamsplitter whereby some of this light passes through the beamsplitter and emanates out of the entire system and is lost, a small amount may be lost within the beamsplitter, and the remaining light is reflected toward the aperture array. In one embodiment as is shown in the Figures, the camera is axial with the imager/reimagers while the light source is not and uses the beamsplitter to introduce the light into the axis defined between the imager/reimagers 134 and 136 and the camera. This design maintains a good transmitted wave front through a pellicle beamsplitter, i.e., the imaging performance is preserved between the imager/reimagers through the array and beamsplitter. The reason for the maintaining of this good transmitted wave front is the combination of the axial camera and reimager design coupled with a pellicle beamsplitter as defined below rather than a polarizing beamsplitter since the pellicle beamsplitter have good transmitting wave fronts in comparison to reflective wave fronts versus the polarizing beamsplitter which has good reflective wave fronts in comparison to its transmitted wave front.
[0031] The beamsplitter 130 is pellicle and is of a broadband configuration, low polarizing effect that is spatially dependent, low scattering, non-absorbing or low absorbing, and is color independent with negligible internal or stray reflections. In contrast to a polarizing beamsplitter where incoming light is reflected at 90 degrees to the path of at least one of the paths of outgoing light such that incoming and all exiting light are basically near normal incident to the faces of the cube, the pellicle beamsplitter in this embodiment overcomes the detrimental design limitations of a typical achromatic beamsplitter. This broadband configuration is necessary because in a typical achromatic beamsplitter it is difficult to successfully achieve very small Fresnel reflections on the surfaces unless the beamsplitter includes coatings that adopt broad wavelength ranges which are very expensive, very sophisticated and difficult to provide.
[0032] The pellicle beamsplitter in one embodiment provides better performance than the polarizing beamsplitter in the above described arrangement with the axial camera and reimagers even though a polarizing beamsplitter and ¼ wave plate with axial camera and reimagers would only require the system to lose half of its light once while the pellicle system with axial cameras and reimagers requires the system to lose half of its light twice or successively. This is acceptable due the providing of broadband illumination from the light source which provides more light so extra loss is allowed.
[0033] A pellicle beamsplitter is preferred over merely a beamsplitter because the pellicle removes internal obstructions and optical aberrations that are undesirable.
[0034] It has been discovered that using the above system, the pellicle beamsplitter is more efficient, provides less stray light, is more spatially uniform, and generally provides better properties than the polarizing beamsplitter when the system uses a broadband light source. The pellicle beamsplitter is all dielectric rather than containing a metallic layer resulting in a beamsplitter that is non-absorbing or low absorbing. The dielectric pellicle beamsplitter is also preferably as close to 50/50 reflective/transmissive. It also preferred that the beamsplitter is low scattering. As a result, the system has optimized the amount of “good” light that passes through while minimizing the amount of “bad” light passing through which is absorbed or scattered light.
[0035] Photon motel 131 is critical because 50% of light is lost in the beamsplitter. This large amount of “lost” light needs to be eliminated from the system so an optimized and efficient photon motel is critical. Photon motel 131 is a two walled device where the first wall is a highly efficient light absorbing and controlled reflecting glass surface and the second wall is a highly efficient light absorbing surface optimally positioned to receive the light reflected from the first wall. The first wall is a piece of highly polished absorbing glass that eliminates significant amounts of the light while the remaining light is reflected in a controlled manner but not scattered. In the one embodiment, 96% of the light is absorbed. The reflected light is directed toward the second face which is a flat black coated surface where significant amounts of the light reflected from the first wall is absorbed while the remainder is scattered into a Lambertian distribution. In one embodiment, 90% of the light reflected to the second wall is absorbed while 10% is scattered. The result is that less than ½ of a percent is scattered back into the intermediate focal assembly since 10% of 4% is less than ½ of a percent.
[0036] An aluminum anodized mounting holder that is pinned holds the aperture array 132 in place. The pins allow the aperture array to be removed, returned and/or replaced in the exact same position.
[0037] Aperture array 132 in the embodiment shown is an opaque pinhole array. Specifically, the aperture array is chrome on glass or chrome on quartz with the chrome being on the first or reflective side while the pinholes are etched out of the second side which is the side facing the sample S (chrome side) while the reflective side faces the beamsplitter. Either one or both sides of the array in one alternative embodiment include an anti-reflective (A/R) coating. The chrome coating has an optical density of 5.
[0038] The pinhole array may be of any x by y number of pinholes, while in the most preferred embodiment is an approximately 100 pinhole by an approximately 1000 pinhole array. The holes in this embodiment are of a circular nature although other configurations are contemplated. However, other aperture, pinhole or like arrays of differing numbers and ranges of holes are contemplated.
[0039] The aperture array is slightly canted as shown by 13 . This canting results in the directing or steering away of stray reflections in directions that do not effect the system. For instance, the canting keeps light reflected from the pellicle toward the aperture array that does not pass through a pinhole in the array from being reflected back into the camera reimager and camera. In the embodiment shown the canting β is 4.5 degrees although it may be at other angles between 0.1 degree and 25 degrees. As discovered, the greater the cant angle the easier it is to remove stray light such as that caused by the reflection from the chrome surface; however, canting too much introduces other negative effects.
[0040] The pinholes in the aperture array are optimized in terms of size and pitch. In one embodiment, the size of the pinholes matches the camera pixels, that is the size of each pinhole matches the diffraction size of the spot coming back from the object imager.
[0041] However, in another embodiment, under sampling is used meaning the system has more pinholes than camera pixels, and as such more than one pinhole is mapped or correlated into each pixel. This under sampling reduces the effects of aliasing in the system so that holes do not have to match up directly with the pixels and thus alignment, distortions, and imperfections in optical system and other similar issues are avoided because this design assures that the same or substantially the same amount of light reaches each pixel regardless of the orientation, phase, etc. of the pixel with respect to a pinhole. The under sampling also broadens the depth response profile of our optical system to allow the system to operate over a broad range of three dimensional heights on the sample S.
[0042] In addition, in one embodiment the apertures are orthogonal or grid-like. However, in alternative embodiments the apertures are non-orthogonal or non-grid-like such as a hexagonal or other geometric pattern. This non-orthogonal pattern in at least certain applications may reduce aliasing and alignment issues.
[0043] Pitch is preferably calculated from pinhole size which is optimized to numerical aperture size. The pinhole size is chosen inter alia to match the diffraction of the object imager. The pitch is twice the pinhole size which optimizes the reduction of cross talk between pinholes while maximizing the number of resolution elements. Magnification and spatial coverage may then be adjusted to optimize resolution at the wafer surface.
[0044] Another key feature of this invention is that light passing from the aperture array is in transmission so that any surface anomalies on the pellicle beamsplitter are irrelevant to the imaging properties of our system and we are not susceptible to vibrations of pellicle beamsplitter.
[0045] The positioning of the aperture array into the system provides a confocal response. Only light that passes through an aperture in the aperture array, passes through the dual telecentric object imager, reflects off of the sample S, passes back through the dual telecentric object imager, and passes back through an aperture in the aperture array is in focus. This confocal principle results in bright illumination of a feature in focus while dim or no illumination of an out of focus feature.
[0046] Aperture array in the preferred embodiment is a fused-silica material such as chrome on glass or chrome on quartz because of the low coefficient of thermal expansion. It may alternatively be made of any other material having a low coefficient of thermal expansion such as air apertures, black materials, etc. This eliminates a mismatch potential between pixel sizes and the CCD camera elements.
[0047] The object imager 134 in the preferred embodiment shown is of a dual telecentric design. The object imager includes a plurality of lenses separated by one or more stops or baffles. In one embodiment, the object imager includes two to six lenses, and preferably three to four, on the right side of the imager and two to six lenses, and preferably three to four, on the left side of the imager separated in the middle by the stop. Since the imager is dual telecentric, the stop is located one group focal length away from the cumulative location of the lenses on each side.
[0048] The object imager functions to: (1) provide a front path for the light or illumination to pass from the aperture array to the object (wafer or sample S), and (2) provide a back path for the reimaging of the object (wafer or other sample S) to the aperture array 132 .
[0049] This system is unique because it is a dual telecentric optical imager/reimager. This dual telecentric property means that when viewed from both ends the pupil is at infinity and that the chief rays across the entire field of view are all parallel to the optical axis. This provides two major benefits. One benefit which relates to the object or sample end of the imager is that magnification across the field remains constant as the objectives focus in and out in relation to the sample. The second benefit relates to the aperture end of the imager where the light that comes through the aperture array is collected efficiently as the telecentric object imager aligns with the telecentric camera reimager.
[0050] The optical throughput is very high. This is a result of a numerical aperture of the system on the object side is in excess of 0.23 with a field of view on the object with a diameter of 5 mm.
[0051] In an alternative embodiment, the numerical aperture of the object imager may be adjustable or changeable by placing a mechanized iris in for the stop. This would allow for different depth response profile widths. This allows for broader ranges of bump or three dimensional measurements since the taller the object that it is desirable to measure the lower the desirable numerical aperture to maintain speed of the system. Similarly the smaller the object to be measured, the more desirable it is to have a higher numerical aperture to maintain sharpness, i.e., accuracy.
[0052] The magnifications of the object imager are 4 x. The aperture array is four times larger than the object (sample S).
[0053] The camera reimager 136 in the preferred embodiment shown is of a telecentric design, although it may in other embodiments be a dual telecentric design. The camera reimager includes a plurality of lenses separated by a stop. In one embodiment, the camera reimager includes two to six lenses, and preferably three to four, on the right side of the reimager and two to six lenses, and preferably three to four, on the left side of the reimager separated in the middle by the stop. Since the reimager is telecentric, on the telecentric side which is the side nearest the pellicle beamsplitter, the stop is located one group focal length away from the cumulative location of the lenses on that side.
[0054] The camera reimager functions to provide a path for the light passing through the aperture array from the object imager to the camera. It is preferable to match or optimize the camera reimager properties to the object imager and the camera where such properties include numerical aperture, magnifications, pixel sizes, fields of view, etc.
[0055] The telecentric properties of the camera reimager are on the aperture array side or end so that it efficiently and uniformly across the field of view couples the light coming through the aperture array from the object imager 134 . It is pixel sampling resolution limited so its aberrations are less than that from the degradation of the pixel sampling. Its numerical aperture is designed based upon the object imager so any misalignments between the reimagers do not translate into a field dependent change in efficiency across the field of view.
[0056] The combined system magnification of the object and camera imagers/reimagers is chosen to match spatial resolution at the object to pixel size.
[0057] The magnifications of the camera reimager are 0.65 x. The CCD or detector array is 0.65 times the aperture array. Thus, the preferred object and camera reimager magnification is 2.6 x.
[0058] The imagers/reimagers have very high numerical apertures, and the greater the numerical aperture the finer the resolution and the sharper/narrower the depth response curve.
[0059] In addition, an optional feature in this invention that is used in certain embodiments is the canting of either the sample S with reference to the optical axis of the entire optical subsystem, or vice versa (that is the canting of the entire optical subsystem with respect to the sample S). This option compensates for the canting of the aperture array as described above thus maintaining the Scheimpflug condition. In the Figure, the canting is shown as a. In the current preferred embodiment, the cant angle a is 0 degrees, although in other embodiments it ranges from 0 to 5 degrees such as a cant angle a of 1.2 degrees in one alternative embodiment.
[0060] It is also an option not to cant the sample or the optical subsystem when the aperture array is canted. In this scenario, some desensitivity of the signal occurs but is often not significant or noteworthy.
[0061] The camera 126 may be any line scan camera, area scan camera, combination of multiple line scan cameras, time delay integration (TDI) line scan camera or other camera or cameras as one of skill in the art would recognize as functionally operational herewith. The camera may be angled γ.
[0062] In the embodiment shown in the Figures, the camera 126 is a TDI camera. TDI provides additional speed by transferring the charge such that the system integrates light over time. The aperture array with line scan camera uses only one array of pinholes while with TDI the aperture array is 100 or more arrays by multiple apertures in each line (an example is 100 lines by 1024 apertures per line).
[0063] Image acquisition is typically limited by camera read rates, stage velocity and light. This broadband solution eliminates or significantly reduces light issues. Thus continue scalability of the system will occur as read rates continue to improve for TDI cameras or related technology such as CMOS imagers. Alternatively, system throughput is also increasable by increasing the number of apertures from approximately 1000 to 2000 or even 4000.
[0064] Sampling or viewing may be 1:1 or at another ratio. Where at 1:1, the camera operates at a 1 pinhole to 1 pixel ratio. Where under sampling is used, the camera is at a ratio other that 1:1 pinholes to pixels, and in one embodiment is at 1½ or 2 pinholes per pixel element at the camera sensor.
[0065] Light passes through the system as follows: Light source 122 illuminates and directs such light toward beamsplitter 130 . Some of the light that reaches the beamsplitter passes through the beamsplitter and emanates out of the entire system thus avoiding interference with the system, a small amount is lost within the beamsplitter, and the remaining light is reflected toward the aperture array. Light that reaches the aperture array either passes through an aperture therein, or hits the plate around the holes in the aperture array and is reflected out of the system due to the cant. Light that passed through the aperture array is reimaged and collimated in the dual telecentric object imager. The light is directed toward the sample S and reflects off of the sample S. If the point that is illuminated is in or near focus, substantially all of the light reflects back into the object imager while if not in focus then little or none is reflected back. Light passes back through the object imager and is directed toward the aperture array. Light that reaches the aperture array either passes through an aperture therein, or hits the plate around the holes in the aperture array and is reflected out of the system due to the cant. Light that passed through the aperture array is in focus due to the confocal principle, and it is reimaged and collimated in the telecentric camera reimager. It is directed into the camera and the intensity recorded. In any given pass, the above process occurs for every point on the sample that is being viewed.
[0066] The light that passes through the system is received by camera 126 and stored. After this process has been repeated at different heights, and across at least a portion of the surface, all of the stored data is then processed by a computer or the like to calculate or determine the topography of the sample including the location, size, shape, contour, roughness, and/or metrology of the bumps or other three dimensional features thereon.
[0067] In one of the current design and embodiment for bumps or other three dimensional features, the process involves one, two or more (generally three or more) passes over all or a selected portion of the sample surface S each at a different surface target elevation to measure surface elevation followed by two or more (generally three or more) passes each at a different bump target elevations to measure bump elevation followed by calculations to determine bump height. The result of the passes is an intensity measurement for each point at each elevation where these points as to surface elevation and separately as to bump elevation are plotted or fitted to a Gaussian curve to determine the elevation of both the surface and the bump from which the actual bump height at a given point is determined. It is the difference between the surface elevation and the bump elevation.
[0068] In more detail, a pass is made over a portion or the entire surface of the sample S. Intensity is determined for each pixel. Initially, a course or approximate surface elevation is used that is approximating the surface location or elevation of the sample S. The entire sample (or portion it is desired to measure) is scanned and the intensities are noted for each pixel, while if very small or no intensity at a given point then the system is significantly out of focus at that location or pixel (an example is scanning at the surface elevation where bumps exists results in little or no intensity feedback). This step is generally repeated twice more (though any number of passes may be used so long as a curve can be calculated from the number of passes) at a slightly different elevation such as 5, 10 or 20 microns difference in elevation to the first pass. The result is three data points of intensity for each pixel to plot or fit a Gaussian curve to determine the actual wafer surface elevation at that location. The wafer surface elevation is now known for the entire sample except where bumps or other significant three dimensional protrusions or valleys exist since each of these reported no intensity as they were too out of focus to reflect back any light. Curve fitting may be used to determine surface location under the bumps.
[0069] The second step is to determine the elevation of these significant protrusions or valleys (such as bumps). Another pass is made over a portion or the entire surface of the sample S (often only where bumps are expected, known, or no intensity was found in the surface elevation passes). This pass occurs at a course or rough approximation as to the elevation of the expected bumps such as 50, 100, 200, 300 or the like microns above the surface. Intensity is determined at each pixel as the entire sample (or only select locations where bumps are expected, known or no intensity was previously found) is scanned and the intensities are noted for each pixel, while if very small or no intensity at a given point then the system is significantly out of focus at that location or pixel (an example is scanning at bump elevations where no bump exists results in little or no intensity feedback). This step is generally repeated several more times (though any number of passes may be used so long as a curve can be calculated from the number of passes) at a slightly different elevation such as 5, 10 or 20 microns different. The result is multiple data points of intensity for each pixel to plot or fit a Gaussian curve to determine the bump elevation at that point.
[0070] Once the surface elevations are known and the bump elevations are known, the bump heights can be determined. The surface elevations are determined for the bump location based upon analysis, plotting, and/or other known curve extension techniques of all of the proximate surface elevations around the bump. The difference between a bump elevation and the proximate surface elevations therearound, or the bump elevation and the calculated surface elevation thereunder, equate to the bump height for a given bump.
[0071] In sum, the scanning process for the above invention is as follows: The system will scan lines across the sample surface S at a fixed elevation above the sample surface S. This scan will generate one z axis elevation on a depth response curve for each pixel on the sample under the scan. The sensor will then be moved in the z axis direction to a second elevation and the scan will be repeated to generate a second z axis elevation on the depth response curve for each location on the sample S under the scan. This can then be repeated any number of times desired for the interpolation method used (typically at least two or three scans, although more are certainly contemplated and will improve accuracy). The multiple locations on the depth response curve are then interpolated for each pixel to generate a map of the surface height under the scan. The elevation of the sample surface S is now known.
[0072] In the case of significant three dimensional protrusions (such as bumps), this process may be repeated at the approximate elevation of the outermost portion of the protrusions just as it was performed above at the approximate elevation of the sample surface S. The bump elevations will then be known, and the bump heights are then calculated as the difference between the surface elevation and the bump elevation.
[0073] It is important to understand that the size of the “in focus” region is determined by the telecentric imaging lens. If this lens has a larger numerical aperture (˜ratio of the focal length to diameter) the focus range will be small, and conversely if the lens has a low numerical aperture the focus range will be large. The best in focus range is dependent on the elevation range that needs to be measured.
[0074] The invention also in at least one embodiment is capable of adjusting depth response. This is desirous since with larger bumps a broader depth response is desirable while with smaller bumps a thinner or smaller depth response is desired. In effect, the system degrades the high numerical aperture to look at larger or taller bumps, and this assists in maintaining speed. Inversely, to view smaller or thinner bumps it is desirable to provide a higher numerical aperture. This broadening of depth response is accomplished either by providing a baffle to adjust the aperture, or by providing or increasing the tilt of the sensor.
[0075] A significantly different alternative involves imaging multiple heights at each point rather than making multiple passes. This is accomplished by using multi-line line scan cameras where each camera or sensor is looking at different elevations. For example, a four line, line-scan camera system would involve line 1 reading elevation 0 , line 2 reading elevation plus 20 microns, line 3 reading elevation plus 40 microns, and line 4 reading elevation plus 60 microns. All four data points in this example are gathered simultaneously. It is also contemplated and recognized that a CMOS imager would work successfully. Alternatively, multiple TDI sensors could also be used stacked close together. It is necessary to introduce a variable amount of optical path difference between each scan lines either by shifting the aperture array or introducing a difference in compensator thickness in a media such as glass between the aperture arrays which are in a plane and the end of the object imager closest to the aperture array. The result is multiple separate planes that are conjugated to separate z heights at the wafer or sample surface S. In this case where imaging occurred as to multiple heights on a given pass, the surface height calculation and the bump height calculation will involve only one pass each.
[0076] In yet another alternative embodiment, two modes of speed are provided. A precise mode is provided where scanning occurs as to every die in either or both surface elevation determination and bump elevation determination. A faster mode is provided where scanning as to wafer surface elevation is performed only in one or a few places along the wafer and interpolation is used to calculate the surface over the remaining surface including at the die.
[0077] Some alternative light sources include an illuminator with a filament designed for providing a uniformly filled area internally imaged first into a numerical aperture stop and then reimaged into the telecentric pupil of the object imager and whereby the angular spectrum from the filament is mapped first into a field stop inside the illuminator and then reimaged to the a filed located in the intermediate focus or IFA of the object imager at the aperture array. Another light source is an illuminator with a filament designed to provide a uniformly filled area that is imaged into the telecentric pupil of the imaging system (object imager) and whereby the angular spectrum from the filament is mapped into the field located in the intermediate focus or IFA of the imaging system at the aperture array and whereby the light outside the useful AΩ product of the imaging system is eliminated via a series of baffles. Yet another light source is an illuminator with an array of bright monochromatic or quasi-monochromatic sources instead of a filament. Yet an even further illuminator is a bright monochromatic or quasi-chromatic source that is collimated and directed into the field located in the intermediate focus or IFA of the imaging system at the aperture array whereby preferably an array of lenslettes are employed to create an angular spectrum at each aperture, whereby it is preferably but optional that the source is apodized.
[0078] Accordingly, the invention as described above and understood by one of skill in the art is simplified, provides an effective, safe, inexpensive, and efficient device, system and process which achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior devices, systems and processes, and solves problems and obtains new results in the art.
[0079] In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed.
[0080] Moreover, the invention's description and illustration is by way of example, and the invention's scope is not limited to the exact details shown or described.
[0081] Having now described the features, discoveries and principles of the invention, the manner in which it is constructed and used, the characteristics of the construction, and the advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.
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A confocal three dimensional inspection system, and process for use thereof, allows for rapid inspecting of bumps and other three dimensional (3D) features on wafers, other semiconductor substrates and other large format micro topographies. The sensor eliminates out of focus light using a confocal principal to create a narrow depth response in the micron range.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a corrugated tube provided with a locking structure.
[0003] 2. Description of the Related Art
[0004] A corrugated tube formed with a longitudinal slit is known conventionally for mounting on a specified position of a wire group. This corrugated tube can be fit sideways on the specified position of the wire group by opening the slit. However, the slit of the corrugated tube is opened when the wire group is bent. Therefore taping or the like needs to be applied.
[0005] U.S. Pat. No. 6,078,009 relates to a corrugated tube with a locking structure for locking the slit in a closed state so that taping is unnecessary This corrugated tube is constructed to lock the slit by forming mutually engageable locking recesses at the opposite ends of the annular projections (opposite ends facing at the opposite sides of the slit) and engaging these locking recesses.
[0006] However, the above construction has a problem when using the corrugated tube with a mounting member, such as a protector, thereon because the mounting member easily gets caught by the locking recesses of the annular projections if an attempt is made to rotate the mounting member in a circumferential direction of the corrugated tube.
[0007] The present invention was developed in view of the above situation and an object thereof is to preventing a mounting member from getting caught in a circumferential direction even if having a locking structure.
SUMMARY OF THE INVENTION
[0008] The invention relates to a corrugated tube with circumferentially extending projections at specified intervals in a longitudinal direction and a slit formed substantially in the longitudinal direction. Opposite ends of projections at opposite sides of the slit are closed substantially by closing walls. A first of the substantially opposite closing walls is formed substantially along the slit. One or more lock projections are provided between the first closing walls and the second closing walls and are dimensioned to fit at least partly inside the projections. Clearances are defined between the lock projections and the second closing walls for receiving the first closing wall. The first closing walls and the lock projections are engaged to lock the slit in a closed state when ends near the first closing walls are fit on or to the lock projections. The outer shape of the corrugated tube with the slit locked is approximate to that of a normal corrugated tube. Accordingly, the corrugated tube will not get caught by a mounting member in a circumferential direction even though the locking structure is provided.
[0009] The lock projections preferably are tapered towards the projecting ends thereof. Thus, the corrugated tube can be produced by a blow molding method similar to the normal corrugated tube.
[0010] Guide surfaces are formed on the lock projections facing the slit and are inclined to increase a projecting distance gradually towards the second closing walls of the annular projections. Thus, the first closing walls are guided by the guiding surfaces of the lock projections to pass the lock projections over merely by closing the slit. Therefore the ends of the annular projections need not be lifted up and a locking operation can be performed easily.
[0011] Ribs may be formed between the lock projections and the second closing walls to increases the rigidity of parts between the second closing walls and the lock projections and to prevent the lock projections from being inclined. Therefore, the slit can be held locked with an increased force.
[0012] The ribs may be provided at positions substantially corresponding to the widthwise centers of the lock projections.
[0013] The lock projections may be provided in a one-to-one correspondence with all of the preferably annular projections. Thus, the slit reliably is held closed.
[0014] The ribs may be provided in a one-to-one correspondence with all of the lock projections. Thus, the inclination of all of the lock projections is prevented and the slit is held closed with even a larger force.
[0015] The lock projections may have a substantially trapezoidal shape when viewed in directions along the circumferential and longitudinal directions of the corrugated tube.
[0016] The corrugated tube may be produced by blow molding or vacuum molding.
[0017] These and other objects, features and advantages of the present invention will become more apparent upon reading of the following detailed description of preferred embodiments and accompanying drawings. It should be understood that even though embodiments are separately described, single features thereof may be combined to additional embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] FIG. 1 is a side view partly in section showing a corrugated tube of one embodiment.
[0019] FIG. 2 is a section along A-A of FIG. 1 .
[0020] FIG. 3 is a section along B-B of FIG. 1 .
[0021] FIG. 4 is a section showing a state before a slit is locked in a closed state.
[0022] FIG. 5 is a side view showing a state where the slit is locked closed.
[0023] FIG. 6 is a section showing the state where the slit is locked closed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] A corrugated tube in accordance with the invention is identified by the numeral 10 in FIGS. 1 to 10 . The corrugate tube 10 is to be mounted on a specified position on an unillustrated wire group for substantially surrounding and protecting the wire group. The corrugated tube 10 is made e.g. of synthetic resin and has a bellows or wave-like shape with annular projections 12 that project at specified intervals from a substantially cylindrical inner wall 11 . Additionally, the corrugate tube 10 has sufficient flexibility to follow a layout path of the wire group. A substantially straight slit 13 is formed over the entire length of the corrugate tube 10 longitudinal direction.
[0025] Each annular projection 12 has a first end 14 at the slit 13 and a second end 15 spaced from the slit 13 . The first and second ends 14 and 15 of each annular projection 12 substantially face one another at the opposite sides of the slit 13 .
[0026] Each annular projection 12 has a projecting end surface 12 A that is substantially parallel to the inner wall 11 of the corrugated tube 10 and opposite side surfaces 12 B that converge towards the projecting end surface 12 A. Thus, each annular projection narrows towards the projecting end surface 12 A and the distance between adjacent annular projections increases at positions closer to the projecting end surfaces 12 A. The respective annular projections 12 have substantially isosceles trapezoidal cross sections when viewed in a direction along the circumferential direction of the corrugated tube 10 .
[0027] The first and second ends 14 and 15 of each annular projection 12 are closed respectively by first and second closing walls 14 A and 15 A. The first and second closing walls 14 A, 15 A have substantially trapezoidal shapes and close the ends of the annular projection 12 by having peripheral edges continuous with the side surfaces 12 B of the annular projection 12 , the projecting end surface 12 A of the annular projection 12 and the inner wall 11 . The first closing walls 14 A are formed along the slit 13 so that the slit 13 extends substantially straight in the longitudinal direction along the first closing walls 14 A.
[0028] Lock projections 16 project from the inner wall 11 at positions between the second closing walls 15 A and the slit 13 and between the first and second closing walls 14 A, 15 A at positions aligned with the annular projections 12 . One lock projection 16 is provided for each annular projection 12 and is at a position slightly distanced from the slit 13 towards the corresponding closing wall 15 A (see FIG. 1 ).
[0029] Each lock projection 16 has a projecting end surface 16 A that is substantially parallel to the inner wall 11 and opposite side surfaces 16 B that converge towards the projecting end surface 16 A. Thus, the spacing between the side surfaces 16 B on adjacent lock projections 16 increases at positions closer to the projecting end surfaces 16 A (see FIG. 2 ). A guiding surface 16 C is formed on each lock projection 16 facing the slit 13 and is inclined to gradually increase a distance to the second closing wall 15 A, as shown in FIG. 4 . A locking surface 16 D is formed on a portion of each lock projection 16 facing the second closing wall 15 A and is aligned substantially perpendicular to the inner wall 11 of the corrugated tube 10 . The locking surface 16 D and the second closing wall 15 A are substantially parallel, and a clearance of two or more times the thickness of the first closing wall 14 A is defined therebetween. An insertion portion 17 is defined between the locking surface 16 D and the second closing wall 15 A for receiving the first closing wall 14 A.
[0030] All of the lock projections 16 have a substantially trapezoidal shape when viewed in directions along the circumferential and longitudinal directions of the corrugated tube 10 . The respective lock projections 16 are dimensioned to fit closely into the corresponding annular projections 12 . More specifically, with the respective lock projections 16 fit in the first ends 14 of the corresponding annular projections 12 , the substantially opposite side surfaces 16 B of the lock projections 16 have substantially the same inclinations as the opposite side surfaces 12 B of the annular projections 12 and are arranged proximate to these side surfaces 12 B.
[0031] Ribs 18 are formed on the inner wall 11 of the corrugated tube 10 between the locking surfaces 16 D of the locking projections 16 and the second closing walls 15 A. The ribs 18 are provided in a one-to-one correspondence with the locking projections 16 and are arranged at positions corresponding to the widthwise centers of the respective locking projections 16 along the longitudinal direction of the corrugated tube 10 and project unitarily from the inner wall 11 while spanning between the locking surfaces 16 D and the second closing walls 15 A. In this way, parts of the inner wall 11 between the locking projections 16 and the second closing walls 15 A where the ribs 18 are provided have a larger wall thickness in inward and outward directions due to the thickness of the ribs 18 as compared with other parts.
[0032] The slit 13 of the corrugated tube 10 is opened and the corrugated tube 10 is fit sideways or substantially radially on the wire group or any other element to be protected. The first closing walls 14 A are guided by the respective inclined guiding surfaces 16 C of the locking projections 16 and move onto the projecting end surfaces 16 A as the slit 13 is closed. The first closing walls 14 A pass the projecting end surfaces 16 A of the locking projections 16 as the slit 13 is closed further and enter into the inserting portions 17 . The inserting portions 17 are slightly larger than the thickness of the first closing walls 14 A. Thus, the first closing walls 14 A enter the inserting portions 17 in inclined postures.
[0033] The locking surfaces 16 D of the locking projections 16 face the first closing walls 14 A when first closing walls 14 A are inserted into the inserting portions 17 to lock the slit 13 in a closed state. More particularly, the first ends 14 of the annular projections 12 are fit on the locking projections 16 and only tiny clearances are left between the first closing walls 14 A in the inserting portions 17 and the second closing walls 15 A. Therefore the annular projections 12 are substantially continuous without any projections or recesses over the entire circumference. In other words, with the slit 13 locked in the closed state, the projecting end surfaces 12 A and side surfaces 12 B of the annular projections 12 of the corrugated tube 10 and the inner wall 11 have smooth substantially cylindrical shapes free from projections and recesses over substantially the entire circumference, and the corrugated tube 10 approximates the outer shape of a normal corrugated tube (i.e. a slit-free corrugated tube or a corrugated tube having no locking structure even if formed with a slit) (see FIGS. 5 and 6 ). Accordingly, a mounting member, such as a protector, can be mounted on the corrugated tube 10 and can be rotated smoothly without getting caught by the mounting member in the circumferential direction.
[0034] The lock projections 16 are tapered toward their projecting ends. Thus, the corrugated tube 10 can be produced by a blow molding method similar to the conventional corrugate tube.
[0035] The first closing walls 14 A are guided by the guiding surfaces 16 C of the lock projections 16 to move over the lock projections 16 while locking the slit 13 in the closed state. Thus, the first ends 14 need not be lifted up to fit on the lock projections 16 so that the locking operation can be performed easily.
[0036] The lock projections 16 are provided for all of the annular projections 12 and the slit 13 is locked at all of the annular projections 12 . Thus, the slit 13 is held reliably closed over substantially the entire length of the corrugated tube 10 .
[0037] The opposite side surfaces 16 B of the lock projections 16 are substantially parallel to the opposite side surfaces 12 B of the annular projections 12 when the first ends 14 fit on the lock projections 16 . Thus, the side surfaces 16 B of the lock projections 16 the contact side surfaces 12 B of the annular projections 12 to prevent relative displacements of the respective lock projections 16 and first ends 14 in the longitudinal direction if the corrugated tube 10 is bent. Therefore, relative displacements of the opposite ends 14 , 15 of the annular projections 12 in the longitudinal direction are restricted and the annular projections 12 are kept substantially continuous in the circumferential direction.
[0038] The ribs 18 between the lock projections 16 and the second closed walls 15 increase rigidity so that these parts are difficult to bend even upon the action of contact forces of the lock projections 16 and the first closing walls 14 A. Specifically, the ribs 18 provide rigidity against bending deformation in a direction that would displace the lock projections 16 inwardly of the corrugated tube 10 and prevent the lock projections 16 from being inclined. Accordingly, the lock projections 16 and the first closing walls 14 A are unlikely to disengage from each other even if relatively large forces act on the lock projections 16 while bending the corrugated tube 10 . Hence, the slit 13 remains closed. Further, the ribs 18 are at positions substantially corresponding to the widthwise centers of the lock projections 16 . Thus, the ribs 18 provide well balanced resistance to bending deformations that could incline the lock projections 16 . The ribs 18 are provided for all of the lock projections 16 . Thus, the inclination of all of the lock projections 16 are prevented and the slit 13 is held closed with an increased force.
[0039] As described above, the outer shape of the corrugated tube 10 in the locked state of the slit 13 is approximate to the outer shape of a normal corrugated tube. Thus, the corrugated tube 10 will not get caught by a mounting member in the circumferential direction despite the existence of the locking structure.
[0040] The invention is not limited to the above described embodiment. For example, the following embodiments also are embraced by the scope of the invention as defined by the claims.
[0041] Although the invention is applied to the corrugated tube 10 having the slit 13 formed over the entire length in the above embodiment, it is also applicable to a corrugated tube having a slit partly formed. Moreover, the corrugate tube may have a cross-sectional shape different from a substantially circular one such as a polygonal, squared, rectangular, elliptical or the like shape.
[0042] Although the lock projections 16 are substantially trapezoidal when viewed in both the circumferential direction and the longitudinal direction in the above embodiment, the lock projections may have any shape provided that they are dimensioned to be fit inside the annular projections and are tapered towards the projecting ends. For example, the lock projections may have a triangular pyramidal shape. Moreover, the projections of the corrugated tube need not to be annular, but may have different shapes such as a substantially spiral shape so that one end of one projection may oppose an end of another projection.
[0043] The inserting portions 17 are slightly larger than the wall thickness of the first closing walls 14 A in the above embodiment, but they may not be larger.
[0044] Surfaces of the lock projections 16 facing the slits 13 are inclined in the above embodiment, but these surfaces may not necessarily be inclined surfaces.
[0045] The ribs 18 are formed between the lock projections 16 and the second closing walls 15 A in the above embodiment. However, they may not be formed.
[0046] The ribs 18 are at the widthwise centers of the lock projections 16 in the above embodiment. However, they may be displaced from the center positions.
[0047] The lock projections 16 are provided for all the annular projections 12 in the above embodiment. However, the lock projections may be provided for fewer than all annular projections, e.g. every other annular projection.
[0048] The ribs 18 are provided for all the lock projections 16 in the above embodiment. However, ribs may be provided only for some lock projections.
[0049] The corrugated tube 10 is produced by the blow molding in the above embodiment, but it may be produced by other methods (e.g. vacuum molding).
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A corrugated tube has a slit ( 13 ) and first closing walls ( 14 A) of circumferentially extending annular projections ( 12 ) are formed along the slit ( 13 ). Lock projections ( 16 ) dimensioned to be fitted inside the annular projections ( 12 ) are provided between the first closing walls ( 14 A) and second closing walls ( 15 A). The lock projections ( 16 ) are tapered toward the projecting ends thereof and clearances, into which the first closing walls ( 14 A) are insertable are defined between the lock projections ( 16 ) and the second closing walls ( 15 A). Out of the opposite ends ( 14, 15 ) of the annular projections ( 12 ), the ends corresponding to the first closing walls ( 14 A) are fitted on the lock projections ( 16 ) to engage the first closing walls ( 14 A) and the lock projections ( 16 ), thereby locking the slit ( 13 ) in a closed state.
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PRIORITY
[0001] This application is a continuation-in-part of, and claims the benefit of the priority of, co-pending Japanese applications JP 2005-175654 and JP 2005-147,482, each filed May 20 , 2005 , and each of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to a method for the production of hypochlorous acid-bearing acidic electrolyzed water, to an apparatus for such production, and to a control method for said production.
BACKGROUND
[0003] Batch type production formats are known that generate hypochlorous acid-bearing acidic electrolyzed water, using raw water that has been stored in a vessel having a fixed capacity. These formats use an electrolysis tank in which the positive electrode chamber and the negative electrode chamber have been divided by a separation membrane. The electrolysis is done in the positive electrode chamber and the negative electrode chamber, using water for electrolytic processing that has had a small amount of a chloride-containing salt added to it to form the electrolyte. Typically, flow through an anode compartment generates acid electrolyzed water, and flow through a cathode compartment generates alkaline electrolyzed water.
[0004] However, there are many problems with this approach. In particular, although acidic electrolyzed water possesses strong bactericidal power, and is a desirable water that causes little contamination of people or the environment, the production systems of the past have weaknesses such as the fact that the resulting acidic water contains salt, has a strong smell of chlorine, and easily corrodes metals. In addition, from the standpoint of the production process, there are troublesome cases in which the generation of alkaline water creates problems. In the marketplace, devices that generate salt-free acidic electrolyzed water without generating alkaline water are not readily available. Finally, in some production systems that employ a cation exchange membrane, the presence of some cations in the salt can foul the ion-selective membrane. Consequently, restrictions are placed on the purity of the electrolyte salt that limit the possible grades of salt that can be used in such systems.
[0005] A system is desired with which stable, reproducible generation of acidic electrolyzed water can be done, where the generation of alkaline water can be avoided or minimized, and where limits on the impurity content of the electrolyte salt can be relaxed.
PROBLEMS OF THE PRIOR ART TO BE SOLVED BY THE INVENTION
[0006] This invention relates to a method of generating electrolyzed water, in which acidic electrolyzed water is generated while generating little or no alkaline electrolyzed water, and in which no salt is contained in the generated water. Thereby, electrolyzed water is generated for which the chlorine smell is low. The electrolysis tank (electrolyzer) contains no cation exchange membrane, so impurity requirements for the electrolyte salt are relaxed. Moreover, the installation and removal of the electrodes is simple, and further, it is possible to generate, in a short period of time, acidic electrolyzed water that reproducibly exhibits targeted physical properties.
[0007] In Japanese patent JP 3,113,645, by the inventor of the present invention, the chloride concentration in the water in the anode chamber is increased by limiting the flow rate of water through the positive electrode (anode) chamber to a rate of 5 to 40 cc per minute per ampere of current. This increases the efficiency of chlorine production on the surface of the positive electrode (anode). The conversion of chlorine to hypochlorous acid is promoted by mixing the electrolyzed water with additional water after the electrolyzed water leaves the anode compartment. Consequently, the amount of chlorine that escapes from the generated water is reduced, and the smell of chlorine is made low.
[0008] A method that generates acidic electrolyzed water that does not include any salt content, and while generating very limited amounts of alkaline electrolyzed water, is described in Japanese Patent Number 3,551,288 by the inventor of the present invention for a system in which the acidic water is stagnant.
SUMMARY OF THE INVENTION
[0009] The present invention is an improvement over the above art. In one improvement, as the means with which hypochlorous acid-bearing acidic electrolyzed water having a low chlorine smell is generated efficiently, means are provided in which an extremely limited amount of raw water is introduced, by a liquid distribution device, into the positive electrode chamber. Chloride ions are selectively introduced into the water in the positive electrode (anode) chamber in close proximity to the anode through an anion selective membrane. The limited amount of raw water is electrolyzed there, and then it is removed from the positive electrode chamber and mixed with non-electrolyzed water. For selecting the amount of raw water that is introduced into the positive electrode chamber to be treated, a flow rate of 5 to 40 cc per minute per ampere of current is preferred.
[0010] The positive electrode (anode) and negative electrode (cathode) chambers are separated by an anion selective membrane. The salt electrolyte is contained in the form of a solution in the negative electrode (cathode) chamber. The electrolyte is preferably highly concentrated, and may contain undissolved salt.
[0011] In addition, to make the attachment and removal of the electrodes simple, means are provided in which the positive and negative electrode plates and the separating membrane have been integrated into a single unit, that is held between flanges or other attachment means that have been attached to the negative electrode chamber and the positive electrode chamber. As described in JP 3,551,288 for a non-integrated membrane, the membrane in the integrated unit may be a non-ion selective membrane or an anion-selective membrane, and preferably is an anion-selective membrane, of any of the types known in the art.
[0012] Also, as a means with which the generated water that accurately exhibits the target physical properties can be produced in a short period of time, an embodiment is provided in which the end of the electrolysis process is determined by integrating the current over time, for example collecting values determined at fixed time intervals, such as each second, and then terminating the electrolysis when the total amount of electricity supplied to the cell reaches a selected value. The selected value will depend on various factors, including the desired final level of active chlorine (hypochlorous acid plus hypochlorite ion plus chlorine gas) or equivalent in the electrolyzed water, and the activity efficiency of the electrodes surfaces toward the various electrolysis reactions and their catalysts. In one embodiment, the selected value is in the range of 420±200 coulombs per liter of raw water that is processed. An alternative embodiment is a format for use in those cases where the current is stable to some degree, where a timer is used instead of integrating the current, and the time is regulated.
[0013] In another embodiment, the present invention is a batch type acidic electrolyzed water production system characterized in that the system uses an electrolyte cell having an easily removable electrode assembly with a unitary, integrated structure, in which the positive and negative electrode plates, and the separating membrane that is in between these plates, are arranged in a layered assembly, and connected, using a flange or the like, in between the positive electrode chamber and the negative electrode chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an overall flow diagram of the water electrolysis system for one embodiment of the present invention.
[0015] FIG. 2 is an oblique view drawing that shows the relationships among the components; and
[0016] FIG. 3 is an exterior drawing of the batch type water electrolysis system of one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] An example of the batch type water electrolysis system of the present invention is shown in FIG. 1 . FIG. 1 is a line diagram in which the water electrolysis system is shown. In this embodiment, the electrolysis system has an assembled electrolyzer assembly (V), which has been furnished with an electrolyte container (L) which is in fluid connection with the negative electrode chamber (cathode chamber) (X), which consists of the space inside frame ( 7 ) of integrated electrode assembly (J), and a space ( 12 ) cut into the face of flange (N). (Y) is the positive electrode chamber, formed in the space inside frame ( 7 ) of integrated electrode assembly (J), and optionally in a space (not illustrated) cut into the positive electrode chamber bounding plate (K). Flanges (M) and (N) are used to connect the two chambers (X) and (Y) and the electrode assembly (J), using fastener means such as bolts (see FIG. 2 ) to form the electrolyzer assembly (V). The direct current power source (D) is connected to said electrode assembly (J). (E) is a raw water tank, (F) is a circulation pump, (G) is a liquid distribution device, and (H) is a liquid mixing device. The water that has been delivered by the circulation pump (F) from the raw water tank (E) is distributed by the liquid distribution device (G) both to the water in the positive electrode chamber (Y), which is water that will be electrolyzed, and to liquid mixing device (H), which is water that will not be electrolyzed, but used to immediately dilute electrolyzed water that is leaving the electrolyzer assembly M. Both of the waters are mixed by the liquid mixing device (H) and, at the same time, the water and the chlorine gas that is generated in the positive electrode chamber are reacted, forming hypochlorous acid, and the mixture is returned once more to the raw water storage tank. A separate pump can be used for the distribution of water for electrolysis, instead of using a distribution device (G).
[0018] However, it should be noted that as a matter of convenience with regard to the layout of the piping, there are cases, which are not illustrated here, in which both of the waters are again returned to the raw water storage tank (E) without first mixing, i.e., in which there is no mixing device (H). There are other cases, not illustrated, in which the raw water storage tank is not the same as the tank that the electrolyzed water mixed with the non-electrolyzed water is stored in. It is not required that the raw water comes from a storage tank, such as tank (E); it could come from a continuous water source, and be regulated in amount by timing, weight or other means. The electrolysis time or charge is calculated, limited according to the result of the calculation, and the acidic electrolyzed water having the target effective chlorine concentration is thereby generated.
[0019] A salt for electrolysis, which is a chloride salt such as sodium chloride, potassium chloride or other chloride salt, is put into the electrolyte storage tank (L) of the negative electrode (cathode) (X). As the electrolysis of the electrolyte progresses, the chloride ions in the cathode move to the positive electrode (anode) chamber (Y) due to electrodialysis, and the chloride ions are replaced in the storage tank by hydroxyl ions, producing a hydroxide such as sodium hydroxide or the like. At some point, it is necessary to exchange the cathode solution with a fresh electrolyte solution before the chloride ions have disappeared, or before the alkalinity becomes excessive.
[0020] FIG. 2 shows a perspective drawing of a particular design of the electrolyzer assembly (V), which includes the negative electrode chamber (X), which may serve as the electrolyte storage tank, and the positive electrode chamber bounding plate (K) as well as the integrated electrode assembly (J), all of which are fastened together by the flanges (N) and (M) to form the electrolysis assembly (V). The integrated electrode assembly (J) is composed of a frame ( 47 ), a positive electrode (+), a membrane ( 46 ), a negative electrode(−) and a second frame ( 47 ). Other features of this embodiment are bolt holes 48 , 49 , 50 , 51 in flanges M and N; and inlet ( 53 ) for raw water and outlet ( 54 ) for electrolyzed water in plate (K).
[0021] FIG. 3 is an exterior view drawing of one version of a complete batch type acidic electrolyzed water production system. (E) is the raw water tank, (L) is a portion of the negative electrode chamber/electrolyte storage tank shown in FIG. 2 , (O) is a control box, also containing the pump (F) (not shown), (P) is the electrolysis control setting device or the timer, and (R) is the water supply orifice for placing water in the tank (E).
[0022] In a preferred embodiment, the electrolyte solution storage tank (L), connected to the cathode chamber (X), is a static system, in which the electrolyte solution is periodically replaced as its chlorine content is depleted. Electrolytes may include, but are not limited to, chlorides of alkali metals, such as sodium and potassium. Raw water is delivered from a raw water storage tank (E) that, in the illustrated embodiment, has a fixed capacity, by a pump (F). Then by means of a liquid distribution device (G), the raw water is distributed in part to the anode chamber (Y) as water that is electrolyzed and generates acidic electrolyzed water, and in part as other raw water not to be electrolyzed that is delivered so that it bypasses the anode. Only the amount of water that is electrolyzed in anode chamber (Y) is regulated at a flow rate of 5 to 40 cc per minute per ampere of current. After the electrolysis, the acidic electrolyzed water from the anode chamber (Y) is collected in a storage tank (E), which in this embodiment is the same as the supply tank. The acidic electrolyzed water may be diluted with other raw water after it leaves the anode the integrated electrode assembly (J), either by in-line dilution or by separate delivery of raw water to a storage tank. In one embodiment, the storage tank (E) for collection may be the same tank that originally contains the raw water for making the batch of acidic electrolyzed water. In this embodiment, some water passes through the anode chamber and is returned to the tank (E), and optionally other water is circulated by a pump, and returns to the tank without electrolysis, for example to promote efficient mixing. The electrolyzed and non-electrolyzed water may be mixed at any point after the acidic electrolyzed water has left the anode compartment, either directly in tank (E) or in a mixer (H).
[0023] It should be noted that while dilution of acid electrolyzed water after it leaves the anode compartment (Y) is possible and in some cases preferred, it is also possible to collect or use acid electrolyzed water without further dilution. One or both of the current and the residence time of water in the anode compartment has to be adjusted appropriately to provide the required final active chlorine concentration. (Active chlorine is the total chlorine present as any of hypochlorous acid, hypochlorite anion, and dimeric chlorine, all of which are in an equilibrium determined by pH and secondarily by other factors.)
[0024] In another embodiment, the present invention is a batch type acidic electrolyzed water production method, characterized by the use of a direct current power source (D) to provide electrical power to an electrolyzer, further characterized by the generation in an anode compartment (Y) of acidic electrolyzed water of known volume W liters, which may be contained in a tank, that is characterized by a known relationship between a target property in the volume W of acidic electrolyzed water, and the cumulative electric charge C (for example, in coulombs or ampere-seconds) required to achieve that property, and also characterized by the integration versus time of the electrical current passed through the electrolyzer assembly (V). When the integration value Q in the selected units is equal to the target value C, the generation of the acidic electrolyzed water is completed. The desired property is one that characterizes the usefulness of the acidic electrolyzed water. In one embodiment the property is the concentration of hypochlorous acid or of total active chlorine in the water in the collection tank, or in the stream of water leaving the anode compartment (Y). In another embodiment the property is the pH in the collection tank. The collection tank may be the same as the fixed volume supply tank (E), or may be a different tank (not illustrated.)
[0025] In another embodiment, the present invention is a batch type acidic electrolyzed water production method, characterized in that a direct current power source to provide a fixed current to an electrolysis tank. The processing time that is required for the time integral of the current that is passed through the electrolysis tank to reach a target value of C coulombs/liter (for the W liters in the storage tank having an active chloride level of U ppm) is calculated. The time is set with a timer, and the generation is terminated when the predetermined generation time is reached.
[0026] In one preferred embodiment, in which the target active chlorine level is about 30 ppm, the time required to apply about 420±200 coulombs per liter of water electrolyzed is calculated, the time is set with a timer, and the generation is terminated when the pre-selected value of total coulombs loaded is reached. The figure is derived from the multiplication of the desired level V of active chlorine (in parts per million) with a factor A. Factor A is in the range of about 8 to 20, in appropriate units, and is a measure of the efficiency of conversion of current flow through the membrane into production of hypochlorite from chloride. (In a perfectly efficient conversion, the value of A would be 1). In effect, the time required T may be calculated as
T+(AUW)/C
[0027] Also, in order to make it such that the physical properties of the generated water can be produced simply and accurately, two methods are described. In a first method, the value of the electrolyzing current is integrated and the point in time at which the coulomb value per liter has reached a predetermined value is made the end point of the generation reaction. In a second method, a power source that can supply a fixed current or voltage is used, the mean electrolyzing current is sought in advance, the time that is required for the coulomb amount to reach the predetermined value is calculated, and the time is set with a timer. An example of a predetermined value is a number lying in the range of 420±200 (i.e., the range 220-620) coulombs per liter of water, but other predetermined values may be set depending on the desired concentration of hypochlorous acid in the product, on the efficiency of the particular electrolyzer, and on local regulations affecting the selected value, for example regulating the pH. These methods are judged to have advanced qualities with regard to the fact that straightforward and logical formats with which the amount of electricity per liter of raw water is regulated to be held constant have been utilized as suitable methods for the simple production of acidic electrolyzed water having an effective chlorine concentration, which is the target, with a batch type acidic electrolyzed water production system.
[0028] An additional advantage of the preferred embodiment described is that the simplicity of changing the electrode. Since the electrode has been integrated as a single unit (J), and is attached to the positive and negative electrode chambers by simple systems such as flanges (M, N) bolted together, the amount of work required to change the electrodes is considerably reduced.
[0029] Thus, in one embodiment, the present invention is a batch type acidic electrolyzed water production system characterized in that the system uses an electrolyte cell having an easily removable structure with an electrode having an integrated structure, in which the positive and negative electrodes and the separating membrane that is between these are arranged in proper order, and are enclosed by frames. The integrated electrode assembly is placed between the positive electrode chamber and the negative electrode chamber, which latter also serves as the electrolyte solution storage tank, and raw water is delivered from a raw water storage tank that has a fixed capacity with a pump, and by means of a liquid distribution device, is distributed as water that is electrolyzed to generate acidic electrolyzed water, and water that is not electrolyzed, and the amount of water that is electrolyzed is 5 to 40 cc per ampere of current, and after the electrolysis, both of the waters are again mixed and circulated to the raw water storage tank.
[0030] In another embodiment, a batch type acidic electrolyzed water production system is characterized in circulating water from a storage tank through an anode at limited flow rate, for example a flow rate of 5 to 40 ml per minute per coulomb of electricity applied to said anode, and the acidic electrolyzed water from the anode is diluted by its return to the storage tank and its mixture with the water contained in the storage tank.
[0031] In another embodiment, the storage tank is a detached container, for example a bottle, and water is removed from said bottle by a pump or equivalent connected to a first tube inserted into said bottle, and after electrolysis the acidic electrolyzed water is returned to said bottle by a second tube. When the designated time has passed, or a measured number of coulombs has been applied, then the tubes are removed and the bottle may be removed and closed.
[0032] In another embodiment, the raw water is supplied by a continuous source, preferably controlled by a valve, and the continuous raw water passes in a limited amount though the anode compartment, and optionally in another amount raw water bypasses the anode compartment and is mixed with the electrolyzed water after it leaves the anode compartment, either in line or in a receiving tank, which can be a fixed tank or an exchangeable tank.
[0033] In the batch-type electrolysis system, the salt solution in the cathode is generally changed in a batch type process, in which the salt solution is replaced after it has been used to generate a certain volume of acidic electrolyzed water having a target concentration of active chlorine, such as hypochlorous acid. The time before replacement could be extended, for example for the convenience of an operator, by circulating salt solution through the cathode compartment from a large tank, or from a tank containing undissolved salt, or both. In principle, electrolyte solution could be generated continuously by automatic means and circulated through the cathode compartment at a rate designed to maintain a particular chloride concentration in the electrolyte solution flowing out of the cathode compartment, in which case, if the anode compartment flow was also continuous, the system might not strictly speaking be a batch system.
[0034] In any of these embodiments the active chlorine concentration in the diluted electrolyzed water can be controlled by any practical combination of alteration of the ratio of diluting raw water to electrolyzed water, and altering the rate of flow of water (for example in ml/min) and/or the rate of current flow (amperes) in the anode compartment. (In any calculation, the influence of changes in the chloride concentration and pH in the cathode compartment on the efficiency A of the system should be considered for the most accurate results.)
[0035] In addition, the invention comprises a batch type acidic electrolyzed water production method characterized in that in those cases where acidic electrolyzed water for which the effective target chlorine concentration is about 30 ppm±20 is generated from the raw water of the raw water storage tank that has a fixed capacity (W liters), the current which is loaded is integrated each second and the generation is completed at the point in time where the integration value Q has reached the value that has been set, which may be a figure in the range of 420±200 coulombs per liter of water.
[0036] In addition, the invention comprises a batch type acidic electrolyzed water production method characterized in that a direct current power source is used to provide a fixed value for the current, or for the voltage with estimation of the current, and by means of the assumption in advance of the mean electrolytic current, the processing time that is required for the amount of the current that is loaded by one liter of raw water of the W liters to become 420±200 coulombs is calculated, the time is set with a timer, and the generation is completed.
[0037] In construction of the system of the invention, regulation of flow through the anode compartment is usually required. Any convenient known means of regulating flow can be used. Flow regulations means include, without limitation, valves, including needle valves, orifices, diaphragm pumps, piston pumps, other metering pumps, and capillary tubing.
[0038] In construction of the invention, any convenient means may be used to connect the flanges of the electrolyzer assembly. Besides bolts and nuts, as mentioned, clamps, screws, latches, snaps, straps, hook/loop closures, and other known fastening systems, and combinations of these, can be used.
[0039] In addition, the device of the invention may comprise means for determining when the salt solution in the cathode needs to be removed and replaced with a fresh salt solution. Any suitable determination means may be used. One means is by calculation, so that after a preset total number of coulombs of electricity are passed through the membrane, which corresponds to a total number of moles of chloride ion passed through the membrane when corrected for the efficiency, the device signals the operator that it is time to replace the salt solution. In an automated version, the device opens valves to remove the old salt solution and add fresh salt solution. In an alternative or supplementary mode of determination, a sensor is present in the cathode compartment and senses a value related to the level of chlorine. The value can be, among others, the pH, measuring the accumulation of hydroxyl ion, or it could be output from a chloride detector, or it could be a measurement of the redox potential of the cathode solution relative to a reference.
[0040] Likewise, for a batch operation, the time of termination of application of electric current to make acid electrolyzed water, and the time for termination of circulation of water through the anode, can be selected to occur upon the attainment of a criterion. Operation can also be contingent on the first of any of several criteria to be attained; or on a combination of criteria to be obtained, which may be weighted or otherwise mathematically interrelated. Criteria, which typically are the attainment of a value lower than, equal to, or greater than a selected value, can be any criterion of usefulness in selecting a particular level of antibiotic activity in the acid electrolyzed water. Preferred criteria include time of operation; integrated current during operation; pH; oxidation/reduction potential (ORP) (also called redox potential); concentration of active chlorine, for example by direct measurement, or a surrogate therefore; or change of color or other visible property of an indicator. “Water” as used herein means water of low salinity, and typically water of a grade useful and permissible for washing persons and animals, food items and other objects. Conventional additives can be added to water when such additives are electrochemically compatible with the presence of active chlorine in the final product.
[0041] Water, as noted, is preferably provided in a batch, but may be continuously replenished in one of several ways. Likewise, the chloride in the electrolyte is gradually expended, and the chloride concentration is maintained by one or more means selected from replacement of the electrolyte and replenishment of the electrolyte. For example, and with out limitation, the electrolyte may be replenished by one or more of recirculating the electrolyte in the cathode from and to a much larger external saline reservoir, or periodically adding salt to the electrolyte in the cathode, or periodically interrupting operation, discharging the electrolyte in the cathode, and refilling the cathode compartment with fresh electrolyte, or pumping electrolyte through the cathode chamber in a single pass mode at a regulated rate from another reservoir. Combinations of these may also be used, and pH may be adjusted independently of or concurrently with the replenishment of chloride ion.
[0042] Several embodiments of the invention have been illustrated or described. Additional embodiments are contemplated in the invention, and the scope of the invention is not limited by the description of particular embodiments, but by the scope of the claims.
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An improved device and method for the creation of acidic electrolyzed water is described. The device has an flow-through anode chamber and a static cathode chamber. The static cathode chamber contains a fixed amount of salt-containing electrolyte, which is renewed as needed. The flow rate of water through the anode is restricted to a range of about 5 to 40 ml per ampere of current passed through the electrode. Electrolyzed water flowing from the anode is diluted to obtain the desired concentration of hypochlorous acid, and is collected in a tank or other vessel. The electrolysis reaction is terminated when a preset amount of current has passed through the anode. Water circulation may be one pass or recycling. In a preferred embodiment, the membrane is anion-selective. Preferably, the membrane and the electrodes are integrated into a preassembled format that can be attached to the anode and cathode compartments via flanges or similar devices allowing quick replacement of an electrode assembly in an electrolyzer. The anion-permeable membrane can be protected by a protection membrane, in which are provided slits or other discontinuities to allow venting of gas.
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SEQUENCE LISTING
[0001] This application contains a sequence listing in computer readable format, the teachings and content of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] One aspect of the present invention is concerned with the recovery of a protein expressed by open reading frame 2 (ORF2) of porcine circovirus type 2 (PCV2). More particularly, the protein is a recombinant protein expressed by a transfected virus containing recombinant coding sequences for porcine circovirus type 2, open reading frame 2. Still more particularly, the transfected virus is permitted to infect cells in growth media and the protein expressed by open reading frame 2 is recovered in the supernate, rather than from inside the cells. Even more particularly, the method involves the steps of amplifying the open reading frame 2 gene from porcine circovirus type 2, cloning this amplified portion into a first vector, excising the open reading frame 2 portion from this first vector and cloning it into a transfer vector, cotransfecting the transfer vector with a viral vector into cells in growth media, causing the cells to become infected by the viral vector and thereby express open reading frame 2, and recovering the expressed recombinant protein coded for by open reading frame 2 in the supernate.
[0004] In another aspect, the present invention is concerned with an immunogenic composition effective for inducing an immune response against PCV2, and methods for producing those immunogenic compositions. More particularly, the present invention is concerned with an immunological composition effective for providing an immune response that protects an animal receiving the composition and reduces, or lessens the severity, of the clinical symptoms associated with PCV2 infection. Still more particularly, the present invention is concerned with a protein-based immunological composition that confers effective protection against infection by PCV2. Even more particularly, the present invention is concerned with an immunological composition comprising ORF2 of PCV2, wherein administration of PCV2-ORF2 results in protection against infection by PCV2. Most particularly, the present invention is concerned with an immunological composition effective for conferring effective immunity to a swine receiving the immunological composition, and wherein the composition comprises the protein expressed by ORF2 of PCV2.
[0005] 2. Description of the Prior Art
[0006] Porcine circovirus type 2 (PCV2) is a small (17-22 nm in diameter), icosahedral, non-enveloped DNA virus, which contains a single-stranded circular genome. PCV2 shares approximately 80% sequence identity with porcine circovirus type 1 (PCV1). However, in contrast with PCV1, which is generally non-virulent, swine infected with PCV2 exhibit a syndrome commonly referred to as Post-weaning Multisystemic Wasting Syndrome (PMWS). PMWS is clinically characterized by wasting, paleness of the skin, unthriftiness, respiratory distress, diarrhea, icterus, and jaundice. In some affected swine, a combination of all symptoms will be apparent while other swine will only have one or two of these symptoms. During necropsy, microscopic and macroscopic lesions also appear on multiple tissues and organs, with lymphoid organs being the most common site for lesions. A strong correlation has been observed between the amount of PCV2 nucleic acid or antigen and the severity of microscopic lymphoid lesions. Mortality rates for swine infected with PCV2 can approach 80%. In addition to PMWS, PCV2 has been associated with several other infections including pseudorabies, porcine reproductive and respiratory syndrome (PRRS), Glasser's disease, streptococcal meningitis, salmonellosis, postweaning colibacillosis, dietetic hepatosis, and suppurative bronchopneumonia.
[0007] Open reading frame 2 (ORF2) protein of PCV2, having an approximate molecular weight of 30 kDa when run on SDS-PAGE gel, has been utilized in the past as an antigenic component in vaccines for PCV2. Typical methods of obtaining ORF2 for use in such vaccines generally consist of amplifying the PCV2 DNA coding for ORF2, transfecting a viral vector with the ORF2 DNA, infecting cells with the viral vector containing the ORF2 DNA, permitting the virus to express ORF2 protein within the cell, and extracting the ORF2 protein from the cell via cell lysis. These procedures generally take up to about four days after infection of the cells by the viral vector. However, these procedures have a disadvantage in that the extraction procedures are both costly and time-consuming. Additionally, the amount of ORF2 recovered from the cells is not very high; consequently, a large number of cells need to be infected by a large number of viral vectors in order to obtain sufficient quantities of the recombinant expressed protein for use in vaccines and the like.
[0008] Current approaches to PCV2 immunization include DNA-based vaccines, such as those described in U.S. Pat. No. 6,703,023. However, such vaccines have been ineffective at conferring protective immunity against PCV2 infection and the clinical signs associated therewith.
[0009] Accordingly, what is needed in the art is a method of obtaining ORF2 protein, which does not require extraction of the ORF2 protein from within infected cells. What is further needed are methods of obtaining recombinant ORF2 protein in quantities sufficient for efficiently preparing vaccine compositions. What is still further needed are methods for obtaining ORF2 protein which do not require the complicated and labor-intensive methods required by the current ORF2 protein extraction protocols. Finally, with respect to compositions, what is needed in the art is an immunogenic composition which does confer protective immunity against PCV2 infection and lessens the severity of or prevents the clinical signs associated therewith.
SUMMARY OF THE INVENTION
[0010] The present invention overcomes the problems inherent in the prior art and provides a distinct advance in the state of the art. Specifically, one aspect of the present invention provides improved methods of producing and/or recovering recombinant PCV2 ORF2 protein, i) by permitting infection of susceptible cells in culture with a recombinant viral vector containing PCV2 ORF2 DNA coding sequences, wherein ORF2 protein is expressed by the recombinant viral vector, and ii) thereafter recovering the ORF2 in the supernate. It has been unexpectedly discovered that ORF2 is released into the supernate in large quantities if the infection and subsequent incubation of the infected cells is allowed to progress past the typical prior PCV 2 ORF2 recovery process, which extracts the PCV2 ORF2 from within cells. It furthermore has been surprisingly found, that PCV ORF2 protein is robust against prototypical degradation outside of the production cells. Both findings together allow a recovery of high amounts of PCV2 ORF2 protein from the supernate of cell cultures infected with recombinant viral vectors containing a PCV2 ORF2 DNA and expressing the PCV2 ORF2 protein. High amounts of PCV2 ORF2 protein means more than about 20 μg/mL supernate, preferably more than about 25 μg/mL, even more preferred more than about 30 μg/mL, even more preferred more than about 40 μg/mL, even more preferred more than about 50 μg/mL, even more preferred more than about 60 μg/mL, even more preferred more than about 80 μg/mL, even more preferred more than about 100 μg/mL, even more preferred than about 150 μg/mL, most preferred than about 190 μg/mL. Those expression rates can also be achieved for example by the methods as described in Examples 1 to 3.
[0011] Preferred cell cultures have a cell count between about 0.3-2.0×10 6 cells/mL, more preferably from about 0.35-1.9×10 6 cells/mL, still more preferably from about 0.4-1.8×10 6 cells/mL, even more preferably from about 0.45-1.7×10 6 cells/mL, and most preferably from about 0.5-1.5×10 6 cells/mL. Preferred cells are determinable by those of skill in the art. Preferred cells are those susceptible for infection with an appropriate recombinant viral vector, containing a PCV2 ORF2 DNA and expressing the PCV2 ORF2 protein. Preferably the cells are insect cells, and more preferably, they include the insect cells sold under the trademark Sf+ insect cells (Protein Sciences Corporation, Meriden, Conn.).
[0012] Appropriate growth media will also be determinable by those of skill in the art with a preferred growth media being serum-free insect cell media such as Excell 420 (JRH Biosciences, Inc., Lenexa, Kans.) and the like. Preferred viral vectors include baculovirus such as BaculoGold (BD Biosciences Pharmingen, San Diego, Calif.), in particular if the production cells are insect cells. Although the baculovirus expression system is preferred, it is understood by those of skill in the art that other expression systems will work for purposes of the present invention, namely the expression of PCV2 ORF2 into the supernatant of a cell culture. Such other expression systems may require the use of a signal sequence in order to cause ORF2 expression into the media. It has been surprisingly discovered that when ORF2 is produced by a baculovirus expression system, it does not require any signal sequence or further modification to cause expression of ORF2 into the media. It is believed that this protein can independently form virus-like particles (Journal of General Virology Vol. 81, pp. 2287 (2000) and be secreted into the culture supernate. The recombinant viral vector containing the PCV2 ORF2 DNA sequences has a preferred multiplicity of infection (MOI) of between about 0.03-1.5, more preferably from about 0.05-1.3, still more preferably from about 0.09-1.1, and most preferably from about 0.1-1.0, when used for the infection of the susceptible cells. Preferably the MOIs mentioned above relates to one mL of cell culture fluid. Preferably, the method described herein comprises the infection of 0.35-1.9×10 6 cells/mL, still more preferably of about 0.4-1.8×10 6 cells/mL, even more preferably of about 0.45-1.7×10 6 cells/mL, and most preferably of about 0.5-1.5×10 6 cells/mL with a recombinant viral vector containing a PCV2 ORF2 DNA and expressing the PCV2 ORF protein having a MOI (multiplicity of infection) of between about 0.03-1.5, more preferably from about 0.05-1.3, still more preferably from about 0.09-1.1, and most preferably from about 0.1-1.0.
[0013] The infected cells are then incubated over a period of up to ten days, more preferably from about two days to about ten days, still more preferably from about four days to about nine days, and most preferably from about five days to about eight days. Preferred incubation conditions include a temperature between about 22-32° C., more preferably from about 24-30° C., still more preferably from about 25-29° C., even more preferably from about 26-28° C., and most preferably about 27° C. Preferably, the Sf+ cells are observed following inoculation for characteristic baculovirus-induced changes. Such observation may include monitoring cell density trends and the decrease in viability during the post-infection period. It was found that peak viral titer is observed 3-5 days after infection and peak ORF2 release from the cells into the supernate is obtained between days 5 and 8, and/or when cell viability decreases to less than 10%.
[0014] Thus, one aspect of the present invention provides an improved method of producing and/or recovering recombinant PCV2 ORF2 protein, preferably in amounts described above, by i) permitting infection of a number of susceptible cells (see above) in culture with a recombinant viral vector with a MOI as defined above, ii) expressing PCV2 ORF2 protein by the recombinant viral vector, and iii) thereafter recovering the PCV2 ORF2 in the supernate of cells obtained between days 5 and 8 after infection and/or cell viability decreases to less then 10%. Preferably, the recombinant viral vector is a recombinant baculovirus containing PCV2 ORF2 DNA coding sequences and the cells are Sf+ cells. Additionally, it is preferred that the culture be periodically examined for macroscopic and microscopic evidence of contamination or for atypical changes in cell morphology during the post-infection period. Any culture exhibiting any contamination should be discarded. Preferably, the expressed ORF2 recombinant protein is secreted by the cells into the surrounding growth media that maintains cell viability. The ORF2 is then recovered in the supernate surrounding the cells rather than from the cells themselves.
[0015] The recovery process preferably begins with the separation of cell debris from the expressed ORF2 in media via a separation step. Preferred separation steps include filtration, centrifugation at speeds up to about 20,000×g, continuous flow centrifugation, chromatographic separation using ion exchange or gel filtration, and conventional immunoaffinity methods. Those methods are known to persons skilled in the art for example by (Harris and Angel (eds.), Protein purification methods—a practical approach, IRL press Oxford 1995). The most preferred separation methods include centrifugation at speeds up to about 20,000×g and filtration. Preferred filtration methods include dead-end microfiltration and tangential flow (or cross flow) filtration including hollow fiber filtration dead-end micro filtration. Of these, dead-end microfiltration is preferred. Preferred pore sizes for dead-end microfiltration are between about 0.30-1.35 μm, more preferably between about 0.35-1.25 μm, still more preferably between about 0.40-1.10 μm, and most preferably between about 0.45-1.0 μm. It is believed that any conventional filtration membrane will work for purposes of the present invention and polyethersulfone membranes are preferred. Any low weight nucleic acid species are removed during the filtration step.
[0016] Thus, one further aspect of the present invention provides an improved method of producing and/or recovering recombinant PCV2 ORF2 protein, preferably in amounts described above, by i) permitting infection of a number of susceptible cells (see above) in culture with a recombinant viral vector with a MOI as defined above, ii) expressing PCV ORF2 protein by the recombinant viral vector, iii) recovering the PCV2 ORF2 in the supernate of cells obtained between days 5 and 8 after infection and/or cell viability decreases to less then 10%, and, iv) separating cell debris from the expressed PCV2 ORF2 via a separation step. Preferably, the recombinant viral vector is a baculovirus containing ORF2 DNA coding sequences and the cells are SF+ cells. Preferred separation steps are those described above. Most preferred is a dead-end microfiltration using a membrane having a pore size between about 0.30-1.35 μm, more preferably between about 0.35-1.25 μm, still more preferably between about 0.40-1.10 μm, and most preferably between about 0.45-1.0 μm.
[0017] For recovery of PCV2 ORF2 that will be used in an immunogenic or immunological composition such as a vaccine, the inclusion of an inactivation step is preferred in order to inactivate the viral vector. An “immunogenic or immunological composition” refers to a composition of matter that comprises at least one antigen which elicits an immunological response in the host of a cellular and/or antibody-mediated immune response to the composition or vaccine of interest. Usually, an “immunological response” includes but is not limited to one or more of the following effects: the production or activation of antibodies, B cells, helper T cells, suppressor T cells, and/or cytotoxic T cells and/or yd T cells, directed specifically to an antigen or antigens included in the composition or vaccine of interest. Preferably, the host will display either a therapeutic or protective immunological response such that resistance to new infection will be enhanced and/or the clinical severity of the disease reduced. Such protection will be demonstrated by either a reduction or lack of symptoms normally displayed by an infected host, a quicker recovery time and/or a lowered viral titer in the infected host. Thus, the present invention also relates to method of producing and/or recovering recombinant PCV2 ORF2 protein, preferably in amounts described above, by i) permitting infection of a number of susceptible cells (see above) in culture with a recombinant viral vector with a MOI as defined above, ii) expressing PCV ORF2 protein by the recombinant viral vector, iii) recovering the PCV2 ORF2 in the supernate of cells obtained between days 5 and 8 after infection and/or cell viability decreases to less then 10%, iv) separating cell debris from the expressed PCV2 ORF2 via a separation step, and v) inactivating the recombinant viral vector.
[0018] Preferably, this inactivation is done either just before or just after the filtration step, with after the filtration step being the preferred time for inactivation. Any conventional inactivation method can be used for purposes of the present invention. Thus, inactivation can be performed by chemical and/or physical treatments. In preferred forms, the volume of harvest fluids is determined and the temperature is brought to between about 32-42° C., more preferably between about 34-40° C., and most preferably between about 35-39° C. Preferred inactivation methods include the addition cyclized binary ethylenimine (BEI), preferably in a concentration of about 1 to about 20 mM, preferably of about 2 to about 10 mM, still more preferably of about 2 to about 8 mM, still more preferably of about 3 to about 7 mM, most preferably of about 5 mM. For example the inactivation includes the addition of a solution of 2-bromoethyleneamine hydrobromide, preferably of about 0.4M, which has been cyclized to 0.2M binary ethylenimine (BEI) in 0.3N NaOH, to the fluids to give a final concentration of about 5 mM BEI. Preferably, the fluids are then stirred continuously for 72-96 hours and the inactivated harvest fluids can be stored frozen at −40° C. or below or between about 1-7° C. After inactivation is completed a sodium thiosulfate solution, preferably at 1.0M is added to neutralize any residual BEI. Preferably, the sodium thiosulfate is added in equivalent amount as compared to the BEI added prior to for inactivation. For example, in the event BEI is added to a final concentration of 5 mM, a 1.0M sodium thiosulfate solution is added to give a final minimum concentration of 5 mM to neutralize any residual BEI.
[0019] Thus, one further aspect of the present invention relates to a method of producing recombinant PCV2 ORF2 protein, preferably in amounts described above, by i) permitting infection of a number of susceptible cells (see above) in culture with a recombinant viral vector with a MOI as defined above, ii) expressing PCV ORF2 protein by the recombinant viral vector, iii) recovering the PCV2 ORF2 in the supernate of cells obtained between days 5 and 8 after infection and/or cell viability decreases to less then 10%, iv) separating cell debris from the expressed PCV2 ORF2 via a separation step, and v) inactivating the recombinant viral vector. Preferably, the recombinant viral vector is a baculovirus containing ORF2 DNA coding sequences and the cells are SF+ cells. Preferred separation steps are those described above, most preferred is the filtration step. Preferred inactivation steps are those described above. Preferably, inactivation is performed between about 35-39° C. and in the presence of 2 to 8 mM BEI, still more preferred in the presence of about 5 mM BEI. It has been surprisingly found, that higher concentrations of BEI negatively affect the PCV2 ORF2 protein.
[0020] According to one further aspect of the present invention, the method described above also includes an neutralization step after step v). This step vi) comprises adding of an equivalent amount of an agent that neutralizes the inactivation agent within the solution. Preferably, if the inactivation agent is BEI, addition of sodium thiosulfate to an equivalent amount is preferred. Thus, according to a further aspect, step vi) comprises adding of a sodium thiosulfate solution to a final concentration of about 1 to about 20 mM, preferably of about 2 to about 10 mM, still more preferably of about 2 to about 8 mM, still more preferably of about 3 to about 7 mM most preferably of about 5 mM, when the inactivation agent is BEI.
[0021] In preferred forms and especially in forms that will use the recombinant PCV2 ORF2 protein in an immunogenic composition such as a vaccine, each lot of harvested ORF2 will be tested for inactivation by passage in the anchorage dependent, baculovirus susceptible Sf+ cells. In a preferred form of this testing, 150 cm 2 of appropriate cell culture monolayer is inoculated with 1.0 mL of inactivated PCV2 fluids and maintained at 25-29° C. for 14 days with at least two passages. At the end of the maintenance period, the cell monolayers are examined for cytopathogenic effect (CPE) typical of PCV2 ORF2 baculovirus. Preferably, positive virus controls are also used. Such controls can consist of one culture of Sf+ cells inoculated with a non-inactivated reference PCV2 ORF2 baculovirus and one flask of Sf+ cells that remain uninoculated. After incubation and passage, the absence of virus-infected cells in the BEI treated viral fluids would constitute a satisfactory inactivation test. The control cells inoculated with the reference virus should exhibit CPE typical of PCV2 ORF2 baculovirus and the uninoculated flask should not exhibit any evidence of PCV2 ORF2 baculovirus CPE. Alternatively, at the end of the maintenance period, the supernatant samples could be collected and inoculated onto a Sf+96 well plate, which has been loaded with Sf+ cells, and then maintained at 25-29° C. for 5-6 days. The plate is then fixed and stained with anti-PCV2 ORF2 antibody conjugated to FITC. The absence of CPE and ORF2 expression, as detected by IFA micoscopy, in the BEI treated viral fluids constitutes a satisfactory inactivation test. The control cells inoculated with the reference virus should exhibit CPE and IFA activity and the uninoculated flask should not exhibit any evidence of PCV2 ORF2 baculovirus CPE and contain no IFA activity.
[0022] Thus a further aspect of the present invention relates to an inactivation test for determining the effectiveness of the inactivation of the recombination viral vector, comprises the steps: i) contacting at least a portion of the culture fluid containing the recombinant viral vector with an inactivating agent, preferably as described above, ii) adding a neutralization agent to neutralize the inactivation agent, preferably as described above, and iii) determining the residual infectivity by the assays as described above.
[0023] After inactivation, the relative amount of recombinant PCV2 ORF2 protein in a sample can be determined in a number of ways. Preferred methods of quantitation include SDS-PAGE densitometry, ELISA, and animal vaccination studies that correlate known quantities of vaccine with clinical outcomes (serology, etc.). When SDS-PAGE is utilized for quantitation, the sample material containing an unknown amount of recombinant PCV2 ORF2 protein is run on a gel, together with samples that contain different known amounts of recombinant PCV2 ORF2 protein. A standard curve can then be produced based on the known samples and the amount of recombinant PCV2 ORF2 in the unknown sample can be determined by comparison with this standard curve. Because ELISAs are generally recognized as the industry standard for antigen quantitation, they are preferred for quantitation.
[0024] Thus, according to a further aspect, the present invention also relates to an ELISA for the quantification of recombinant PCV2 ORF2 protein. A preferred ELISA as provided herewith will generally begin with diluting the capture antibody 1:6000 or an appropriate working dilution in coating buffer. A preferred capture antibody is Swine anti-PCV2 PAb Prot. G purified, and a preferred coating buffer is 0.05M Carbonate buffer, which can be made by combining 2.93 g NaHCO 3 (Sigma Cat. No. S-6014, or equivalent) and 1.59 g NaCO 3 (Sigma Cat. No. S-6139, or equivalent). The mixture is combined with distilled water, or equivalent, to make one liter at a pH of 9.6±0.1. Next, the capture antibody is diluted 1:6000, or any other appropriate working dilution, in coating buffer. For example, for four plates, one would need 42 mLs of coating buffer and seven μL of capture antibody. Using a reverse pipetting method, 100 μL of diluted capture antibody is added to all of the wells. In order to obtain an even coating, the sides of each plate should be gently tapped. The plates are then sealed with plate sealers, prior to stacking the plates and capping the stack with an empty 96-well plate. The plates are incubated overnight (14-24 hours) at 35-39° C. Each plate is then washed three times with wash buffer using the ultra wash plus micro titer plate washer set at 250 μL/wash with three washes and no soak time. After the last wash, the plates should be tapped onto a paper towel. Again, using the reverse pipetting technique, 250 μL of blocking solution should be added to all of the wells. The test plates should be sealed and incubated for approximately one hour (±five minutes) at 35-37° C. Preferably, the plates will not be stacked after this step. During the blocking step, all test samples should be pulled out and thawed at room temperature. Next, four separate dilution plates should be prepared by adding 200 μL of diluent solution to all of the remaining wells except for row A and row H, columns 1-3. Next, six test tubes should be labeled as follows, low titer, medium titer, high titer, inactivated/filtered (1:240), inactivated/filtered (1:480), and internal control. In the designated tubes, an appropriate dilution should be prepared for the following test samples. The thawed test samples should be vortexed prior to use. For four plates, the following dilutions will be made: A) the low titer will not be pre-diluted: 3.0 mLs of low titer; B) negative control at a 1:30 dilution (SF+ cells): 3.77 mLs of diluent+130 μL of the negative control; C) medium titer at a 1:30 dilution (8 μg/mL): 3.77 mLs of diluent+130 μL of the medium titer; D) high titer at a 1:90 dilution (16 μg/mL): 2.967 mLs of diluent+33 μL of high titer; E) inactivated/filtered at a 1:240 dilution: 2.39 mLs of diluent+10 μL of inactivated/filtered sample; F) inactivated/filtered at a 1:480 dilution: 1.0 mL of diluent+1.0 mL of inact/filtered (1:240) prepared sample from E above; G) internal control at 1:30 dilution: 3.77 mLs of diluent+130 μL of the internal control. Next, add 300 μL of the prepared samples to corresponding empty wells in the dilution plates for plates 1 through 4. The multichannel pipettor is then set to 100 μL, and the contents in Row A are mixed by pipetting up and down for at least 5 times and then 100 μL is transferred to Row B using the reverse pipetting technique. The tips should be changed and this same procedure is followed down the plate to Row G. Samples in these dilution plates are now ready for transfer to the test plates once the test plates have been washed 3 times with wash buffer using the ultrawash plus microtiter plate washer (settings at 250 μL/wash, 3 washes, no soak time). After the last wash, the plates should be tapped onto a paper towel. Next, the contents of the dilution plate are transferred to the test plate using a simple transfer procedure. More specifically, starting at row H, 100 μL/well is transferred from the dilution plate(s) to corresponding wells of the test plate(s) using reverse pipetting technique. After each transfer, the pipette tips should be changed. From Row G, 100 μL/well in the dilution plate(s) is transferred to corresponding wells of the test plate(s) using reverse pipetting technique. The same set of pipette tips can be used for the remaining transfer. To ensure a homogenous solution for the transfer, the solution should be pipetted up and down at least 3 times prior to transfer. Next, the test plate(s) are sealed and incubated for 1.0 hour±5 minutes at 37° C.±2.0° C. Again, it is preferable not to stack the plates. The plates are then washed 3 times with wash buffer using the ultrawash plus microtiter plate washer (settings at 250 μL/wash, 3 washes, and no soak time). After the last wash, the plates are tapped onto a paper towel. Using reverse pipetting technique, 100 μL of detection antibody diluted 1:300, or appropriate working dilution, in diluent solution is added to all of the wells of the test plate(s). For example, for four plates, one will need 42 mLs of diluent solution with 140 μL of capture antibody. The test plate(s) are then sealed and incubated for 1.0 hour±5 minutes at 37° C.±2.0° C. Again, the plates are washed 3 times with wash buffer using the ultrawash plus microtiter plate washer (settings at 250 μL/wash, 3 washes, and no soak time). After the last wash, the plates are tapped onto a paper towel. Next, the conjugate diluent is prepared by adding 1% normal rabbit serum to the diluent. For example, for four plates, 420 μL of normal rabbit serum is added to 42 mL of diluent. The conjugate antibody is diluted to 1:10,000, or any other appropriate working dilution, in a freshly prepared conjugate diluent solution to all wells of the test plate(s). Using a reverse pipetting technique, 100 μL of this diluted conjugate antibody is added to all the wells. The test plate(s) are then sealed and incubated for 45±5 minutes at 37° C.±2.0° C.
[0025] Preferably, the plates are not stacked. The plates are then washed 3 times with wash buffer using the ultrawash plus microtiter plate washer (settings at 250 μL/wash, 3 washes, and no soak time). After the last wash, the plates are tapped onto a paper towel. Next, equal volumes of TMB Peroxidase Substrate (Reagent A) with Peroxidase Solution B (Reagent B) are mixed immediately prior to use. The amount mixed will vary depending upon the quantity of plates but each plate will require 10 mL/plate+2 mLs. Therefore, for 4 plates, it will be 21 mL of Reagent A+21 mL of Reagent B. Using a reverse pipetting technique, 100 μL of substrate is added to all wells of the test plate(s). The plates are then incubated at room temperature for 15 minutes±15 seconds. The reaction is stopped by the addition of 100 μL of 1N HCl solution to all wells using a reverse pipetting technique. The ELISA plate reader is then turned on and allowed to proceed through its diagnostics and testing phases in a conventional manner.
[0026] A further aspect of the invention relates to a method for constructing a recombinant viral vector containing PCV2 ORF2 DNA and expressing PCV2 ORF2 protein in high amounts, when infected into susceptible cells. It has been surprisingly found that the recombinant viral vector as provided herewith expresses high amounts, as defined above, of PCV2 ORF2 after infecting susceptible cells. Therefore, the present invention also relates to an improved method for producing and/or recovering of PCV2 ORF2 protein, preferably comprises the step: constructing a recombinant viral vector containing PCV2 ORF2 DNA and expressing PCV2 ORF2 protein. Preferably, the viral vector is a recombinant baculorvirus. Details of the method for constructing recombinant viral vectors containing PCV2 ORF2 DNA and expressing PCV2 ORF2 protein, as provided herewith, are described to the following: In preferred forms the recombinant viral vector containing PCV2 ORF 2 DNA and expressing PCV2 ORF2 protein used to infect the cells is generated by transfecting a transfer vector that has had an ORF2 gene cloned therein into a viral vector. Preferably, only the portion of the transfer vector is transfected into the viral vector, that contains the ORF2 DNA. The term “transfected into a viral vector” means, and is used as a synonym for “introducing” or “cloning” a heterologous DNA into a viral vector, such as for example into a baculovirus vector. The viral vector is preferably but not necessarily a baculovirus.
[0027] Thus, according to a further aspect of the present invention, the recombinant viral vector is generated by recombination between a transfer vector containing the heterologous PCV2 ORF2 DNA and a viral vector, preferably a baculorvirus, even more preferably a linearized replication-deficient baculovirus (such as Baculo Gold DNA). A “transfer vector” means a DNA molecule, that includes at least one origin of replication, the heterologous gene, in the present case PCV2 ORF2, and DNA sequences which allows the cloning of said heterologous gene into the viral vector. Preferably the sequences which allow cloning of the heterologous gene into the viral vector are flanking the heterologous gene. Even more preferably those flanking sequences are at least homologous in parts with sequences of the viral vector. The sequence homology then allows recombination of both molecules, the viral vector and the transfer vector to generate a recombinant viral vector containing the heterologous gene. One preferred transfer vector is the pVL1392 vector (BD Biosciences Pharmingen), which is designed for co-transfection with the BaculoGold DNA into the preferred Sf+ cell line. Preferably, said transfer vector comprises a PCV2 ORF2 DNA. The construct co-transfected is approximately 10,387 base pairs in length.
[0028] In more preferred forms, the methods of the present invention will begin with the isolation of PCV2 ORF2 DNA. Generally, this can be from a known or unknown strain as the ORF2 DNA appears to be highly conserved with at least about 95% sequence identity between different isolates. Any PCV2 ORF2 gene known in the art can be used for purposes of the present invention as each would be expressed into the supernate. The PCV ORF2 DNA is preferably amplified using PCR methods, even more preferred together with the introduction of a 5′ flanking Kozak's consensus sequence (CCGCCAUG) (SEQ ID NO 1) and/or a 3′ flanking EcoR1 site (GAATTC) (SEQ ID NO 2). Such introduction of a 5′ Kozak's consensus preferably removes the naturally occurring start codon AUG of PCV2 ORF2. The 3′ EcoR1 site is preferably introduced downstream of the stop codon of the PCV2 ORF2. More preferably it is introduced downstream of a poly A transcription termination sequence, that itself is located downstream of the PCV2 ORF2 stop codon. It has been found, that the use of a Kozak consensus sequence, in particular as described above, increases the expression level of the subsequent PCV2 ORF2 protein. The amplified PCV2 ORF2 DNA, with these additional sequences, is cloned into a vector. A preferred vector for this initial cloning step is the pGEM-T-Easy Vector (Promega, Madison, Wis.). The PCV2 ORF2 DNA including some pGEM vector sequences (SEQ ID NO: 7) is preferably excised from the vector at the Not1 restriction site. The resulting DNA is then cloned into the transfer vector.
[0029] Thus, in one aspect of the present invention, a method for constructing a recombinant viral vector containing PCV2 ORF2 DNA is provided. This method comprises the steps: i) cloning a recombinant PCV2 ORF2 into a transfer vector; and ii) transfecting the portion of the transfer vector containing the recombinant PCV2 ORF2 into a viral vector, to generate the recombinant viral vector. Preferably, the transfer vector is that described above or is constructed as described above or as exemplarily shown in FIG. 1 . Thus according to a further aspect, the transfer vector, used for the construction of the recombinant viral vector as described herein, contains the sequence of SEQ ID NO: 7.
[0030] According to a further aspect, this method further comprises prior to step i) the following step: amplifying the PCV2 ORF2 DNA in vitro, wherein the flanking sequences of the PCV2 ORF2 DNA are modified as described above. In vitro methods for amplifying the PCV2 ORF2 DNA and modifying the flanking sequences, cloning in vitro amplified PCV2 ORF2 DNA into a transfer vector and suitable transfer vectors are described above, exemplarily shown in FIG. 1 , or known to a person skilled in the art. Thus according to a further aspect, the present invention relates to a method for constructing a recombinant viral vector containing PCV2 ORF2 DNA and expressing PCV2 ORF2 protein comprises the steps of: i) amplifying PCV2 ORF2 DNA in vitro, wherein the flanking sequences of said PCV2 ORF2 DNA are modified, ii) cloning the amplified PCV2 ORF2 DNA into a transfer vector; and iii) transfecting the transfer vector or a portion thereof containing the recombinant PCV2 ORF2 DNA into a viral vector to generate the recombinant viral vector. Preferably, the modification of the flanking sequences of the PCV2 ORF2 DNA is performed as described above, e.g. by introducing a 5′ Kozak sequence and/or a EcoR 1 site, preferably as described above.
[0031] According to a further aspect, a method of producing and/or recovering recombinant protein expressed by open reading frame 2 of PCV2 is provided. The method generally comprises the steps of: i) cloning a recombinant PCV2 ORF2 into a transfer vector; ii) transfecting the portion of the transfer vector containing the recombinant PCV2 ORF2 into a virus; iii) infecting cells in media with the transfected virus; iv) causing the transfected virus to express the recombinant protein from PCV2 ORF2; v) separating cells from the supernate; and vi) recovering the expressed PCV2 ORF2protein from the supernate.
[0032] Methods of how to clone a recombinant PCV2 ORF2 DNA into a transfer vector are described above. Preferably, the transfer vector contains the sequence of SEQ ID NO:3, SEQ ID NO:4, SEQ ID NO:7. However, the transfer vector can contain any PCV2 ORF2 DNA, unmodified or modified, as long as the PCV2 ORF2 DNA, when transfected into a recombinant viral vector, is expressed in cell culture. Preferably, the recombinant viral vector comprises the sequence of SEQ ID NO:8. Moreover, methods of how to infect cells, preferably how to infect insect cells with a defined number of recombinant baculovirus containing PCV2 ORF2 DNA and expressing PCV2 ORF2 protein are described above in detail. Moreover, steps of separating cells from the supernate as well as steps for recovering the expressed PCV2 ORF2 protein are also described above in detail. Any of these specific process steps, as described herein, are part of the method of producing and/or recovering recombinant protein expressed by open reading frame 2 of PCV2 as described above. Preferably, the cells are SF+ cells. Still more preferably, cell cultures have a cell count between about 0.3-2.0×10 6 cells/mL, more preferably from about 0.35-1.9×10 6 cells/mL, still more preferably from about 0.4-1.8×10 6 cells/mL, even more preferably from about 0.45-1.7×10 6 cells/mL, and most preferably from about 0.5-1.5×10 6 cells/mL. Preferably, the recombinant viral vector containing the PCV2 ORF2 DNA has a preferred multiplicity of infection (MOI) of between about 0.03-1.5, more preferably from about 0.05-1.3, still more preferably from about 0.09-1.1, still more preferably from about 0.1-1.0, and most preferably to about 0.5, when used for the infection of the susceptible cells. Preferably, recovering of the PCV2 ORF2 protein in the supernate of cells obtained between days 5 and 8 after infection and/or cell viability decreases to less then 10%. Preferably, for producing PCV2 ORF2 protein, cells are cultivated at 25 to 29° C. Preferably, the separation step is a centrifugation or a filtration step.
[0033] Optionally, this method can include the step of amplifying the PCV2 ORF2 DNA from a strain of PCV2 prior to cloning the PCV2 ORF2 DNA into the transfer vector. In preferred forms, a 5′ Kozak's sequence, a 3′ EcoR1 site, and combinations thereof can also be added to the amplified sequence, preferably prior to or during amplification. A preferred 5′Kozak's sequence comprises SEQ ID NO: 1. A preferred 3′ EcoR1 site comprises SEQ ID NO: 2. Preferred PCV2 ORF2 DNA comprises the nucleotide sequence Genbank Accession No. AF086834 (SEQ ID NO: 3) and SEQ ID NO: 4. Preferred recombinant PCV2 ORF2 protein comprises the amino acid sequence of SEQ ID NO: 5, which is the protein encoded by SEQ ID NO: 3 (Genbank Accession No. AF086834) and SEQ ID No: 6, which is the protein encoded by SEQ ID NO: 4. A preferred media comprises serum-free insect cell media, still more preferably Excell 420 media. When the optional amplification step is performed, it is preferable to first clone the amplified open reading frame 2 into a first vector, excise the open reading frame 2 from the first vector, and use the excised open reading frame for cloning into the transfer vector. A preferred cell line for cotransfection is the SF+ cell line. A preferred virus for cotransfection is baculovirus. In preferred forms of this method, the transfected portion of the transfer vector comprises SEQ ID NO: 8. Finally, for this method, it is preferred to recover the PCV2 open reading frame 2 (ORF2) protein in the cell culture supernate at least 5 days after infecting the cells with the virus.
[0034] Thus, a further aspect of the invention relates to a method for producing and/or recovering the PCV2 open reading frame 2, comprises the steps: i) amplifying the PCV2 ORF2 DNA in vitro, preferably by adding a 5′ Kozak sequence and/or by adding a 3′ EcoR1 restriction site, ii) cloning the amplified PCV2 ORF2 into a transfer vector; iii) transfecting the portion of the transfer vector containing the recombinant PCV2 ORF2 into a virus; iv) infecting cells in media with the transfected virus; v) causing the transfected virus to express the recombinant protein from PCV2 ORF2; vi) separating cells from the supernate; and vii) recovering the expressed PCV2 ORF2 protein from the supernate.
[0035] A further aspect of the present invention relates to a method for preparing a composition comprising PCV2 ORF2 protein, and inactivated viral vector. This method comprises the steps: i) cloning the amplified PCV2 ORF2 into a transfer vector; ii) transfecting the portion of the transfer vector containing the recombinant PCV2 ORF2 into a virus; iii) infecting cells in media with the transfected viral vector; iv) causing the transfected viral vector to express the recombinant protein from PCV2 ORF2; v) separating cells from the supernate; vi) recovering the expressed PCV2 ORF2 protein from the supernate; and vii) inactivating the recombinant viral vector. Preferably, the recombinant viral vector is a baculovirus containing ORF2 DNA coding sequences and the cells are SF+ cells. Preferred separation steps are those described above, most preferred is the filtration step. Preferred inactivation steps are those described above. Preferably, inactivation is performed between about 35-39° C. and in the presence of 2 to 8 mM BEI, still more preferred in the presence of about 5 mM BEI. It has been surprisingly found, that higher concentrations of BEI negatively affect the PCV2 ORF2 protein, and lower concentrations are not effective to inactivate the viral vector within 24 to 72 hours of inactivation. Preferably, inactivation is performed for at least 24 hours, even more preferred for 24 to 72 hours.
[0036] According to a further aspect, the method for preparing a composition comprising PCV2 ORF2 protein, and inactivated viral vector, as described above, also includes an neutralization step after step vii). This step viii) comprises adding of an equivalent amount of an agent that neutralizes the inactivation agent within the solution. Preferably, if the inactivation agent is BEI, addition of sodium thiosulfate to an equivalent amount is preferred. Thus, according to a further aspect, step viii) comprises adding of a sodium thiosulfate solution to a final concentration of about 1 to about 20 mM, preferably of about 2 to about 10 mM, still more preferably of about 2 to about 8 mM, still more preferably of about 3 to about 7 mM, most preferably of about 5 mM, when the inactivation agent is BEI.
[0037] According to a further aspect, the method for preparing a composition comprising PCV2 ORF2 protein, and inactivated viral vector, as described above, comprises prior to step i) the following step: amplifying the PCV2 ORF2 DNA in vitro, wherein the flanking sequences of the PCV2 ORF2 DNA are modified as described above. In vitro methods for amplifying the PCV2 ORF2 DNA and modifying the flanking sequences, cloning in vitro amplified PCV2 ORF2 DNA into a transfer vector and suitable transfer vectors are described above, exemplarily shown in FIG. 1 , or known to a person skilled in the art. Thus according to a further aspect, this method comprises the steps: i) amplifying PCV2 ORF2 DNA in vitro, wherein the flanking sequences of said PCV2 ORF2 DNA are modified, ii) cloning the amplified PCV2 ORF2 DNA into a transfer vector; and iii) transfecting the transfer vector or a portion thereof containing the recombinant PCV2 ORF2 DNA into a viral vector to generate the recombinant viral vector, iv) infecting cells in media with the transfected virus; v) causing the transfected virus to express the recombinant protein from PCV2 ORF2; vi) separating cells from the supernate; vii) recovering the expressed PCV2 ORF2 protein from the supernate; viii) inactivating the recombinant viral vector, preferably, in the presence of about 1 to about 20 mM BEI, most preferred in the presence of about 5 mM BEI; and ix) adding of an equivalent amount of an agent that neutralizes the inactivation agent within the solution, preferably, adding of a sodium thiosulfate solution to a final concentration of about 1 to about 20 mM, preferably of about 5 mM, when the inactivation agent is BEI.
[0038] In another aspect of the present invention, a method for preparing a composition, preferably an antigenic composition, such as for example a vaccine, for invoking an immune response against PCV2 is provided. Generally, this method includes the steps of transfecting a construct into a virus, wherein the construct comprises i) recombinant DNA from ORF2 of PCV2, ii) infecting cells in growth media with the transfected virus, iii) causing the virus to express the recombinant protein from PCV2 ORF2, iv) recovering the expressed ORF2 protein from the supernate, v) and preparing the composition by combining the recovered protein with a suitable adjuvant and/or other pharmaceutically acceptable carrier.
[0039] “Adjuvants” as used herein, can include aluminum hydroxide and aluminum phosphate, saponins e.g., Quil A, QS-21 (Cambridge Biotech Inc., Cambridge Mass.), GPI-0100 (Galenica Pharmaceuticals, Inc., Birmingham, Ala.), water-in-oil emulsion, oil-in-water emulsion, water-in-oil-in-water emulsion. The emulsion can be based in particular on light liquid paraffin oil (European Pharmacopea type); isoprenoid oil such as squalane or squalene; oil resulting from theoligomerization of alkenes, in particular of isobutene or decene; esters of acids or of alcohols containing a linear alkyl group, more particularly plant oils, ethyl oleate, propylene glycol di-(caprylate/caprate), glyceryl tri-(caprylate/caprate) or propylene glycol dioleate; esters of branched fatty acids or alcohols, in particular isostearic acid esters. The oil is used in combination with emulsifiers to form the emulsion. The emulsifiers are preferably nonionic surfactants, in particular esters of sorbitan, of mannide (e.g. anhydromannitol oleate), of glycol, of polyglycerol, of propylene glycol and of oleic, isostearic, ricinoleic or hydroxystearic acid, which are optionally ethoxylated, and polyoxypropylene-polyoxyethylene copolymer blocks, in particular the Pluronic products, especially L121. See Hunter et al., The Theory and Practical Application of Adjuvants (Ed. Stewart-Tull, D. E. S.). JohnWiley and Sons, NY, pp 51-94 (1995) and Todd et al., Vaccine 15:564-570 (1997).
[0040] For example, it is possible to use the SPT emulsion described on page 147 of “Vaccine Design, The Subunit and Adjuvant Approach” edited by M. Powell and M. Newman, Plenum Press, 1995, and the emulsion MF59 described on page 183 of this same book.
[0041] A further instance of an adjuvant is a compound chosen from the polymers of acrylic or methacrylic acid and the copolymers of maleic anhydride and alkenyl derivative. Advantageous adjuvant compounds are the polymers of acrylic or methacrylic acid which are cross-linked, especially with polyalkenyl ethers of sugars or polyalcohols. These compounds are known by the term carbomer (Phameuropa Vol. 8, No. 2, June 1996). Persons skilled in the art can also refer to U.S. Pat. No. 2,909,462 which describes such acrylic polymers cross-linked with a polyhydroxylated compound having at least 3 hydroxyl groups, preferably not more than 8, the hydrogen atoms of at least three hydroxyls being replaced by unsaturated aliphatic radicals having at least 2 carbon atoms. The preferred radicals are those containing from 2 to 4 carbon atoms, e.g. vinyls, allyls and other ethylenically unsaturated groups. The unsaturated radicals may themselves contain other substituents, such as methyl. The products sold under the name Carbopol; (BF Goodrich, Ohio, USA) are particularly appropriate. They are cross-linked with an allyl sucrose or with allyl pentaerythritol. Among then, there may be mentioned Carbopol 974P, 934P and 971P. Most preferred is the use of Cabopol 971P. Among the copolymers of maleic anhydride and alkenyl derivative, the copolymers EMA (Monsanto) which are copolymers of maleic anhydride and ethylene. The dissolution of these polymers in water leads to an acid solution that will be neutralized, preferably to physiological pH, in order to give the adjuvant solution into which the immunogenic, immunological or vaccine composition itself will be incorporated.
[0042] Further suitable adjuvants include, but are not limited to, the RIBI adjuvant system (Ribi Inc.), Block co-polymer (CytRx, Atlanta Ga.), SAF-M (Chiron, Emeryville Calif.), monophosphoryl lipid A, Avridine lipid-amine adjuvant, heat-labile enterotoxin from E. coli (recombinant or otherwise), cholera toxin, IMS 1314 or muramyl dipeptide among many others.
[0043] Preferably, the adjuvant is added in an amount of about 100 μg to about 10 mg per dose. Even more preferred the adjuvant is added in an amount of about 100 μg to about 10 mg per dose. Even more preferred the adjuvant is added in an amount of about 500 μg to about 5 mg per dose. Even more preferred the adjuvant is added in an amount of about 750 μg to about 2.5 mg per dose. Most preferred the adjuvant is added in an amount of about 1 mg per dose.
[0044] Thus, according to a further aspect, the method for preparing an antigenic composition, such as for example a vaccine, for invoking an immune response against PCV2 comprises i) preparing and recovering PCV2 ORF2 protein, and ii) admixing this with a suitable adjuvant. Preferably, the adjuvant is Carbopol 971P. Even more preferred, Carbopol 971P is added in an amount of about 500 μg to about 5 mg per dose, even more preferred in an amount of about 750 μg to about 2.5 mg per dose and most preferred in an amount of about 1 mg per dose. Preferably, the process step i) includes the process steps as described for the preparation and recovery of PCV2 ORF2. For example, in preferred forms of this method, the construct comprising PCV2 ORF2 DNA is obtained in a transfer vector. Suitable transfer vectors and methods of preparing them are described above. Optionally, the method may include the step of amplifying the ORF2 from a strain of PCV2 through PCR prior to cloning the ORF2 into the transfer vector. Preferred open reading frame sequences, Kozak's sequences, 3′ EcoR1 site sequences, recombinant protein sequences, transfected construct sequences, media, cells, and viruses are as described in the previous methods. Another optional step for this method includes cloning the amplified PCV2 ORF2 DNA into a first vector, excising the ORF2 DNA from this first vector, and using this excised PCV2 ORF2 DNA for cloning into the transfer vector. As with the other methods, it is preferred to wait for at least 5 days after infection of the cells by the transfected baculovirus prior to recovery of recombinant ORF2 protein from the supernate. Preferably, the recovery step of this method also includes the step of separating the media from the cells and cell debris. This can be done in a variety of ways but for ease and convenience, it is preferred to filter the cells, cell debris, and growth media through a filter having pores ranging in size from about 0.45 μM to about 1.0 μM. Finally, for this method, it is preferred to include a virus inactivation step prior to combining the recovered recombinant PCV2 ORF2 protein in a composition. This can be done in a variety of ways, but it is preferred in the practice of the present invention to use BEI.
[0045] Thus according to a further aspect, this method comprises the steps: i) amplifying PCV2 ORF2 DNA in vitro, wherein the flanking sequences of said PCV2 ORF2 DNA are modified, ii) cloning the amplified PCV2 ORF2 DNA into a transfer vector; and iii) transfecting the transfer vector or a portion thereof containing the recombinant PCV2 ORF2 DNA into a viral vector to generate the recombinant viral vector, iv) infecting cells in media with the transfected virus; v) causing the transfected virus to express the recombinant protein from PCV2 ORF2; vi) separating cells from the supernate; vii) recovering the expressed PCV2 ORF2 protein from the supernate; viii) inactivating the recombinant viral vector, preferably, in the presence of about 1 to about 20 mM BEI, most preferred in the presence of about 5 mM BEI; ix) adding of an equivalent amount of an agent that neutralizes the inactivation agent within the solution, preferably, adding of a sodium thiosulfate solution to a final concentration of about 1 to about 20 mM, preferably of about 5 mM, when the inactivation agent is BEI, and x) adding a suitable amount of an adjuvant, preferably adding Carbopol, more preferably Carbopol 971P, even more preferred in amounts as described above (e.g. of about 500 μg to about 5 mg per dose, even more preferred in an amount of about 750 μg to about 2.5 mg per dose and most preferred in an amount of about 1 mg per dose).
[0046] Additionally, the composition can include one or more pharmaceutical-acceptable carriers. As used herein, “a pharmaceutical-acceptable carrier” includes any and all solvents, dispersion media, coatings, stabilizing agents, diluents, preservatives, antibacterial and antifungal agents, isotonic agents, adsorption delaying agents, and the like. Most preferred, the composition provided herewith, contains PCV2 ORF2 protein recovered from the supernate of in vitro cultured cells, wherein said cells were infected with a recombinant viral vector containing PCV2 ORF2 DNA and expressing PCV2 ORF2 protein, and wherein said cell culture were treated with about 2 to about 8 mM BEI, preferably with about 5 mM BEI to inactivate the viral vector, and an equivalent concentration of a neutralization agent, preferably sodium thiosulfate solution to a final concentration of about 2 to about 8 mM, preferably of about 5 mM, Carbopol, more preferably Carbopol 971P, preferably in amounts of about 500 μg to about 5 mg per dose, even more preferred in an amount of about 750 μg to about 2.5 mg per dose and most preferred in an amount of about 1 mg per dose, and physiological saline, preferably in an amount of about 50 to about 90% (v/v), more preferably to about 60 to 80% (v/v), still more preferably of about 70% (v/v).
[0047] Thus, a further aspect relates to a method for preparing an antigenic composition, such as for example a vaccine, for invoking an immune response against PCV2 comprising the steps: i) amplifying PCV2 ORF2 DNA in vitro, wherein the flanking sequences of said PCV2 ORF2 DNA are modified, ii) cloning the amplified PCV2 ORF2 DNA into a transfer vector; and iii) transfecting the transfer vector or a portion thereof containing the recombinant PCV2 ORF2 DNA into a viral vector to generate the recombinant viral vector, iv) infecting cells in media with the transfected virus; v) causing the transfected virus to express the recombinant protein from PCV2 ORF2; vi) separating cells from the supernate; vii) recovering the expressed PCV2 ORF2 protein from the supernate; viii) inactivating the recombinant viral vector, preferably, in the presence of about 2 to about 20 mM BEI, most preferred in the presence of about 5 mM BEI; ix) adding of an equivalent amount of an agent that neutralize the inactivation agent within the solution, preferably, adding of a sodium thiosulfate solution to a final concentration of about 0.5 to about 20 mM, preferably of about 5 mM, when the inactivation agent is BEI, x) adding a suitable amount of an adjuvants, preferably adding Carbopol, more preferably Carbopol 971P, still more preferred in amounts as described above (e.g. of about 500 μg to about 5 mg per dose, even more preferred in an amount of about 750 μg to about 2.5 mg per dose and most preferred in an amount of about 1 mg per dose); and xi) adding physiological saline, preferably in an amount of about 50 to about 90% (v/v), more preferably to about 60 to 80% (v/v), still more preferably of about 70% (v/v). Optionally, this method can also include the addition of a protectant. A protectant as used herein, refers to an anti-microbiological active agent, such as for example Gentamycin, Merthiolate, and the like. In particular adding of a protectant is most preferred for the preparation of a multi-dose composition. Those anti-microbiological active agents are added in concentrations effective to prevent the composition of interest for any microbiological contamination or for inhibition of any microbiological growth within the composition of interest.
[0048] Moreover, this method can also comprise addition of any stabilizing agent, such as for example saccharides, trehalose, mannitol, saccharose and the like, to increase and/or maintain product shelf-life. However, it has been surprisingly found, that the resulting formulation is immunologically effective over a period of at least 24 months, without adding any further stabilizing agent.
[0049] A further aspect of the present invention relates to the products result from the methods as described above. In particular, the present invention relates to a composition of matter comprises recombinantly expressed PCV2 ORF2 protein. Moreover, the present invention also relates to a composition of matter that comprises recombinantly expressed PCV2 ORF2 protein, recovered from the supernate of an insect cell culture. Moreover, the present invention also relates to a composition of matter comprises recombinantly expressed PCV2 ORF2 protein, recovered from the supernate of an insect cell culture. Preferably, this composition of matter also comprises an agent suitable for the inactivation of viral vectors. Preferably, said inactivation agent is BEI. Moreover, the present invention also relates to a composition of matter that comprises recombinantly expressed PCV2 ORF2 protein, recovered from the supernate of an insect cell culture, and comprises an agent, suitable for the inactivation of viral vectors, preferably BEI and a neutralization agent for neutralization of the inactivation agent. Preferably, that neutralization agent is sodium thiosulfate, when BEI is used as an inactivation agent.
[0050] In yet another aspect of the present invention, an immunogenic composition that induces an immune response and, more preferably, confers protective immunity against the clinical signs of PCV2 infection, is provided. The composition generally comprises the polypeptide, or a fragment thereof, expressed by Open Reading Frame 2 (ORF2) of PCV2, as the antigenic component of the composition.
[0051] PCV2 ORF2 DNA and protein, as used herein for the preparation of the compositions and also as used within the processes provided herein is a highly conserved domain within PCV2 isolates and thereby, any PCV2 ORF2 would be effective as the source of the PCV ORF2 DNA and/or polypeptide as used herein. A preferred PCV2 ORF2 protein is that of SEQ ID NO. 11. A preferred PCV ORF2 polypeptide is provided herein as SEQ ID NO. 5, but it is understood by those of skill in the art that this sequence could vary by as much as 6-10% in sequence homology and still retain the antigenic characteristics that render it useful in immunogenic compositions. The antigenic characteristics of an immunological composition can be, for example, estimated by the challenge experiment as provided by Example 4. Moreover, the antigenic characteristic of an modified antigen is still retained, when the modified antigen confers at least 70%, preferably 80%, more preferably 90% of the protective immunity as compared to the PCV2 ORF 2 protein, encoded by the polynucleotide sequence of SEQ ID NO:3 or SEQ ID NO:4. An “immunogenic composition” as used herein, means a PCV2 ORF2 protein which elicits an “immunological response” in the host of a cellular and/or antibody-mediated immune response to PCV2 ORF2 protein. Preferably, this immunogenic composition is capable to confer protective immunity against PCV2 infection and the clinical signs associated therewith. In some forms, immunogenic portions of PCV2 ORF2 protein are used as the antigenic component in the composition. The term “immunogenic portion” as used herein refers to truncated and/or substituted forms, or fragments of PCV2 ORF2 protein and/or polynucleotide, respectively. Preferably, such truncated and/or substituted forms, or fragments will comprise at least 6 contiguous amino acids from the full-length ORF2 polypeptide. More preferably, the truncated or substituted forms, or fragments will have at least 10, more preferably at least 15, and still more preferably at least 19 contiguous amino acids from the full-length ORF2 polypeptide. Two preferred sequences in this respect are provided herein as SEQ ID NOs. 9 and 10. It is further understood that such sequences may be a part of larger fragments or truncated forms. A further preferred PCV2 ORF2 polypeptide provided herein is encoded by the nucleotide sequences of SEQ ID NO: 3 or SEQ ID NO: 4. But it is understood by those of skill in the art that this sequence could vary by as much as 6-20% in sequence homology and still retain the antigenic characteristics that render it useful in immunogenic compositions. In some forms, a truncated or substituted form, or fragment of ORF2 is used as the antigenic component in the composition. Preferably, such truncated or substituted forms, or fragments will comprise at least 18 contiguous nucleotides from the full-length ORF2 nucleotide sequence, e.g. of SEQ ID NO: 3 or SEQ ID NO: 4. More preferably, the truncated or substituted forms, or fragments will have at least 30, more preferably at least 45, and still more preferably at least 57 contiguous nucleotides the full-length ORF2 nucleotide sequence, e.g. of SEQ ID NO: 3 or SEQ ID NO: 4.
[0052] “Sequence Identity” as it is known in the art refers to a relationship between two or more polypeptide sequences or two or more polynucleotide sequences, namely a reference sequence and a given sequence to be compared with the reference sequence. Sequence identity is determined by comparing the given sequence to the reference sequence after the sequences have been optimally aligned to produce the highest degree of sequence similarity, as determined by the match between strings of such sequences. Upon such alignment, sequence identity is ascertained on a position-by-position basis, e.g., the sequences are “identical” at a particular position if at that position, the nucleotides or amino acid residues are identical. The total number of such position identities is then divided by the total number of nucleotides or residues in the reference sequence to give % sequence identity. Sequence identity can be readily calculated by known methods, including but not limited to, those described in Computational Molecular Biology, Lesk, A. N., ed., Oxford University Press, New York (1988), Biocomputing: Informatics and Genome Projects, Smith, D. W., ed., Academic Press, New York (1993); Computer Analysis of Sequence Data, Part I, Griffin, A. M., and Griffin, H. G., eds., Humana Press, New Jersey (1994); Sequence Analysis in Molecular Biology, von Heinge, G., Academic Press (1987); Sequence Analysis Primer, Gribskov, M. and Devereux, J., eds., M. Stockton Press, New York (1991); and Carillo, H., and Lipman, D., SIAM J. Applied Math., 48: 1073 (1988), the teachings of which are incorporated herein by reference. Preferred methods to determine the sequence identity are designed to give the largest match between the sequences tested. Methods to determine sequence identity are codified in publicly available computer programs which determine sequence identity between given sequences. Examples of such programs include, but are not limited to, the GCG program package (Devereux, J., et al., Nucleic Acids Research, 12(1):387 (1984)), BLASTP, BLASTN and FASTA (Altschul, S. F. et al., J. Molec. Biol., 215:403-410 (1990). The BLASTX program is publicly available from NCBI and other sources (BLAST Manual, Altschul, S. et al., NCVI NLM NIH Bethesda, Md. 20894, Altschul, S. F. et al., J. Molec. Biol., 215:403-410 (1990), the teachings of which are incorporated herein by reference). These programs optimally align sequences using default gap weights in order to produce the highest level of sequence identity between the given and reference sequences. As an illustration, by a polynucleotide having a nucleotide sequence having at least, for example, 85%, preferably 90%, even more preferably 95% “sequence identity” to a reference nucleotide sequence, it is intended that the nucleotide sequence of the given polynucleotide is identical to the reference sequence except that the given polynucleotide sequence may include up to 15, preferably up to 10, even more preferably up to 5 point mutations per each 100 nucleotides of the reference nucleotide sequence. In other words, in a polynucleotide having a nucleotide sequence having at least 85%, preferably 90%, even more preferably 95% identity relative to the reference nucleotide sequence, up to 15%, preferably 10%, even more preferably 5% of the nucleotides in the reference sequence may be deleted or substituted with another nucleotide, or a number of nucleotides up to 15%, preferably 10%, even more preferably 5% of the total nucleotides in the reference sequence may be inserted into the reference sequence. These mutations of the reference sequence may occur at the 5′ or 3′ terminal positions of the reference nucleotide sequence or anywhere between those terminal positions, interspersed either individually among nucleotides in the reference sequence or in one or more contiguous groups within the reference sequence. Analogously, by a polypeptide having a given amino acid sequence having at least, for example, 85%, preferably 90%, even more preferably 95% sequence identity to a reference amino acid sequence, it is intended that the given amino acid sequence of the polypeptide is identical to the reference sequence except that the given polypeptide sequence may include up to 15, preferably up to 10, even more preferably up to 5 amino acid alterations per each 100 amino acids of the reference amino acid sequence. In other words, to obtain a given polypeptide sequence having at least 85%, preferably 90%, even more preferably 95% sequence identity with a reference amino acid sequence, up to 15%, preferably up to 10%, even more preferably up to 5% of the amino acid residues in the reference sequence may be deleted or substituted with another amino acid, or a number of amino acids up to 15%, preferably up to 10%, even more preferably up to 5% of the total number of amino acid residues in the reference sequence may be inserted into the reference sequence. These alterations of the reference sequence may occur at the amino or the carboxy terminal positions of the reference amino acid sequence or anywhere between those terminal positions, interspersed either individually among residues in the reference sequence or in the one or more contiguous groups within the reference sequence. Preferably, residue positions which are not identical differ by conservative amino acid substitutions. However, conservative substitutions are not included as a match when determining sequence identity.
[0053] “Sequence homology”, as used herein, refers to a method of determining the relatedness of two sequences. To determine sequence homology, two or more sequences are optimally aligned, and gaps are introduced if necessary. However, in contrast to “sequence identity”, conservative amino acid substitutions are counted as a match when determining sequence homology. In other words, to obtain a polypeptide or polynucleotide having 95% sequence homology with a reference sequence, 85%, preferably 90%, even more preferably 95% of the amino acid residues or nucleotides in the reference sequence must match or comprise a conservative substitution with another amino acid or nucleotide, or a number of amino acids or nucleotides up to 15%, preferably up to 10%, even more preferably up to 5% of the total amino acid residues or nucleotides, not including conservative substitutions, in the reference sequence may be inserted into the reference sequence. Preferably the homolog sequence comprises at least a stretch of 50, even more preferred of 100, even more preferred of 250, even more preferred of 500 nucleotides.
[0054] A “conservative substitution” refers to the substitution of an amino acid residue or nucleotide with another amino acid residue or nucleotide having similar characteristics or properties including size, hydrophobicity, etc., such that the overall functionality does not change significantly.
[0055] Isolated” means altered “by the hand of man” from its natural state, i.e., if it occurs in nature, it has been changed or removed from its original environment, or both. For example, a polynucleotide or polypeptide naturally present in a living organism is not “isolated,” but the same polynucleotide or polypeptide separated from the coexisting materials of its natural state is “isolated”, as the term is employed herein.
[0056] Thus, a further aspect of the present invention relates to an immunogenic composition effective for lessening the severity of clinical symptoms associated with PCV2 infection comprising PCV2 ORF2 protein. Preferably, the PCV2 ORF2 protein is anyone of those, described above. Preferably, said PCV2 ORF2 protein is
i) a polypeptide comprising the sequence of SEQ ID NO: 5, SEQ ID NO: 6, SEQ ID NO: 9, SEQ ID NO: 10 or SEQ ID NO: 11; ii) any polypeptide that is at least 80% homologous to the polypeptide of i), iii) any immunogenic portion of the polypeptides of i) and/or ii) iv) the immunogenic portion of iii), comprising at least 10 contiguous amino acids included in the sequences of SEQ ID NO: 5, SEQ ID NO: 6, SEQ ID NO: 9, SEQ ID NO: 10 or SEQ ID NO: 11, v) a polypeptide that is encoded by a DNA comprising the sequence of SEQ ID NO: 3 or SEQ ID NO: 4. vi) any polypeptide that is encoded by a polynucleotide that is at least 80% homolog to the polynucleotide of v), vii) any immunogenic portion of the polypeptides encoded by the polynucleotide of v) and/or vi) viii) the immunogenic portion of vii), wherein polynucleotide coding for said immunogenic portion comprises at least 30 contiguous nucleotides included in the sequences of SEQ ID NO: 3, or SEQ ID NO: 4.
[0065] Preferably any of those immunogenic portions having the immunogenic characteristics of PCV2 ORF2 protein that is encoded by the sequence of SEQ ID NO: 3 or SEQ ID NO: 4.
[0066] According to a further aspect, PCV2 ORF2 protein is provided in the immunological composition at an antigen inclusion level effective for inducing the desired immune response, namely reducing the incidence of or lessening the severity of clinical signs resulting from PCV2 infection. Preferably, the PCV2 ORF2 protein inclusion level is at least 0.2 μg antigen/ml of the final immunogenic composition (μg/ml), more preferably from about 0.2 to about 400 μg/ml, still more preferably from about 0.3 to about 200 μg/ml, even more preferably from about 0.35 to about 100 μg/ml, still more preferably from about 0.4 to about 50 μg/ml, still more preferably from about 0.45 to about 30 μg/ml, still more preferably from about 0.6 to about 15 μg/ml, even more preferably from about 0.75 to about 8 μg/ml, even more preferably from about 1.0 to about 6 μg/ml, still more preferably from about 1.3 to about 3.0 μg/ml, even more preferably from about 1.4 to about 2.5 μg/ml, even more preferably from about 1.5 to about 2.0 μg/ml, and most preferably about 1.6 μg/ml.
[0067] According to a further aspect, the ORF2 antigen inclusion level is at least 0.2 μg PCV2 ORF2 protein as described above per dose of the final antigenic composition (μg/dose), more preferably from about 0.2 to about 400 μg/dose, still more preferably from about 0.3 to about 200 μg/dose, even more preferably from about 0.35 to about 100 μg/dose, still more preferably from about 0.4 to about 50 μg/dose, still more preferably from about 0.45 to about 30 μg/dose, still more preferably from about 0.6 to about 15 μg/dose, even more preferably from about 0.75 to about 8 μg/dose, even more preferably from about 1.0 to about 6 μg/dose, still more preferably from about 1.3 to about 3.0 μg/dose, even more preferably from about 1.4 to about 2.5 μg/dose, even more preferably from about 1.5 to about 2.0 μg/dose, and most preferably about 1.6 μg/dose.
[0068] The PCV2 ORF2 polypeptide used in an immunogenic composition in accordance with the present invention can be derived in any fashion including isolation and purification of PCV2 ORF2, standard protein synthesis, and recombinant methodology. Preferred methods for obtaining PCV2 ORF2 polypeptide are described herein above and are also provided in U.S. patent application Ser. No. 11/034,797, the teachings and content of which are hereby incorporated by reference. Briefly, susceptible cells are infected with a recombinant viral vector containing PCV2 ORF2 DNA coding sequences, PCV2 ORF2 polypeptide is expressed by the recombinant virus, and the expressed PCV2 ORF2 polypeptide is recovered from the supernate by filtration and inactivated by any conventional method, preferably using binary ethylenimine, which is then neutralized to stop the inactivation process.
[0069] Thus, according to a further aspect the immunogenic composition comprises i) any of the PCV2 ORF2 protein described above, preferably in concentrations described above, and ii) at least a portion of the viral vector expressing said PCV2 ORF2 protein, preferably of a recombinant baculovirus. Moreover, according to a further aspect, the immunogenic composition comprises i) any of the PCV2 ORF2 protein described above, preferably in concentrations described above, ii) at least a portion of the viral vector expressing said PCV2 ORF2 protein, preferably of a recombinant baculovirus, and iii) a portion of the cell culture supernate.
[0070] According to one specific embodiment of the production and recovery process for PCV2 ORF2 protein, the cell culture supernate is filtered through a membrane having a pore size, preferably between about 0.45 to 1 μm. Thus, a further aspect relates to an immunogenic composition that comprises i) any of the PCV2 ORF2 protein described above, preferably in concentrations described above, ii) at least a portion of the viral vector expressing said PCV2 ORF2 protein, preferably of a recombinant baculovirus, and iii) a portion of the cell culture; wherein about 90% of the components have a size smaller than 1 μm.
[0071] According to a further aspect, the present invention relates to an immunogenic composition that comprises i) any of the PCV2 ORF2 protein described above, preferably in concentrations described above, ii) at least a portion of the viral vector expressing said PCV2 ORF2 protein, iii) a portion of the cell culture, iv) and inactivating agent to inactivate the recombinant viral vector preferably BEI, wherein about 90% of the components i) to iii) have a size smaller than 1 μm. Preferably, BEI is present in concentrations effective to inactivate the baculovirus. Effective concentrations are described above.
[0072] According to a further aspect, the present invention relates to an immunogenic composition that comprises i) any of the PCV2 ORF2 protein described above, preferably in concentrations described above, ii) at least a portion of the viral vector expressing said PCV2 ORF2 protein, iii) a portion of the cell culture, iv) an inactivating agent to inactivate the recombinant viral vector preferably BEI, and v) an neutralization agent to stop the inactivation mediated by the inactivating agent, wherein about 90% of the components i) to iii) have a size smaller than 1 μm. Preferably, if the inactivating agent is BEI, said composition comprises sodium thiosulfate in equivalent amounts to BEI.
[0073] The polypeptide is incorporated into a composition that can be administered to an animal susceptible to PCV2 infection. In preferred forms, the composition may also include additional components known to those of skill in the art (see also Remington's Pharmaceutical Sciences. (1990). 18th ed. Mack Publ., Easton). Additionally, the composition may include one or more veterinary-acceptable carriers. As used herein, “a veterinary-acceptable carrier” includes any and all solvents, dispersion media, coatings, adjuvants, stabilizing agents, diluents, preservatives, antibacterial and antifungal agents, isotonic agents, adsorption delaying agents, and the like.
[0074] In a preferred embodiment, the immunogenic composition comprises PCV2 ORF2 protein as provided herewith, preferably in concentrations described above as an antigenic component, which is mixed with an adjuvant, preferably Carbopol, and physiological saline.
[0075] Those of skill in the art will understand that the composition herein may incorporate known injectable, physiologically acceptable sterile solutions. For preparing a ready-to-use solution for parenteral injection or infusion, aqueous isotonic solutions, such as e.g. saline or corresponding plasma protein solutions are readily available. In addition, the immunogenic and vaccine compositions of the present invention can include diluents, isotonic agents, stabilizers, or adjuvants. Diluents can include water, saline, dextrose, ethanol, glycerol, and the like. Isotonic agents can include sodium chloride, dextrose, mannitol, sorbitol, and lactose, among others. Stabilizers include albumin and alkali salts of ethylendiamintetracetic acid, among others. Suitable adjuvants, are those described above. Most preferred is the use of Carbopol, in particular the use of Carbopol 971P, preferably in amounts as described above (e.g. of about 500 μg to about 5 mg per dose, even more preferred in an amount of about 750 μg to about 2.5 mg per dose and most preferred in an amount of about 1 mg per dose).
[0076] Thus, the present invention also relates to an immunogenic composition that comprises i) any of the PCV2 ORF2 proteins described above, preferably in concentrations described above, ii) at least a portion of the viral vector expressing said PCV2 ORF2 protein, iii) a portion of the cell culture, iv) an inactivating agent to inactivate the recombinant viral vector preferably BEI, and v) an neutralization agent to stop the inactivation mediated by the inactivating agent, preferably sodium thiosulfate in equivalent amounts to BEI; and vi) a suitable adjuvant, preferably Carbopol 971 in amounts described above; wherein about 90% of the components i) to iii) have a size smaller than 1 μm. According to a further aspect, this immunogenic composition further comprises a pharmaceutical acceptable salt, preferably a phosphate salt in physiologically acceptable concentrations. Preferably, the pH of said immunogenic composition is adjusted to a physiological pH, meaning between about 6.5 and 7.5.
[0077] Thus, the present invention also relates to an immunogenic composition comprises per one ml i) at least 1.6 μg of PCV2 ORF2 protein described above, ii) at least a portion of baculovirus expressing said PCV2 ORF2 protein iii) a portion of the cell culture, iv) about 2 to 8 mM BEI, v) sodium thiosulfate in equivalent amounts to BEI; and vi) about 1 mg Carbopol 971, and vii) phosphate salt in a physiologically acceptable concentration; wherein about 90% of the components i) to iii) have a size smaller than 1 μm and the pH of said immunogenic composition is adjusted to about 6.5 to 7.5.
[0078] The immunogenic compositions can further include one or more other immunomodulatory agents such as, e.g., interleukins, interferons, or other cytokines. The immunogenic compositions can also include Gentamicin and Merthiolate. While the amounts and concentrations of adjuvants and additives useful in the context of the present invention can readily be determined by the skilled artisan, the present invention contemplates compositions comprising from about 50 μg to about 2000 μg of adjuvant and preferably about 250 μg/ml dose of the vaccine composition. In another preferred embodiment, the present invention contemplates vaccine compositions comprising from about 1 ug/ml to about 60 μg/ml of antibiotics, and more preferably less than about 30 μg/ml of antibiotics.
[0079] Thus, the present invention also relates to an immunogenic composition that comprises i) any of the PCV2 ORF2 proteins described above, preferably in concentrations described above, ii) at least a portion of the viral vector expressing said PCV2 ORF2 protein, iii) a portion of the cell culture, iv) an inactivating agent to inactivate the recombinant viral vector preferably BEI, and v) an neutralization agent to stop the inactivation mediated by the inactivating agent, preferably sodium thiosulfate in equivalent amounts to BEI; vi) a suitable adjuvant, preferably Carbopol 971 in amounts described above; vii) a pharmaceutical acceptable concentration of a saline buffer, preferably of a phosphate salt, and viii) an anti-microbiological active agent; wherein about 90% of the components i) to iii) have a size smaller than 1 μm.
[0080] It has been surprisingly found, that the immunogenic composition provided herewith comprises was highly stable over a period of 24 months. It has also been found the immunogenic compositions provided herewith, comprising recombinant, baculovirus expressed PCV2 ORF2 protein as provided herewith are very effective in reducing the clinical symptoms associated with PCV2 infections. It has been surprisingly found, that the immunogenic compositions comprising the recombinant baculovirus expressed PCV2 ORF2 protein as provided herewith, are more effective than an immunogenic composition comprising the whole PCV2 virus in an inactivated form, or isolated viral PCV2 ORF2 antigen. In particular, it has been surprisingly found, that the recombinant baculovirus expressed PCV2 ORF2 protein is effective is in very low concentrations, which means in concentrations up to 0.25 μg/dose. This unexpected high immunogenic potential of the PCV2 ORF2 protein could be further increased by the addition of Carbopol.
[0081] A further aspect relates to a container comprises at least one dose of the immunogenic composition of PCV2 ORF2 protein as provided herewith, wherein one dose comprises at least 2 μg PCV2 ORF2 protein, preferably 2 to 16 μg PCV2 ORF2 protein. Said container can comprises 1 to 250 doses of the immunogenic composition, preferably it contains 1, 10, 25, 50, 100, 150, 200, or 250 doses of the immunogenic composition of PCV2 ORF2 protein. Preferably, each of the containers comprising more than one dose of the immunogenic composition of PCV2 ORF2 protein further comprises an anti-microbiological active agent. Those agents are for example antibiotics including Gentamicin and Merthiolate and the like. Thus, one aspect of the present invention relates to a container that comprises 1 to 250 doses of the immunogenic composition of PCV2 ORF2 protein, wherein one dose comprises at least 2 μg PCV2 ORF2 protein, and Gentamicin and/or Merthiolate, preferably from about 1 μg/ml to about 60 μg/ml of antibiotics, and more preferably less than about 30 μg/ml.
[0082] A further aspect relates to a kit, comprising any of the containers, described above, and an instruction manual, including the information for the intramuscular application of at least one dose of the immunogenic composition of PCV2 ORF2 protein into piglets to lessening the severity of clinical symptoms associated with PCV2 infection. Moreover, according to a further aspect, said instruction manual comprises the information of a second or further administration(s) of at least one dose of the immunogenic composition of PCV2 ORF2, wherein the second administration or any further administration is at least 14 days beyond the initial or any former administration. Preferably, said instruction manual also includes the information, to administer an immune stimulant. Preferably, said immune stimulant shall be given at least twice. Preferably, at least 3, more preferably at least 5, even more preferably at least 7 days are between the first and the second or any further administration of the immune stimulant. Preferably, the immune stimulant is given at least 10 days, preferably 15, even more preferably 20, even more preferably at least 22 days beyond the initial administration of the immunogenic composition of PCV2 ORF2 protein. A preferred immune stimulant is for example is keyhole limpet hemocyanin (KLH), still preferably emulsified with incomplete Freund's adjuvant (KLH/ICFA). However, it is herewith understood, that any other immune stimulant known to a person skilled in the art can also be used “Immune stimulant” as used herein, means any agent or composition that can trigger the immune response, preferably without initiating or increasing a specific immune response, for example the immune response against a specific pathogen. It is further instructed to administer the immune stimulant in a suitable dose. Moreover, the kit may also comprises a container, including at least one dose of the immune stimulant, preferably one dose of KLH, or KLH/ICFA.
[0083] Moreover, it has also been surprisingly found that the immunogenic potential of the immunogenic compositions comprising recombinant baculovirus expressed PCV2 ORF2 protein, preferably in combination with Carbopol, can be further enhanced by the administration of the IngelVac PRRS MLV vaccine (see Example 5). PCV2 clinical signs and disease manifestations are greatly magnified when PRRS infection is present. However, the immunogenic compositions and vaccination strategies as provided herewith lessened this effect greatly, and more than expected. In other words, an unexpected synergistic effect was observed when animals, preferably pigs are treated with any of the PCV2 ORF2 immunogenic composition, as provided herewith, and the Ingelvac PRRS MLV vaccine (Boehringer Ingelheim).
[0084] Thus, a further aspect of the present invention relates to the kit as described above, comprising the immunogenic composition of PCV2 ORF2 as provided herewith and the instruction manual, wherein the instruction manual further include the information to administer the PCV2 ORF2 immunogenic composition together with immunogenic composition that comprises PRRS antigen, preferably adjuvanted PRRS antigen. Preferably, the PRRS antigen is adjuvanted with Carbopol. Preferably, the PRRS antigen is IngelVac® PRRS MLV (Boehringer Ingelheim).
[0085] A further aspect of the present invention also relates to a kit comprising i) a container containing at least one dose of an immunogenic composition of PCV2 ORF2 as provided herewith, and ii) a container containing an immunogenic composition comprising PRRS antigen, preferably adjuvanted PRRS antigen. Preferably, the PRRS antigen is adjuvanted with Carbopol. Preferably the PRRS antigen is IngelVac® PRRS MLV (Boehringer Ingelheim). More preferably, the kit further comprises an instruction manual, including the information to administer both pharmaceutical compositions. Preferably, it contains the information that the PCV2 ORF2 containing composition is administered temporally prior to the PRRS containing composition.
[0086] A further aspect, relates to the use of any of the compositions provided herewith as a medicament, preferably as a veterinary medicament, even more preferred as a vaccine. Moreover, the present invention also relates to the use of any of the compositions described herein, for the preparation of a medicament for lessening the severity of clinical symptoms associated with PCV2 infection. Preferably, the medicament is for the prevention of a PCV2 infection, even more preferably in piglets.
[0087] A further aspect relates to a method for (i) the prevention of an infection, or re-infection with PCV2 or (ii) the reduction or elimination of clinical symptoms caused by PCV2 in a subject, comprising administering any of the immunogenic compositions provided herewith to a subject in need thereof. Preferably, the subject is a pig. Preferably, the immunogenic composition is administered intramuscular. Preferably, one dose or two doses of the immunogenic composition is/are administered, wherein one dose preferably comprises at least about 2 μg PCV2 ORF2 protein, even more preferably about 2 to about 16 μg, and at least about 0.1 to about 5 mg Carbopol, preferably about 1 mg Carbopol. A further aspect relates to the method of treatment as described above, wherein a second application of the immunogenic composition is administered. Preferably, the second administration is done with the same immunogenic composition, preferably having the same amount of PCV2 ORF2 protein. Preferably the second administration is also given intramuscular. Preferably, the second administration is done at least 14 days beyond the initial administration, even more preferably at least 4 weeks beyond the initial administration.
[0088] According to a further aspect, the method of treatment also comprises the administration of an immune stimulant. Preferably, said immune stimulant is administered at least twice. Preferably, at least 3, more preferably at least 5 days, even more preferably at least 7 days are between the first and the second administration of the immune stimulant. Preferably, the immune stimulant is administered at least 10 days, preferably 15, even more preferably 20, even more preferably at least 22 days beyond the initial administration of the PCV2 ORF2 immunogenic composition. A preferred immune stimulant is for example is keyhole limpet hemocyanin (KLH), still preferably emulsified with incomplete Freund's adjuvant (KLH/ICFA). However, it is herewith understood, that any other immune stimulant known to a person skilled in the art can also be used. It is within the general knowledge of a person skilled in the art to administer the immune stimulant in a suitable dose.
[0089] According to a further aspect, the method of treatments described above also comprises the administration of PRRS antigen. Preferably, the PRRS antigen is adjuvanted with Carbopol. Preferably the PRRS antigen is IngelVac® PRRS MLV (Boehringer Ingelheim). Preferably, said PRRS antigen is administered temporally beyond the administration of the immunogenic composition of PCV2 ORF2 protein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0090] FIG. 1 is a schematic flow diagram of a preferred construction of PCV2 ORF2 recombinant baculovirus; and
[0091] FIGS. 2 a and 2 b are a schematic flow diagram of how to produce a composition in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0092] The following examples set forth preferred materials and procedures in accordance with the present invention. It is to be understood, however, that these examples are provided by way of illustration only, and nothing therein should be deemed a limitation upon the overall scope of the invention.
Example 1
[0093] This example compares the relative yields of ORF2 using methods of the present invention with methods that are known in the prior art. Four 1000 mL spinner flasks were each seeded with approximately 1.0×10 6 Sf+ cells/ml in 300 mL of insect serum free media, Excell 420 (JRH Biosciences, Inc., Lenexa, Kans.). The master cell culture is identified as SF+( Spodoptera frugiperda ) Master Cell Stock, passage 19, Lot#N112-095W. The cells used to generate the SF+Master Cell Stock were obtained from Protein Sciences Corporation, Inc., Meriden, Conn. The SF+ cell line for this example was confined between passages 19 and 59. Other passages will work for purposes of the present invention, but in order to scale the process up for large scale production, at least 19 passages will probably be necessary and passages beyond 59 may have an effect on expression, although this was not investigated. In more detail, the initial SF+ cell cultures from liquid nitrogen storage were grown in Excell 420 media in suspension in sterile spinner flasks with constant agitation. The cultures were grown in 100 mL to 250 mL spinner flasks with 25 to 150 mL of Excell 420 serum-free media. When the cells had multiplied to a cell density of 1.0-8.0×10 6 cells/mL, they were split to new vessels with a planting density of 0.5-1.5×10 6 cells/mL. Subsequent expansion cultures were grown in spinner flasks up to 36 liters in size or in stainless steel bioreactors of up to 300 liters for a period of 2-7 days at 25-29° C.
[0094] After seeding, the flasks were incubated at 27° C. for four hours. Subsequently, each flask was seeded with a recombinant baculovirus containing the PCV2 ORF2 gene (SEQ ID NO: 4). The recombinant baculovirus containing the PCV2 ORF2 gene was generated as follows: the PCV2 ORF2 gene from a North American strain of PCV2 was PCR amplified to contain a 5′ Kozak's sequence (SEQ ID NO: 1) and a 3′ EcoR1 site (SEQ ID NO: 2), cloned into the pGEM-T-Easy vector (Promega, Madison, Wis.). Then, it was subsequently excised and subcloned into the transfer vector pVL1392 (BD Biosciences Pharmingen, San Diego, Calif.). The subcloned portion is represented herein as SEQ ID NO: 7. The pVL1392 plasmid containing the PCV2 ORF2 gene was designated N47-064Y and then co-transfected with BaculoGold® (BD Biosciences Pharmingen) baculovirus DNA into Sf+ insect cells (Protein Sciences, Meriden, Conn.) to generate the recombinant baculovirus containing the PCV2 ORF2 gene. The new construct is provided herein as SEQ ID NO: 8. The recombinant baculovirus containing the PCV2 ORF2 gene was plaque-purified and Master Seed Virus (MSV) was propagated on the SF+ cell line, aliquotted, and stored at −70° C. The MSV was positively identified as PCV2 ORF2 baculovirus by PCR-RFLP using baculovirus specific primers. Insect cells infected with PCV2 ORF2 baculovirus to generate MSV or Working Seed Virus express PCV2 ORF2 antigen as detected by polyclonal serum or monoclonal antibodies in an indirect fluorescent antibody assay. Additionally, the identity of the PCV2 ORF2 baculovirus was confirmed by N-terminal amino acid sequencing. The PCV2 ORF2 baculovirus MSV was also tested for purity in accordance with 9 C.F.R. 113.27 (c), 113.28, and 113.55. Each recombinant baculovirus seeded into the spinner flasks had varying multiplicities of infection (MOIs). Flask 1 was seeded with 7.52 mL of 0.088 MOI seed; flask 2 was seeded with 3.01 mL of 0.36MOI seed; flask 3 was seeded with 1.5 mL of 0.18MOI seed; and flask 4 was seeded with 0.75 mL of 0.09MOI seed. A schematic flow diagram illustrating the basic steps used to construct a PCV2 ORF2 recombinant baculovirus is provided herein as FIG. 1 .
[0095] After being seeded with the baculovirus, the flasks were then incubated at 27±2° C. for 7 days and were also agitated at 100 rpm during that time. The flasks used ventilated caps to allow for air flow. Samples from each flask were taken every 24 hours for the next 7 days. After extraction, each sample was centrifuged, and both the pellet and the supernatant were separated and then microfiltered through a 0.45-1.0 μm pore size membrane.
[0096] The resulting samples then had the amount of ORF2 present within them quantified via an ELISA assay. The ELISA assay was conducted with capture antibody Swine anti-PCV2 Pab IgG Prot. G purified (diluted 1:250 in PBS) diluted to 1:6000 in 0.05M Carbonate buffer (pH 9.6). 100 μL of the antibody was then placed in the wells of the mictrotiter plate, sealed, and incubated overnight at 37° C. The plate was then washed three times with a wash solution which comprised 0.5 mL of Tween 20 (Sigma, St. Louis, Mo.), 100 mL of 10×D-PBS (Gibco Invitrogen, Carlsbad, Calif.) and 899.5 mL of distilled water. Subsequently, 250 μL of a blocking solution (5 g Carnation Non-fat dry milk (Nestle, Glendale, Calif.) in 10 mL of D-PBS QS to 100 mL with distilled water) was added to each of the wells. The next step was to wash the test plate and then add pre-diluted antigen. The pre-diluted antigen was produced by adding 200 μL of diluent solution (0.5 mL Tween 20 in 999.5 mL D-PBS) to each of the wells on a dilution plate. The sample was then diluted at a 1:240 ratio and a 1:480 ratio, and 100 μL of each of these diluted samples was then added to one of the top wells on the dilution plate (i.e. one top well received 100 μL of the 1:240 dilution and the other received 100 μL of the 1:480 dilution). Serial dilutions were then done for the remainder of the plate by removing 100 μL form each successive well and transferring it to the next well on the plate. Each well was mixed prior to doing the next transfer. The test plate washing included washing the plate three times with the wash buffer. The plate was then sealed and incubated for an hour at 37° C. before being washed three more times with the wash buffer. The detection antibody used was monoclonal antibody to PCV ORF2. It was diluted to 1:300 in diluent solution, and 100 μL of the diluted detection antibody was then added to the wells. The plate was then sealed and incubated for an hour at 37° C. before being washed three times with the wash buffer. Conjugate diluent was then prepared by adding normal rabbit serum (Jackson Immunoresearch, West Grove, Pa.) to the diluent solution to 1% concentration. Conjugate antibody Goat anti-mouse (H+1)−HRP (Jackson Immunoresearch) was diluted in the conjugate diluent to 1:10,000. 100 μL of the diluted conjugate antibody was then added to each of the wells. The plate was then sealed and incubated for 45 minutes at 37° C. before being washed three times with the wash buffer. 100 μL of substrate (TMB Peroxidase Substrate, Kirkgaard and Perry Laboratories (KPL), Gaithersberg, Md.), mixed with an equal volume of Peroxidase Substrate B (KPL) was added to each of the wells. The plate was incubated at room temperature for 15 minutes. 100 μL of 1N HCL solution was then added to all of the wells to stop the reaction. The plate was then run through an ELISA reader. The results of this assay are provided in Table 1 below:
[0000]
TABLE 1
Day
Flask
ORF2 in pellet (μg)
ORF2 in supernatant (μg)
3
1
47.53
12
3
2
57.46
22
3
3
53.44
14
3
4
58.64
12
4
1
43.01
44
4
2
65.61
62
4
3
70.56
32
4
4
64.97
24
5
1
31.74
100
5
2
34.93
142
5
3
47.84
90
5
4
55.14
86
6
1
14.7
158
6
2
18.13
182
6
3
34.78
140
6
4
36.88
146
7
1
6.54
176
7
2
12.09
190
7
3
15.84
158
7
4
15.19
152
[0097] These results indicate that when the incubation time is extended, expression of ORF2 into the supernatant of the centrifuged cells and media is greater than expression in the pellet of the centrifuged cells and media. Accordingly, allowing the ORF2 expression to proceed for at least 5 days and recovering it in the supernate rather than allowing expression to proceed for less than 5 days and recovering ORF2 from the cells, provides a great increase in ORF2 yields, and a significant improvement over prior methods.
Example 2
[0098] This example provides data as to the efficacy of the invention claimed herein. A 1000 mL spinner flask was seeded with approximately 1.0×10 6 Sf+ cells/ml in 300 mL of Excell 420 media. The flask was then incubated at 27° C. and agitated at 100 rpm. Subsequently, the flask was seeded with 10 mL of PCV2 ORF2/Bac p+6 (the recombinant baculovirus containing the PCV2 ORF2 gene passaged 6 additional times in the Sf9 insect cells) virus seed with a 0.1 MOI after 24 hours of incubation.
[0099] The flask was then incubated at 27° C. for a total of 6 days. After incubation, the flask was then centrifuged and three samples of the resulting supernatant were harvested and inactivated. The supernatant was inactivated by bringing its temperature to 37±2° C. To the first sample, a 0.4M solution of 2-bromoethyleneamine hydrobromide which had been cyclized to 0.2M binary ethlylenimine (BEI) in 0.3N NaOH is added to the supernatant to give a final concentration of BEI of 5 mM. To the second sample, 10 mM BEI was added to the supernatant. To the third sample, no BEI was added to the supernatant. The samples were then stirred continuously for 48 hrs. A 1.0 M sodium thiosulfate solution to give a final minimum concentration of 5 mM was added to neutralize any residual BEI. The quantity of ORF2 in each sample was then quantified using the same ELISA assay procedure as described in Example 1. The results of this may be seen in Table 2 below:
[0000]
TABLE 2
Sample
ORF2 in supernatant (μg)
1
78.71
2
68.75
3
83.33
[0100] This example demonstrates that neutralization with BEI does not remove or degrade significant amounts of the recombinant PCV2 ORF2 protein product. This is evidenced by the fact that there is no large loss of ORF2 in the supernatant from the BEI or elevated temperatures. Those of skill in the art will recognize that the recovered ORF2 is a stable protein product.
Example 3
[0101] This example demonstrates that the present invention is scalable from small scale production of recombinant PCV2 ORF2 to large scale production of recombinant PCV2 ORF2. 5.0×10 5 cells/ml of SF+ cells/ml in 7000 mL of ExCell 420 media was planted in a 20000 mL Applikon Bioreactor. The media and cells were then incubated at 27° C. and agitated at 100 RPM for the next 68 hours. At the 68 th hour, 41.3 mL of PCV2 ORF2 Baculovirus MSV+3 was added to 7000 mL of ExCell 420 medium. The resultant mixture was then added to the bioreactor. For the next seven days, the mixture was incubated at 27° C. and agitated at 100 RPM. Samples from the bioreactor were extracted every 24 hours beginning at day 4, post-infection, and each sample was centrifuged. The supernatant of the samples were preserved and the amount of ORF2 was then quantified using SDS-PAGE densitometry. The results of this can be seen in Table 3 below:
[0000]
TABLE 3
Day after infection:
ORF2 in supernatant (μg/mL)
4
29.33
5
41.33
6
31.33
7
60.67
Example 4
[0102] This example tests the efficacy of seven PCV2 candidate vaccines and further defines efficacy parameters following exposure to a virulent strain of PCV2. One hundred and eight (108) cesarean derived colostrum deprived (CDCD) piglets, 9-14 days of age, were randomly divided into 9 groups of equal size. Table 4 sets forth the General Study Design for this Example.
[0000]
TABLE 4
General Study Design
KLH/
ICF A
Challenged
Day
on Day
with
No.
of
21
Virulent
Necropsy
Of
Treat-
and
PCV2 on
on
Group
Pigs
Treatment
ment
Day 27
Day 24
Day 49
1
12
PCV2 Vaccine
0
+
+
+
No. 1—
(vORF2 16 μg)
2
12
PCV2 Vaccine
0
+
+
+
No. 2—
(vORF2 8 μg)
3
12
PCV2 Vaccine
0
+
+
+
No. 3—
(vORF2 4 μg)
4
12
PCV2 Vaccine
0
+
+
+
No. 4—
(rORF2 16 μg)
5
12
PCV2 Vaccine
0
+
+
+
No. 5—
(rORF2 8 μg)
6
12
PCV2 Vaccine
0
+
+
+
No. 6—
(rORF2 4 μg)
7
12
PCV2 Vaccine
0
+
+
+
No. 7—
(Killed
whole cell
virus)
8
12
None—
N/A
+
+
+
Challenge
Controls
9
12
None—
N/A
+
−
+
Strict
Negative
Control
Group
vORF2 = isolated viral ORF2; rORF2 = recombinant baculovirus expressed ORF2; killed whole cell virus = PCV2 virus grown in suitable cell culture
[0103] Seven of the groups (Groups 1-7) received doses of PCV2 ORF2 polypeptide, one of the groups acted as a challenge control and received no PCV2 ORF2, and another group acted as the strict negative control group and also received no PCV2 ORF2. On Day 0, Groups 1 through 7 were treated with assigned vaccines. Piglets in Group 7 were given a booster treatment on Day 14. Piglets were observed for adverse events and injection site reactions following vaccination and on Day 19, piglets were moved to the second study site. At the second study site, Groups 1-8 were group housed in one building while Group 9 was housed in a separate building. All pigs received keyhole limpet hemocyanin (KLH)/incomplete Freund's adjuvant (ICFA) on Days 21 and 27 and on Day 24, Groups 1-8 were challenged with a virulent PCV2.
[0104] Pre- and post-challenge, blood samples were collected for PCV2 serology. Post-challenge, body weight data for determination of average daily weight gain (ADWG), and clinical symptoms, as well as nasal swab samples to determine nasal shedding of PCV2, were collected. On Day 49, all surviving pigs were necropsied, lungs were scored for lesions, and selected tissues were preserved in formalin for Immunohistochemistry (IHC) testing at a later date.
Materials and Methods
[0105] This was a partially blinded vaccination-challenge feasibility study conducted in CDCD pigs, 9 to 14 days of age on Day 0. To be included in the study, PCV2 IFA titers of sows were ≦1:1000. Additionally, the serologic status of sows were from a known PRRS-negative herd. Twenty-eight (28) sows were tested for PCV2 serological status. Fourteen (14) sows had a PCV2 titer of ≦1000 and were transferred to the first study site. One hundred ten (110) piglets were delivered by cesarean section surgeries and were available for this study on Day −4. On Day −3, 108 CDCD pigs at the first study site were weighed, identified with ear tags, blocked by weight and randomly assigned to 1 of 9 groups, as set forth above in table 4. If any test animal meeting the inclusion criteria was enrolled in the study and was later excluded for any reason, the Investigator and Monitor consulted in order to determine the use of data collected from the animal in the final analysis. The date of which enrolled piglets were excluded and the reason for exclusion was documented. Initially, no sows were excluded. A total of 108 of an available 110 pigs were randomly assigned to one of 9 groups on Day −3. The two smallest pigs (No. 17 and 19) were not assigned to a group and were available as extras, if needed. During the course of the study, several animals were removed. Pig 82 (Group 9) on Day −1, Pig No. 56 (Group 6) on Day 3, Pig No. 53 (Group 9) on Day 4, Pig No. 28 (Group 8) on Day 8, Pig No. 69 (Group 8) on Day 7, and Pig No. 93 (Group 4) on Day 9, were each found dead prior to challenge. These six pigs were not included in the final study results. Pig no 17 (one of the extra pigs) was assigned to Group 9. The remaining extra pig, No. 19, was excluded from the study.
[0106] The formulations given to each of the groups were as follows: Group 1 was designed to administer 1 ml of viral ORF2 (vORF2) containing 16 μg ORF2/ml. This was done by mixing 10.24 ml of viral ORF2 (256 μg/25 μg/ml=10.24 ml vORF2) with 3.2 ml of 0.5% Carbopol and 2.56 ml of phosphate buffered saline at a pH of 7.4. This produced 16 ml of formulation for group 1. Group 2 was designed to administer 1 ml of vORF2 containing 8 μg vORF2/ml. This was done by mixing 5.12 ml of vORF2 (128 μg/25 μg/ml=5.12 ml vORF2) with 3.2 ml of 0.5% Carbopol and 7.68 ml of phosphate buffered saline at a pH of 7.4. This produced 16 ml of formulation for group 2. Group 3 was designed to administer 1 ml of vORF2 containing 4 μg vORF2/ml. This was done by mixing 2.56 ml of vORF2 (64 μg/25 μg/ml=2.56 ml vORF2) with 3.2 ml of 0.5% Carbopol and 10.24 ml of phosphate buffered saline at a pH of 7.4. This produced 16 ml of formulation for group 3. Group 4 was designed to administer 1 ml of recombinant ORF2 (rORF2) containing 16 μg rORF2/ml. This was done by mixing 2.23 ml of rORF2 (512 μg/230 μg/ml=2.23 ml rORF2) with 6.4 ml of 0.5% Carbopol and 23.37 ml of phosphate buffered saline at a pH of 7.4. This produced 32 ml of formulation for group 4. Group 5 was designed to administer 1 ml of rORF2 containing 8 μg rORF2/ml. This was done by mixing 1.11 ml of rORF2 (256 μg/230 μg/ml=1.11 ml rORF2) with 6.4 ml of 0.5% Carbopol and 24.49 ml of phosphate buffered saline at a pH of 7.4. This produced 32 ml of formulation for group 5. Group 6 was designed to administer 1 ml of rORF2 containing 8 μg rORF2/ml. This was done by mixing 0.56 ml of rORF2 (128 μg/230 μg/ml=0.56 ml rORF2) with 6.4 ml of 0.5% Carbopol and 25.04 ml of phosphate buffered saline at a pH of 7.4. This produced 32 ml of formulation for group 6. Group 7 was designed to administer 2 ml of PCV2 whole killed cell vaccine (PCV2 KV) containing the MAX PCV2 KV. This was done by mixing 56 ml of PCV2 KV with 14 ml of 0.5% Carbopol. This produced 70 ml of formulation for group 7. Finally group 8 was designed to administer KLH at 0.5 μg/ml or 1.0 μg/ml per 2 ml dose. This was done by mixing 40.71 ml KLH (7.0 μg protein/ml at 0.5 μg/ml=570 ml (7.0 μg/ml)(x)=(0.5)(570 ml)), 244.29 ml phosphate buffered saline at a pH of 7.4, and 285 ml Freunds adjuvant. Table 5 describes the time frames for the key activities of this Example.
[0000]
TABLE 5
Study Activities
Study Day
Study Activity
−4, 0 to 49
General observations for overall health and clinical symptoms
−3
Weighed; Randomized to groups; Collected blood samples
from all pigs
0
Health examination; Administered IVP Nos. 1-7 to Groups 1-7,
respectively
0-7
Observed pigs for injection site reactions
14
Boostered Group 7 with PCV2 Vaccine No. 7; Blood samples
from all pigs
14-21
Observed Group 7 for injection site reactions
16-19
Treated all pigs with antibiotics (data missing)
19
Pigs transported from the first test site to a second test site
21
Treated Groups 1-9 with KLH/ICFA
24
Collected blood and nasal swab samples from all pigs;
Weighed all pigs; Challenged Groups 1-8 with PCV2 challenge
material
25, 27,
Collected nasal swab samples from all pigs
29, 31,
33, 35,
37, 39,
41, 43,
45, 47
27
Treated Groups 1-9 with KLH/ICFA
31
Collected blood samples from all pigs
49
Collected blood and nasal swab samples from all pigs;
Weighed all pigs; Necropsy all pigs; Gross lesions noted with
emphasis placed on icterus and gastric ulcers; Lungs evaluated
for lesions; Fresh and formalin fixed tissue samples saved; In-
life phase of the study completed
[0107] Following completion of the in-life phase of the study, formalin fixed tissues were examined by Immunohistochemistry (MC) for detection of PCV2 antigen by a pathologist, blood samples were evaluated for PCV2 serology, nasal swab samples were evaluated for PCV2 shedding, and average daily weight gain (ADWG) was determined from Day 24 to Day 49.
[0108] Animals were housed at the first study site in individual cages in five rooms from birth to approximately 11 days of age (approximately Day 0 of the study). Each room was identical in layout and consisted of stacked individual stainless steel cages with heated and filtered air supplied separately to each isolation unit. Each room had separate heat and ventilation, thereby preventing cross-contamination of air between rooms. Animals were housed in two different buildings at the second study site. Group 9 (The Strict negative control group) was housed separately in a converted finisher building and Groups 1-8 were housed in converted nursery building. Each group was housed in a separate pen (11-12 pigs per pen) and each pen provided approximately 3.0 square feet per pig. Each pen was on an elevated deck with plastic slatted floors. A pit below the pens served as a holding tank for excrement and waste. Each building had its own separate heating and ventilation systems, with little likelihood of cross-contamination of air between buildings.
[0109] At the first study site, piglets were fed a specially formulated milk ration from birth to approximately 3 weeks of age. All piglets were consuming solid, special mixed ration by Day 19 (approximately 4½ h weeks of age). At the second study site, all piglets were fed a custom non-medicated commercial mix ration appropriate for their age and weight, ad libitum. Water at both study sites was also available ad libitum.
[0110] All test pigs were treated with Vitamin E on Day −2, with iron injections on Day −1 and with NAXCEL® (1.0 mL, 1M, in alternating hams) on Days 16, 17, 18 and 19. In addition, Pig No. 52 (Group 9) was treated with an iron injection on Day 3, Pig 45 (Group 6) was treated with an iron injection on Day 11, Pig No. 69 (Group 8) was treated with NAXCEL® on Day 6, Pig No. 74 (Group 3) was treated with dexamethazone and penicillin on Day 14, and Pig No. 51 (Group 1) was treated with dexamethazone and penicillin on Day 13 and with NAXCEL® on Day 14 for various health reasons.
[0111] While at both study sites, pigs were under veterinary care. Animal health examinations were conducted on Day 0 and were recorded on the Health Examination Record Form. All animals were in good health and nutritional status before vaccination as determined by observation on Day 0. All test animals were observed to be in good health and nutritional status prior to challenge. Carcasses and tissues were disposed of by rendering. Final disposition of study animals was records on the Animal Disposition Record.
[0112] On Day 0, pigs assigned to Groups 1-6 received 1.0 mL of PCV2 Vaccines 1-6, respectively, IM in the left neck region using a sterile 3.0 mL Luer-lock syringe and a sterile 20 g×½″ needle. Pigs assigned to Group 7 received 2.0 mL of PCV2 Vaccine No. 7 IM in the left neck region using a sterile 3.0 mL Luer-lock syringe and a sterile 20 g×½″ needle. On Day 14, pigs assigned to Group 7 received 2.0 mL of PCV2 Vaccine No. 7 IM in the right neck region using a sterile 3.0 mL Luer-lock syringe and a sterile 20 g×½″ needle.
[0113] On Day 21 all test pigs received 2.0 mL of KLH/ICFA IM in the right ham region using a sterile 3.0 mL Luer-lock syringe and a sterile 20 g×1″ needle. On Day 27 all test pigs received 2.0 mL of KLH/ICFA in the left ham region using a sterile 3.0 mL Luer-lock syringe and a sterile 20 g×1″ needle.
[0114] On Day 24, pigs assigned to Groups 1-8 received 1.0 mL of PCV2 ISUVDL challenge material (5.11 log 10 TCID 50 /mL) IM in the left neck region using a sterile 3.0 mL Luer-lock syringe and a sterile 20 g×1″ needle. An additional 1.0 mL of the same material was administered IN to each pig (0.5 mL per nostril) using a sterile 3.0 mL Luer-lock syringe and nasal canula.
[0115] Test pigs were observed daily for overall health and adverse events on Day −4 and from Day 0 to Day 19. Observations were recorded on the Clinical Observation Record. All test pigs were observed from Day 0 to Day 7, and Group 7 was further observed from Day 14 to 21, for injection site reactions. Average daily weight gain was determined by weighing each pig on a calibrated scale on Days −3, 24 and 49, or on the day that a pig was found dead after challenge. Body weights were recorded on the Body Weight Form. Day −3 body weights were utilized to block pigs prior to randomization. Day 24 and Day 49 weight data was utilized to determine the average daily weight gain (ADWG) for each pig during these time points. For pigs that died after challenge and before Day 49, the ADWG was adjusted to represent the ADWG from Day 24 to the day of death.
[0116] In order to determine PCV2 serology, venous whole blood was collected from each piglet from the orbital venous sinus on Days −3 and 14. For each piglet, blood was collected from the orbital venous sinus by inserting a sterile capillary tube into the medial canthus of one of the eyes and draining approximately 3.0 mL of whole blood into a 4.0 mL Serum Separator Tube (SST). On Days 24, 31, and 49, venous whole blood from each pig was collected from the anterior vena cava using a sterile 18 g×1½″ Vacutainer needle (Becton Dickinson and Company, Franklin Lakes, N.J.), a Vacutainer needle holder and a 13 mL SST. Blood collections at each time point were recorded on the Sample Collection Record. Blood in each SST was allowed to clot, each SST was then spun down and the serum harvested. Harvested serum was transferred to a sterile snap tube and stored at −70±10° C. until tested at a later date. Serum samples were tested for the presence of PCV2 antibodies by BIVI-R&D personnel.
[0117] Pigs were observed once daily from Day 20 to Day 49 for clinical symptoms and clinical observations were recorded on the Clinical Observation Record.
[0118] To test for PCV2 nasal shedding, on Days 24, 25, and then every other odd numbered study day up to and including Day 49, a sterile dacron swab was inserted intra nasally into either the left or right nostril of each pig (one swab per pig) as aseptically as possible, swished around for a few seconds and then removed. Each swab was then placed into a single sterile snap-cap tube containing 1.0 mL of EMEM media with 2% IFBS, 500 units/mL of Penicillin, 500 μg/mL of Streptomycin and 2.5 μg/mL of Fungizone. The swab was broken off in the tube, and the snap tube was sealed and appropriately labeled with animal number, study number, date of collection, study day and “nasal swab.” Sealed snap tubes were stored at −40±10° C. until transported overnight on ice to BIVI-St. Joseph. Nasal swab collections were recorded on the Nasal Swab Sample Collection Form. BIVI-R&D conducted quantitative virus isolation (VI) testing for PCV2 on nasal swab samples. The results were expressed in log 10 values. A value of 1.3 logs or less was considered negative and any value greater than 1.3 logs was considered positive.
[0119] Pigs that died (Nos. 28, 52, 56, 69, 82, and 93) at the first study site were necropsied to the level necessary to determine a diagnosis. Gross lesions were recorded and no tissues were retained from these pigs. At the second study site, pigs that died prior to Day 49 (Nos. 45, 23, 58, 35), pigs found dead on Day 49 prior to euthanasia (Nos. 2, 43) and pigs euthanized on Day 49 were necropsied. Any gross lesions were noted and the percentages of lung lobes with lesions were recorded on the Necropsy Report Form.
[0120] From each of the 103 pigs necropsied at the second study site, a tissue sample of tonsil, lung, heart, liver, mesenteric lymph node, kidney and inguinal lymph node was placed into a single container with buffered 10% formalin; while another tissue sample from the same aforementioned organs was placed into a Whirl-pak (M-Tech Diagnostics Ltd., Thelwall, UK) and each Whirl-pak was placed on ice. Each container was properly labeled. Sample collections were recorded on the Necropsy Report Form. Afterwards, formalin-fixed tissue samples and a Diagnostic Request Form were submitted for IHC testing. IHC testing was conducted in accordance with standard ISU laboratory procedures for receiving samples, sample and slide preparation, and staining techniques. Fresh tissues in Whirl-paks were shipped with ice packs to the Study Monitor for storage (−70°±10° C.) and possible future use. Formalin-fixed tissues were examined by a pathologist for detection of PCV2 by IHC and scored using the following scoring system: 0=None; 1=Scant positive staining, few sites; 2=Moderate positive staining, multiple sites; and 3=Abundant positive staining, diffuse throughout the tissue. Due to the fact that the pathologist could not positively differentiate inguinal LN from mesenteric LN, results for these tissues were simply labeled as Lymph Node and the score given the highest score for each of the two tissues per animal.
Results
[0121] Results for this example are given below. It is noted that one pig from Group 9 died before Day 0, and 5 more pigs died post-vaccination (1 pig from Group 4; 1 pig from Group 6; 2 pigs from Group 8; and 1 pig from Group 9). Post-mortem examination indicated all six died due to underlying infections that were not associated with vaccination or PMWS. Additionally, no adverse events or injection site reactions were noted with any groups.
[0122] Average daily weight gain (ADWG) results are presented below in Table 6. Group 9, the strict negative control group, had the highest ADWG (1.06±0.17 lbs/day), followed by Group 5 (0.94±0.22 lbs/day), which received one dose of 8 μg of rORF2. Group 3, which received one dose of 4 μg of vORF2, had the lowest ADWG (0.49±0.21 lbs/day), followed by Group 7 (0.50±0.15 lbs/day), which received 2 doses of killed vaccine.
[0000]
TABLE 6
Summary of Group Average Daily Weight Gain (ADWG)
ADWG - lbs/day
(Day 24 to Day 49) or adjusted
Group
Treatment
N
for pigs dead before Day 29
1
vORF2 - 16 μg (1 dose)
12
0.87 ± 0.29 lbs/day
2
vORF2 - 8 μg (1 dose)
12
0.70 ± 0.32 lbs/day
3
vORF2 - 4 μg (1 dose)
12
0.49 ± 0.21 lbs/day
4
rORF2 - 16 μg (1 dose)
11
0.84 ± 0.30 lbs/day
5
rORF2 - 8 μg (1 dose)
12
0.94 ± 0.22 lbs/day
6
rORF2 - 4 μg (1 dose)
11
0.72 ± 0.25 lbs/day
7
KV (2 doses)
12
0.50 ± 0.15 lbs/day
8
Challenge Controls
10
0.76 ± 0.19 lbs/day
9
Strict Negative Controls
11
1.06 ± 0.17 lbs/day
vORF2 = isolated viral ORF2;
rORF2 = recombinant baculovirus expressed ORF2;
killed whole cell virus = PCV2 virus grown in suitable cell culture
[0123] PCV2 serology results are presented below in Table 7. All nine groups were seronegative for PCV2 on Day −3. On Day 14, Groups receiving vORF2 vaccines had the highest titers, which ranged from 187.5 to 529.2. Pigs receiving killed viral vaccine had the next highest titers, followed by the groups receiving rORF2 vaccines. Groups 8 and 9 remained seronegative at this time. On Day 24 and Day 31, pigs receiving vORF2 vaccines continued to demonstrate a strong serological response, followed closely by the group that received two doses of a killed viral vaccine. Pigs receiving rORF2 vaccines were slower to respond serologically and Groups 8 and 9 continued to remain seronegative. On Day 49, pigs receiving vORF2 vaccine, 2 doses of the killed viral vaccine and the lowest dose of rORF2 demonstrated the strongest serological responses. Pigs receiving 16 μg and 8 μg of rORF2 vaccines had slightly higher IFA titers than challenge controls. Group 9 on Day 49 demonstrated a strong serological response.
[0000]
TABLE 7
Summary of Group PCV2 IFA Titers
AVERAGE IFA TITER
Day
Day
Day
Day
Day
Group
Treatment
−3
14
24
31**
49***
1
vORF2—
50.0
529.2
4400.0
7866.7
11054.5
16 μg (1 dose)
2
vORF2—
50.0
500.0
3466.7
6800.0
10181.8
8 μg (1 dose)
3
vORF2—
50.0
187.5
1133.3
5733.3
9333.3
4 μg (1 dose)
4
rORF2—
50.0
95.5
1550.0
3090.9
8000.0
16 μg (1 dose)
5
rORF2—
50.0
75.0
887.5
2266.7
7416.7
8 μg (1 dose)
6
rORF2—
50.0
50.0
550.0
3118.2
10570.0
4 μg (1 dose)
7
KV
50.0
204.2
3087.5
4620.8
8680.0
(2 doses)
8
Challenge
50.0
55.0
50.0
50.0
5433.3
Controls
9
Strict Negative
50.0
59.1
59.1
54.5
6136.4
Controls
vORF2 = isolated viral ORF2; rORF2 = recombinant baculovirus expressed ORF2; killed whole cell virus = PCV2 virus grown in suitable cell culture
*For calculation purposes, a ≦100 IFA titer was designated as a titer of “50”; a ≧6400 IFA titer was designated as a titer of “12,800”.
**Day of Challenge
***Day of Necropsy
[0124] The results from the post-challenge clinical observations are presented below in Table 8. This summary of results includes observations for Abnormal Behavior, Abnormal Respiration, Cough and Diarrhea. Table 9 includes the results from the Summary of Group Overall Incidence of Clinical Symptoms and Table 10 includes results from the Summary of Group Mortality Rates Post-challenge. The most common clinical symptom noted in this study was abnormal behavior, which was scored as mild to severe lethargy. Pigs receiving the 2 lower doses of vORF2, pigs receiving 16 μg of rORF2 and pigs receiving 2 doses of KV vaccine had incidence rates of ≧27.3%. Pigs receiving 8 μg of rORF2 and the strict negative control group had no abnormal behavior. None of the pigs in this study demonstrated any abnormal respiration. Coughing was noted frequently in all groups (0 to 25%), as was diarrhea (0-20%). None of the clinical symptoms noted were pathognomic for PMWS.
[0125] The overall incidence of clinical symptoms varied between groups. Groups receiving any of the vORF2 vaccines, the group receiving 16 μg of rORF2, the group receiving 2 doses of KV vaccine and the challenge control group had the highest incidence of overall clinical symptoms (≧36.4%). The strict negative control group, the group receiving 8 μg of rORF2 and the group receiving 4 μg of rORF2 had overall incidence rates of clinical symptoms of 0%, 8.3% and 9.1%, respectively.
[0126] Overall mortality rates between groups varied as well. The group receiving 2 doses of KV vaccine had the highest mortality rate (16.7%); while groups that received 4 μg of vORF2, 16 μg of rORF2, or 8 μg of rORF2 and the strict negative control group all had 0% mortality rates.
[0000]
TABLE 8
Summary of Group Observations for Abnormal Behavior,
Abnormal Respiration, Cough, and Diarrhea
Abnormal
Abnormal
Group
Treatment
N
Behavior 1
Behavior 2
Cough 3
Diarrhea 4
1
vORF2—
12
2/12
0/12
3/12
2/12
16 μg (1 dose)
(16.7%
(0%)
(25%)
(16/7%)
2
vORF2—
12
4/12
0/12
1/12
1/12
8 μg (1 dose)
(33.3%)
(0%)
(8.3%
(8.3%)
3
vORF2—
12
8/12
0/12
2/12
1/12
4 μg (1 dose)
(66.7%)
(0%)
(16.7%)
(8.3%)
4
rORF2—
11
3/11
0/11
0/11
2/11
16 μg (1 dose)
(27.3%)
(0%)
(0%)
(18.2%)
5
rORF2—
12
0/12
0/12
1/12
0/12
8 μg (1 dose)
(0%)
(0%)
(8.3%)
(0%)
6
rORF2—
11
1/11
0/11
0/11
0/12
4 μg (1 dose)
(9.1%)
(0%)
(0%)
(0%)
7
KV
12
7/12
0/12
0/12
1/12
(2 doses)
(58.3)
(0%)
(0%)
(8.3%)
8
Challenge
10
1/10
0/10
2/10
2/10
Controls
(10%)
(0%)
(20%)
(20%)
9
Strict Negative
11
0/11
0/11
0/11
0/11
Controls
(0%)
(0%)
(0%
(0%)
vORF2 = isolated viral ORF2; rORF2 = recombinant baculovirus expressed ORF2; killed whole cell virus = PCV2 virus grown in suitable cell culture
1 Total number of pigs in each group that demonstrated any abnormal behavior for at least one day
2 Total number of pigs in each group that demonstrated any abnormal respiration for at least one day
3 Total number of pigs in each group that demonstrated a cough for at least one day
4 Total number of pigs in each group that demonstrated diarrhea for at least one day
[0000]
TABLE 9
Summary of Group Overall Incidence of Clinical Symptoms
Incidence
of pigs with
Incidence
Group
Treatment
N
Clinical Symptoms 1
Rate
1
vORF2 - 16 μg (1 dose)
12
5
41.7%
2
vORF2 - 8 μg (1 dose)
12
5
41.7%
3
vORF2 - 4 μg (1 dose)
12
8
66.7%
4
rORF2 - 16 μg (1 dose)
11
4
36.4%
5
rORF2 - 8 μg (1 dose)
12
1
8.3%
6
rORF2 - 4 μg (1 dose)
11
1
9.1%
7
KV (2 doses)
12
7
58.3%
8
Challenge Controls
10
4
40%
9
Strict Negative Controls
11
0
0%
vORF2 = isolated viral ORF2;
rORF2 = recombinant baculovirus expressed ORF2;
killed whole cell virus = PCV2 virus grown in suitable cell culture
1 Total number of pigs in each group that demonstrated any clinical symptom for at least one day
[0000]
TABLE 10
Summary of Group Mortality Rates Post-challenge
Dead Post-
Group
Treatment
N
challenge
Mortality Rate
1
vORF2 - 16 μg (1 dose)
12
1
8.3%
2
vORF2 - 8 μg (1 dose)
12
1
8.3%
3
vORF2 - 4 μg (1 dose)
12
0
0%
4
rORF2 - 16 μg (1 dose)
11
0
0%
5
rORF2 - 8 μg (1 dose)
12
0
0%
6
rORF2 - 4 μg (1 dose)
11
1
9.1%
7
KV (2 doses)
12
2
16.7%
8
Challenge Controls
10
1
10%
9
Strict Negative Controls
11
0
0%
vORF2 = isolated viral ORF2;
rORF2 = recombinant baculovirus expressed ORF2;
killed whole cell virus = PCV2 virus grown in suitable cell culture
[0127] PCV2 nasal shedding results are presented below in Table 11. Following challenge on Day 24, 1 pig in Group 7 began shedding PCV2 on Day 27. None of the other groups experienced shedding until Day 33. The bulk of nasal shedding was noted from Day 35 to Day 45. Groups receiving any of the three vORF2 vaccines and groups receiving either 4 or 8 μg of rORF2 had the lowest incidence of nasal shedding of PCV2 (≦9.1%). The challenge control group (Group 8) had the highest shedding rate (80%), followed by the strict negative control group (Group 9), which had an incidence rate of 63.6%.
[0000]
TABLE 11
Summary of Group Incidence of Nasal Shedding of PCV2
No. Of
pigs that shed
Incidence
Group
Treatment
N
for at least one day
Rate
1
vORF2 - 16 μg (1 dose)
12
1
8.3%
2
vORF2 - 8 μg (1 dose)
12
1
8.3%
3
vORF2 - 4 μg (1 dose)
12
1
8.3%
4
rORF2 - 16 μg (1 dose)
11
2
18.2%
5
rORF2 - 8 μg (1 dose)
12
1
8.3%
6
rORF2 - 4 μg (1 dose)
11
1
9.1%
7
KV (2 doses)
12
5
41.7%
8
Challenge Controls
10
8
80%
9
Strict Negative Controls
11
7
63.6%
vORF2 = isolated viral ORF2;
rORF2 = recombinant baculovirus expressed ORF2;
killed whole cell virus = PCV2 virus grown in suitable cell culture
[0128] The Summary of Group Incidence of Icterus, Group Incidence of Gastric Ulcers, Group Mean Lung Lesion Scores, and Group Incidence of Lung Lesions are shown below in Table 12. Six pigs died at the first test site during the post-vaccination phase of the study (Group 4, N=1; Group 6, N=1; Group 8, N=2; Group 9, N=2). Four out of six pigs had fibrinous lesions in one or more body cavities, one pig (Group 6) had lesions consistent with clostridial disease, and one pig (Group 9) had no gross lesions. None of the pigs that died during the post-vaccination phased of the study had lesions consistent with PMWS.
[0129] Pigs that died post-challenge and pigs euthanized on Day 49 were necropsied. At necropsy, icterus and gastric ulcers were not present in any group. With regard to mean % lung lesions, Group 9 had lowest mean % lung lesions (0%), followed by Group 1 with 0.40±0.50% and Group 5 with 0.68±1.15%. Groups 2, 3, 7 and 8 had the highest mean % lung lesions (≧7.27%). Each of these four groups contained one pig with % lung lesions ≧71.5%, which skewed the results higher for these four groups. With the exception of Group 9 with 0% lung lesions noted, the remaining 8 groups had ≦36% lung lesions. Almost all lung lesions noted were described as red/purple and consolidated.
[0000]
TABLE 12
Summary of Group Incidence of Icterus, Group Incidence
of Gastric Ulcers, Group Mean % Lung Lesion Scores, and
Group Incidence of Lung Lesions Noted
Inci-
dence
of Lung
Gastric
Mean % Lung
Lesions
Group
Treatment
Icterus
Ulcers
Lesions
Noted
1
vORF2 - 16 μg
0/12 (0%)
0/12
0.40 ± 0.50%
10/12
(1 dose)
(0%)
(83%)
2
vORF2 - 8 μg
0/12 (0%)
0/12
7.41 ± 20.2%
10/12
(1 dose)
(0%)
(83%)
3
vORF2 - 4 μg
0/12 (0%)
0/12
9.20 ± 20.9%
10/12
(1 dose)
(0%)
(83%)
4
rORF2 - 16 μg
0/11 (0%)
0/11
1.5 ± 4.74%
4/11
(1 dose)
(0%)
(36%)
5
rORF2 - 8 μg
0/12 (0%)
0/12
0.68 ± 1.15%
9/12
(1 dose)
(0%)
(75%)
6
rORF2 - 4 μg
0/11 (0%)
0/11
2.95 ± 5.12%
7/11
(1 dose)
(0%)
(64%)
7
KV (2 doses)
0/12 (0%)
0/12
7.27 ± 22.9%
9/12
(0%)
(75%)
8
Challenge
0/10 (0%)
0/10
9.88 ± 29.2%
8/10
Controls
(0%)
(80%)
9
Strict Negative
0/11 (0%)
0/11
0/11
0/11
Controls
(0%)
(0%)
(0%)
vORF2 = isolated viral ORF2;
rORF2 = recombinant baculovirus expressed ORF2;
KV or killed whole cell virus = PCV2 virus grown in suitable cell culture
[0130] The Summary of Group IHC Positive Incidence Results are shown in Table 13. Group 1 (vORF2-16 μg) and Group 5 (rORF2-8 μg) had the lowest rate of IHC positive results (16.7%). Group 8 (Challenge Controls) and Group 9 (Strict Negative Controls) had the highest rate of IHC positive results, 90% and 90.9%, respectively.
[0000]
TABLE 13
Summary of Group IHC Positive Incidence Rate
No. Of pigs that had
at least one tissue
Incidence
Group
Treatment
N
positive for PCV2
Rate
1
vORF2 - 16 μg (1 dose)
12
2
16.7%
2
vORF2 - 8 μg (1 dose)
12
3
25.0%
3
vORF2 - 4 μg (1 dose)
12
8
66.7%
4
rORF2 - 16 μg (1 dose)
11
4
36.3%
5
rORF2 - 8 μg (1 dose)
12
2
16.7%
6
rORF2 - 4 μg (1 dose)
11
4
36.4%
7
KV (2 doses)
12
5
41.7%
8
Challenge Controls
10
9
90.0%
9
Strict Negative Controls
11
10
90.9%
vORF2 = isolated viral ORF2;
rORF2 = recombinant baculovirus expressed ORF2;
KV or killed whole cell virus = PCV2 virus grown in suitable cell culture
[0131] Post-challenge, Group 5, which received one dose of 8 μg of rORF2 antigen, outperformed the other 6 vaccine groups. Group 5 had the highest ADWG (0.94±0.22 lbs/day), the lowest incidence of abnormal behavior (0%), the second lowest incidence of cough (8.3%), the lowest incidence of overall clinical symptoms (8.3%), the lowest mortality rate (0%), the lowest rate of nasal shedding of PCV2 (8.3%), the second lowest rate for mean lung lesions (0.68±1.15%) and the lowest incidence rate for positive tissues (16.7%). Groups receiving various levels of rORF2 antigen overall outperformed groups receiving various levels of vORF2 and the group receiving 2 doses of killed whole cell PCV2 vaccine performed the worst. Tables 14 and 15 contain summaries of group post-challenge data.
[0000]
TABLE 14
Summary of Group Post-Challenge Data—Part 1
Overall
Incidence of
ADWG
Abnormal
Clinical
Group
N
Treatment
(lbs/day)
Behavior
Cough
Symptoms
1
12
vORF2—16 μg
0.87 ±
2/12
3/12
41.7%
(1 dose)
0.29
(16.7%)
(25%)
2
12
vORF2—8 μg
0.70 ±
4/12
1/12
41.7%
(1 dose)
0.32
(33.3%
(8.3%
3
12
vORF2—4 μg
0.49 ±
8/12
2/12
66.7%
(1 dose)
0.21
(66.7%)
(16.7%
4
11
rORF2—16 μg
0.84 ±
3/11
0/11
36.4%
(1 dose)
0.30
(27.3%)
(0%)
5
12
rORF2—8 μg
0.94 ±
0/12
1/12
8.3%
(1 dose)
0.22
(0%)
(8.3%
6
11
rORF2—4μg
0.72 ±
1/11
0/11
9.1%
(1 dose)
0.25
(9.1%
(0%)
7
12
KV
0.50 ±
7/12
0/12
58.3%
(2 doses)
0.15
(58.3)
(0%)
8
10
Challenge
0.76 ±
1/10
2/10
40%
Controls
0.19
(10%)
(20%
9
11
Strict Negative
1.06 ±
0/11
0/11
0%
Controls
0.17
(0%)
(0%)
vORF2 = isolated viral ORF2; rORF2 = recombinant baculovirus expressed ORF2; KV or killed whole cell virus = PCV2 virus grown in suitable cell culture
[0000]
TABLE 15
Summary of Group Post-Challenge Data—Part 2
Incidence Rate of
Mor-
Nasal
Mean %
at least one tissue
tality
Shed-
Lung
IHC positive
Group
N
Treatment
Rate
ding
Lesions
for PCV2
1
12
vORF2—16 μg
8.3%
8.3%
0.40 ±
16.7%
(1 dose)
0.50%
2
12
vORF2—8 μg
8.3%
8.3%
7.41 ±
25.0%
(1 dose)
20.2%
3
12
vORF2—4 μg
0%
8.3%
9.20 ±
66.7%
(1 dose)
20.9%
4
11
rORF2—16 μg
0%
18.2%
1.50 ±
36.3%
(1 dose)
4.74%
5
12
rORF2—8 μg
0%
8.3%
0.68 ±
16.7%
(1 dose)
1.15%
6
11
rORF2—4 μg
9.1%
9.1%
2.95 ±
36.4%
(1 dose)
5.12%
7
12
KV
16.7%
41.7%
7.27 ±
41.7%
(2 doses)
22.9%
8
10
Challenge
10%
80%
9.88 ±
90.0%
Controls
29.2%
9
11
Strict Negative
0%
63.6%
0/11
90.9%
Controls
(0%)
vORF2 = isolated viral ORF2; rORF2 = recombinant baculovirus expressed ORF2; KV or killed whole cell virus = PCV2 virus grown in suitable cell culture
[0132] Results of this study indicate that all further vaccine efforts should focus on a rORF2 vaccine. Overall, nasal shedding of PCV2 was detected post-challenge and vaccination with a PCV2 vaccine resulted in a reduction of shedding Immunohistochemistry of selected lymphoid tissues also served as a good parameter for vaccine efficacy, whereas large differences in ADWG, clinical symptoms, and gross lesions were not detected between groups. This study was complicated by the fact that extraneous PCV2 was introduced at some point during the study, as evidenced by nasal shedding of PCV2, PCV2 seroconversion and positive IHC tissues in Group 9, the strict negative control group.
Discussion
[0133] Seven PCV2 vaccines were evaluated in this study, which included three different dose levels of vORF2 antigen administered once on Day 0, three different dose levels of rORF2 antigen administered once on Day 0 and one dose level of killed whole cell PCV2 vaccine administered on Day 0 and Day 14. Overall, Group 5, which received 1 dose of vaccine containing 8 μg of rORF2 antigen, had the best results. Group 5 had the highest ADWG, the lowest incidence of abnormal behavior, the lowest incidence of abnormal respiration, the second lowest incidence of cough, the lowest incidence of overall clinical symptoms, the lowest mortality rate, the lowest rate of nasal shedding of PCV2, the second lowest rate for mean % lung lesions and the lowest incidence rate for positive IHC tissues.
[0134] Interestingly, Group 4, which received a higher dose of rORF2 antigen than Group 5, did not perform as well or better than Group 5. Group 4 had a slightly lower ADWG, a higher incidence of abnormal behavior, a higher incidence of overall clinical symptoms, a higher rate of nasal shedding of PCV2, a higher mean % lung lesions, and a higher rate for positive IHC tissues than Group 5. Statistical analysis, which may have indicated that the differences between these two groups were not statistically significant, was not conducted on these data, but there was an observed trend that Group 4 did not perform as well as Group 5.
[0135] Post-vaccination, 6 pigs died at the first study site. Four of the six pigs were from Group 8 or Group 9, which received no vaccine. None of the six pigs demonstrated lesions consistent with PMWS, no adverse events were reported and overall, all seven vaccines appeared to be safe when administered to pigs approximately 11 days of age. During the post-vaccination phase of the study, pigs receiving either of three dose levels of vORF2 vaccine or killed whole cell vaccine had the highest IFAT levels, while Group 5 had the lowest IFAT levels just prior to challenge, of the vaccine groups.
[0136] Although not formally proven, the predominant route of transmission of PCV2 to young swine shortly after weaning is believed to be by oronasal direct contact and an efficacious vaccine that reduces nasal shedding of PCV2 in a production setting would help control the spread of infection. Groups receiving one of three vORF2 antigen levels and the group receiving 8 μg of rORF2 had the lowest incidence rate of nasal shedding of PCV2 (8.3%). Expectedly, the challenge control group had the highest incidence rate of nasal shedding (80%).
[0137] Gross lesions in pigs with PMWS secondary to PCV2 infection typically consist of generalized lymphadenopathy in combination with one or a multiple of the following: (1) interstitial pneumonia with interlobular edema, (2) cutaneous pallor or icterus, (3) mottled atrophic livers, (4) gastric ulcers and (5) nephritis. At necropsy, icterus, hepatitis, nephritis, and gastric ulcers were not noted in any groups and lymphadenopathy was not specifically examined for. The mean % lung lesion scores varied between groups. The group receiving 16 μg of vORF2 antigen had the lowest mean % lung lesion score (0.40±0.50%), followed by the group that received 8 μg of rORF2 (0.68±1.15%). As expected, the challenge control group had the highest mean % lung lesion score (9.88±29.2%). In all four groups, the mean % lung lesion scores were elevated due to one pig in each of these groups that had very high lung lesion scores. Most of the lung lesions were described as red/purple and consolidated. Typically, lung lesions associated with PMWS are described as tan and non-collapsible with interlobular edema. The lung lesions noted in this study were either not associated with PCV2 infection or a second pulmonary infectious agent may have been present. Within the context of this study, the % lung lesion scores probably do not reflect a true measure of the amount of lung infection due to PCV2.
[0138] Other researchers have demonstrated a direct correlation between the presence of PCV2 antigen by IHC and histopathology. Histopathology on select tissues was not conducted with this study. Group 1 (16 μg of vORF2) and Group 5 (8 μg of rORF2) had the lowest incidence rate of pigs positive for PCV2 antigen (8.3%), while Group 9 (the strict negative control group—90.9%) and Group 8 (the challenge control group—90.0%) had the highest incidence rates for pigs positive for PCV2 antigen. Due to the non-subjective nature of this test, IHC results are probably one of the best parameters to judge vaccine efficacy on.
[0139] Thus, in one aspect of the present invention, the Minimum Portective Dosage (MPD) of a 1 ml/1 dose recombinant product with extracted PCV2 ORF2 (rORF2) antigen in the CDCD pig model in the face of a PCV2 challenge was determined. Of the three groups that received varying levels of rORF2 antigen, Group 5 (8 μg of rORF2 antigen) clearly had the highest level of protection. Group 5 either had the best results or was tied for the most favorable results with regard to all of the parameters examined. When Group 5 was compared with the other six vaccine groups post-challenge, Group 5 had the highest ADWG (0.94±0.22 lbs/day), the lowest incidence of abnormal behavior (0%), the second lowest incidence of cough (8.3%), the lowest incidence of overall clinical symptoms (8.3%), the lowest mortality rate (0%), the lowest rate of nasal shedding of PCV2 (8.3%), the second lowest rate for mean % lung lesions (0.68±1.15%) and the lowest incidence rate for positive IHC tissues (16.7%).
[0140] In another aspect of the present invention, the MPD of a 1 ml/1 dose conventional product that is partially purified PCV2 ORF2 (vORF2) antigen in the CDCD pig model in the face of a PCV2 challenge was determined. Of the three groups that received varying levels of vORF2 antigen, Group 1 (16 μg of vORF2) had the highest level of protection. Group 1 outperformed Groups 2 and 3 with respect to ADWG, mean % lung lesions, and IHC. Groups 1 and 2 (8 μg of vORF2 antigen) performed equally with respect to overall incidence of clinical symptoms, Group 3 (4 μg of vORF2 antigen) had the lowest mortality rate, and all three groups performed equally with respect to nasal shedding. Overall, vORF vaccines did not perform as well as rORF vaccines.
[0141] In yet another aspect of the present invention, the efficacy of a maximum dose of a 2 ml/2 dose Conventional Killed PCV2 vaccine in the CDCD pig model in the face of a PCV2 challenge was determined. Of the seven vaccines evaluated in this study, the killed whole cell PCV2 vaccine performed the worst. Piglets receiving two doses of killed whole cell PCV2 vaccine had the lowest ADWG, the second highest rate of abnormal behavior (58.3%), the second highest overall incidence of clinical symptoms (58.3%), the highest mortality rate (16.7%), the second highest incidence of nasal shedding (41.7%), highest mean % lung lesions (9.88±29.2%), a high incidence of lung lesions noted (75%) and a moderate IHC incidence rate in tissues (41.7%). However, it was still effective at invoking an immune response.
[0142] In still another aspect of the present invention, nasal shedding of PCV2 was assessed as an efficacy parameter and the previous PCV2 efficacy parameters from previous studies were reconfirmed. Results from this study indicate that nasal shedding of PCV2 occurs following intra nasal challenge and that PCV2 vaccines reduce nasal shedding of PCV2 post-challenge. Furthermore, results from this study and reports in the literature indicate that IHC should continue to be evaluated in future PCV2 vaccine trials as well.
[0143] Some additional conclusions arising from this study are that lymphadenopathy is one of the hallmarks of PMWS. Another one of the hallmarks of PMWS is lymphoid depletion and multinucleated/giant histiocytes. Additionally, no adverse events or injection site reactions were noted for any of the 7 PCV2 vaccines and all 7 PCV2 vaccines appeared to be safe when administered to young pigs.
Example 5
[0144] This example tests the efficacy of eight PCV2 candidate vaccines and reconfirms PCV2 challenge parameters from earlier challenge studies following exposure to a virulent strain of PCV2. One hundred and fifty (150) cesarean derived colostrum deprived (CDCD) piglets, 6-16 days of age, were blocked by weight and randomly divided into 10 groups of equal size. Table 16 sets forth the General Study Design for this Example.
[0000]
TABLE 16
General Study Design
Challenge
with
KLH/ICFA
Virulent
PRRSV
Necropsy
No. Of
Day of
on Day 22
PCV2 on
MLV on
on Day
Group
Pigs
Treatment
Treatment
and Day 28
Day 25
Day 46
50
1
15
PVC2 Vaccine 1
0 & 14
+
+
+
+
16 μg
rORF2—IMS 1314
2
15
PVC2 Vaccine 2
0 & 14
+
+
+
+
16 μg
vORF2—Carbopol
3
15
PCV2 Vaccine 3
0 & 14
+
+
+
+
16 μg
rORF2—Carbopol
4
15
PCV2 Vaccine 2
0
+
+
+
+
16 μg
vORF2—Carbopol
5
15
PVC2 Vaccine 3
0 & 14
+
+
+
+
4 μg
rORF2—Carbopol
6
15
PVC2 Vaccine 3
0 & 14
+
+
+
+
1 μg
rORF2—Carbopol
7
15
PVC2 Vaccine 3
0 & 14
+
+
+
+
0.25 μg
rORF2—Carbopol
8
15
PVC2 Vaccine 4
0 & 14
+
+
+
+
>8.0 log
KV—Carbopol
9
15
Challenge
N/A
+
+
+
+
Controls
10
15
None—Strict
N/A
+
−
+
+
Negative Control
Group
vORF2 = isolated viral ORF2; rORF2 = recombinant baculovirus expressed ORF2; KV or killed whole cell virus = PCV2 virus grown in suitable cell culture
[0145] The vaccine formulation given to each group were as follows. PCV2 Vaccine No. 1, administered at 1×2 ml dose to Group 1, was a high dose (16 ug/2 ml dose) of inactivated recombinant ORF2 antigen adjuvanted with IMS 1314 (16 ug rORF2-IMS 1314). PCV2 Vaccine No. 2, administered at 1×2 ml dose to Group 2, was a high dose (16 ug/2 ml dose) of a partially purified VIDO R-1 generated PCV2 ORF2 antigen adjuvanted with Carbopol (16 ug vORF2-Carbopol). PCV2 Vaccine No. 3, administered at 1×2 ml dose to Group 3, was a high dose (16 ug/2 ml dose) of inactivated recombinant ORF2 antigen adjuvanted with Carbopol (16 ug rORF2—Carbopol). PCV2 Vaccine No. 4, administered at 1×1 ml dose to Group 4, was a high dose (16 ug/1 ml dose) of a partially purified VIDO R-1 generated PCV2 ORF2 antigen adjuvanted with Carbopol (16 ug vORF2-Carbopol). Vaccine No. 5, administered at 1×2 ml dose to Group 5, was a 4 ug/2 ml dose of an inactivated recombinant ORF2 antigen adjuvanted with Carbopol (4 ug rORF2-Carbopol). PCV2 Vaccine No. 6, administered at 1×2 ml dose to Group 6, was a 1 ug/2 ml dose of an inactivated recombinant ORF2 antigen adjuvanted with Carbopol (1 ug rORF2-Carbopol). PCV2 Vaccine No. 7, administered at 1×2 ml dose to Group 7, was a low dose (0.25 ug/2 ml dose) of inactivated recombinant ORF2 antigen adjuvanted with Carbopol (0.25 ug rORF2-Carbopol). PCV2 Vaccine No. 8, administered at 1×2 ml dose to Group 8, was a high dose (pre-inactivation titer >8.0 log/2 ml dose) Inactivated Conventional Killed VIDO R-1 generated PCV2 Struve antigen adjuvanted with Carbopol (>8.0 log KV-Carbopol). On Day 0, Groups 1-8 were treated with their assigned vaccines. Groups 1-3 and 5-8 received boosters of their respective vaccines again on Day 14. The effectiveness of a single dose of 16 μg of vORF2-Carbopol was tested on Group 4 which did not receive a booster on Day 14. Piglets were observed for adverse events and injection site reactions following both vaccinations. On Day 21 the piglets were moved to a second study site where Groups 1-9 were group housed in one building and Group 10 was housed in a separate building. All pigs received keyhole limpet hemocyanin emulsified with incomplete Freund's adjuvant (KLH/ICFA) on Days 22 and 28. On Day 25, Groups 1-9 were challenged with approximately 4 logs of virulent PCV2 virus. By Day 46, very few deaths had occurred in the challenge control group. In an attempt to immunostimulate the pigs and increase the virulence of the PCV2 challenge material, all Groups were treated with INGELVAC® PRRSV MLV (Porcine Reproductive and Respiratory Vaccine, Modified Live Virus) on Day 46.
[0146] Pre- and post-challenge blood samples were collected for PCV2 serology. Post-challenge, body weight data for determination of average daily weight gain (ADWG) and observations of clinical signs were collected. On Day 50, all surviving pigs were necropsied, gross lesions were recorded, lungs were scored for pathology, and selected tissues were preserved in formalin for examination by Immunohistochemistry (IHC) for detection of PCV2 antigen at a later date.
Materials and Methods
[0147] This was a partially-blind vaccination-challenge feasibility study conducted in CDCD pigs, 6 to 16 days of age on Day 0. To be included in the study, PCV2 IFA titers of sows were ≦1:1000. Additionally, the serologic status of sows were from a known PRRS-negative herd. Sixteen (16) sows were tested for PCV2 serological status and all sixteen (16) had a PCV2 titer of ≦1000 and were transferred to the first study site. One hundred fifty (150) piglets were delivered by cesarean section surgeries and were available for this study on Day −3. On Day −3, 150 CDCD pigs at the first study site were weighed, identified with ear tags, blocked by weight and randomly assigned to 1 of 10 groups, as set forth above in table 16. Blood samples were collected from all pigs. If any test animal meeting the inclusion criteria was enrolled in the study and was later excluded for any reason, the Investigator and Monitor consulted in order to determine the use of data collected from the animal in the final analysis. The date of which enrolled piglets were excluded and the reason for exclusion was documented. No sows meeting the inclusion criteria, selected for the study and transported to the first study site were excluded. No piglets were excluded from the study, and no test animals were removed from the study prior to termination. Table 17 describes the time frames for the key activities of this Example.
[0000]
TABLE 17
Study Activities
Study Day
Actual Dates
Study Activity
−3
Apr. 04, 2003
Weighed pigs; health exam; randomized to groups; collected
blood samples
−3, 0-21
Apr. 04, 2003
Apr. 07, 2003 to
Observed for overall health and for adverse events post-
May 27, 2003
vaccination
0
Apr. 07, 2003
Administered respective IVPs to Groups 1-8
0-7
Apr. 07, 2003 to
Observed pigs for injection site reactions
Apr. 14, 2003
14
Apr. 21, 2003
Boostered Groups 1-3, 5-8 with respective IVPs; blood
sampled all pigs
14-21
Apr. 21, 2003 to
Observed pigs for injection reactions
Apr. 28, 2003
19-21
Apr. 26, 2003 to
Treated all pigs with antibiotics
Apr. 28, 2003
21
Apr. 28, 2003
Pigs transported from Struve Labs, Inc. to Veterinary
Resources, Inc.(VRI)
22-50
Apr. 28, 2003 to
Observed pigs for clinical signs post-challenge
May 27, 2003
22
Apr. 29, 2003
Treated Groups 1-10 with KLH/ICFA
25
May 02, 2003
Collected blood samples from all pigs; weighed all pigs;
challenged Groups 1-9 with PCV2 challenge material
28
May 05, 2003
Treated Groups 1-10 with KLH/ICFA
32
May 09, 2003
Collected blood samples from all pigs
46
May 23, 2003
Administered INGELVAC ® PRRS MLV to all groups
50
May 27, 2003
Collected blood samples, weighed and necropsied all pigs;
gross lesions were recorded; lungs were evaluated for
lesions; fresh and formalin fixed tissue samples were saved;
In-life phase of the study was completed
[0148] Following completion of the in-life phase of the study, formalin fixed tissues were examined by Immunohistochemistry (MC) for detection of PCV2 antigen by a pathologist, blood samples were evaluated for PCV2 serology, and average daily weight gain (ADWG) was determined from Day 25 to Day 50.
[0149] Animals were housed at the first study site in individual cages in seven rooms from birth to approximately 11 days of age (approximately Day 0 of the study). Each room was identical in layout and consisted of stacked individual stainless steel cages with heated and filtered air supplied separately to each isolation unit. Each room had separate heat and ventilation, thereby preventing cross-contamination of air between rooms. Animals were housed in two different buildings at the second study site. Group 10 (The Strict negative control group) was housed separately in a converted nursery building and Groups 1-9 were housed in a converted farrowing building. Each group was housed in a separate pen (14-15 pigs per pen) and each pen provided approximately 2.3 square feet per pig. Groups 2, 4 and 8 were penned in three adjacent pens on one side of the alleyway and Groups 1, 3, 5, 6, 7, and 9 were penned in six adjacent pens on the other side of the alleyway. The Group separation was due to concern by the Study Monitor that vaccines administered to Groups 2, 4, and 8 had not been fully inactivated. Each pen was on an elevated deck with plastic slatted floors. A pit below the pens served as a holding tank for excrement and waste. Each building had its own separate heating and ventilation systems, with little likelihood of cross-contamination of air between buildings.
[0150] At the first study site, piglets were fed a specially formulated milk ration from birth to approximately 3 weeks of age. All piglets were consuming solid, special mixed ration by Day 21 (approximately 4½ h weeks of age). At the second study site, all piglets were fed a custom non-medicated commercial mix ration appropriate for their age and weight, ad libitum. Water at both study sites was also available ad libitum.
[0151] All test pigs were treated with 1.0 mL of NAXCEL®, IM, in alternating hams on Days 19, 20, and 21. In addition, Pig No. 11 (Group 1) was treated with 0.5 mL of NAXCEL® IM on Day 10, Pig No. 13 (Group 10) was treated with 1 mL of Penicillin and 1 mL of PREDEF® 2× on Day 10, Pig No. 4 (Group 9) was treated with 1.0 mL of NAXCEL® IM on Day 11, and Pigs 1 (Group 1), 4 and 11 were each treated with 1.0 mL of NAXCEL® on Day 14 for various health reasons.
[0152] While at both study sites, pigs were under veterinary care. Animal health examinations were conducted on Day −3 and were recorded on the Health Examination Record Form. All animals were in good health and nutritional status before vaccination as determined by observation on Day 0. All test animals were observed to be in good health and nutritional status prior to challenge. Carcasses and tissues were disposed of by rendering. Final disposition of study animals was recorded on the Animal Disposition Record.
[0153] On Days 0 and 14, pigs assigned to Groups 1-3 and 5-8 received 2.0 mL of assigned PCV2 Vaccines 1-4, respectively, IM in the right and left neck region, respectively, using a sterile 3.0 mL Luer-lock syringe and a sterile 20 g×½″ needle. Pigs assigned to Group 4 received 1.0 mL of PCV2 Vaccine No. 2, IM in the right neck region using a sterile 3.0 mL Luer-lock syringe and a sterile 20 g×½″ needle on Day 0 only.
[0154] On Day 22 all test pigs received 2.0 mL of KLH/ICFA IM in the left neck region using a sterile 3.0 mL Luer-lock syringe and a sterile 20 g×1″ needle. On Day 28 all test pigs received 2.0 mL of KLH/ICFA in the right ham region using a sterile 3.0 mL Luer-lock syringe and a sterile 20 g×1″ needle.
[0155] On Day 25, pigs assigned to Groups 1-9 received 1.0 mL of PCV2 ISUVDL challenge material (3.98 log 10 TCID 50 /mL) IM in the right neck region using a sterile 3.0 mL Luer-lock syringe and a sterile 20 g×1″ needle. An additional 1.0 mL of the same material was administered IN to each pig (0.5 mL per nostril) using a sterile 3.0 mL Luer-lock syringe and nasal canula.
[0156] On Day 46, all test pigs received 2.0 mL INGELVAC® PRRS MLV, IM, in the right neck region using a sterile 3.0 mL Luer0lock syringe and a sterile 20 g×1″ needle. The PRRSV MLV was administered in an attempt to increase virulence of the PCV2 challenge material.
[0157] Test pigs were observed daily for overall health and adverse events on Day −3 and from Day 0 to Day 21. Each of the pigs were scored for normal or abnormal behavior, respiration or cough. Observations were recorded on the Clinical Observation Record. All test pigs were observed from Day 0 to Day 7, and Group 7 was further observed from Day 14 to 21, for injection site reactions. Average daily weight gain was determined by weighing each pig on a calibrated scale on Days −3, 25 and 50, or on the day that a pig was found dead after challenge. Body weights were recorded on the Body Weight Form. Day −3 body weights were utilized to block pigs prior to randomization. Day 25 and Day 50 weight data was utilized to determine the average daily weight gain (ADWG) for each pig during these time points. For pigs that died after challenge and before Day 50, the ADWG was adjusted to represent the ADWG from Day 25 to the day of death.
[0158] In order to determine PCV2 serology, venous whole blood was collected from each piglet from the orbital venous sinus on Days −3 and 14. For each piglet, blood was collected from the orbital venous sinus by inserting a sterile capillary tube into the medial canthus of one of the eyes and draining approximately 3.0 mL of whole blood into a 4.0 mL Serum Separator Tube (SST). On Days 25, 32, and 50, venous whole blood from each pig was collected from the anterior vena cava using a sterile 20 g×1½″ Vacutainer® needle (Becton Dickinson and Company, Franklin Lakes, N.J.), a Vaccutainer® needle holder and a 13 mL SST. Blood collections at each time point were recorded on the Sample Collection Record. Blood in each SST was allowed to clot, each SST was then spun down and the serum harvested. Harvested serum was transferred to a sterile snap tube and stored at −70±10° C. until tested at a later date. Serum samples were tested for the presence of PCV2 antibodies by BIVI-R&D personnel.
[0159] Pigs were observed once daily from Day 22 to Day 50 for clinical symptoms and scored for normal or abnormal behavior, respiration or cough. Clinical observations were recorded on the Clinical Observation Record.
[0160] Pigs Nos. 46 (Group 1) and 98 (Groups 9) died at the first study site. Both of these deaths were categorized as bleeding deaths and necropsies were not conducted on these two pigs. At the second study site, pigs that died after challenge and prior to Day 50, and pigs euthanized on Day 50, were necropsied. Any gross lesions were noted and the percentages of lung lobes with lesions were recorded on the Necropsy Report Form.
[0161] From each of the pigs necropsied at the second study site, a tissue sample of tonsil, lung, heart, and mesenteric lymph node was placed into a single container with buffered 10% formalin; while another tissue sample from the same aforementioned organs was placed into a Whirl-pak® (M-Tech Diagnostics Ltd., Thelwall, UK) and each Whirl-pak® was placed on ice. Each container was properly labeled. Sample collections were recorded on the Necropsy Report Form. Afterwards, formalin-fixed tissue samples and a Diagnostic Request Form were submitted for IHC testing. IHC testing was conducted in accordance with standard laboratory procedures for receiving samples, sample and slide preparation, and staining techniques. Fresh tissues in Whirl-paks® were shipped with ice packs to the Study Monitor for storage (−70°±10° C.) and possible future use.
[0162] Formalin-fixed tissues were examined by a pathologist for detection of PCV2 by IHC and scored using the following scoring system: 0=None; 1=Scant positive staining, few sites; 2=Moderate positive staining, multiple sites; and 3=Abundant positive staining, diffuse throughout the tissue. For analytical purposes, a score of 0 was considered “negative,” and a score of greater than 0 was considered “positive.”
Results
[0163] Results for this example are given below. It is noted that Pigs No. 46 and 98 died on days 14 and 25 respectively. These deaths were categorized as bleeding deaths. Pig No. 11 (Group 1) was panting with rapid respiration on Day 15. Otherwise, all pigs were normal for behavior, respiration and cough during this observation period and no systemic adverse events were noted with any groups. No injection site reactions were noted following vaccination on Day 0. Following vaccination on Day 14, seven (7) out of fourteen (14) Group 1 pigs (50.0%) had swelling with a score of “2” on Day 15. Four (4) out of fourteen (14) Group 1 (28.6%) still had a swelling of “2” on Day 16. None of the other groups experienced injection site reactions following either vaccination.
[0164] Average daily weight gain (ADWG) results are presented below in Table 18. Pigs No. 46 and 98 that died from bleeding were excluded from group results. Group 4, which received one dose of 16 ug vORF2-Carbopol, had the highest ADWG (1.16±0.26 lbs/day), followed by Groups 1, 2, 3, 5, 6, and 10 which had ADWGs that ranged from 1.07±0.23 lbs/day to 1.11±0.26 lbs/day. Group 9 had the lowest ADWG (0.88±0.29 lbs/day), followed by Groups 8 and 7, which had ADWGs of 0.93±0.33 lbs/day and 0.99±0.44 lbs/day, respectively.
[0000]
TABLE 18
Summary of Group Average Daily Weight Gains (ADWG)
ADWG - lbs/day
(Day 25 to Day 50)
or adjusted for pigs
Group
Treatment
N
dead before Day 50
1
rORF2 - 16 μg - IMS 1314 2 doses
14
1.08 ± 0.30 lbs/day
2
vORF2 - 16 μg - Carbopol 2 doses
15
1.11 ± 0.16 lbs/day
3
rORF2 - 16 μg - Carbopol 2 doses
15
1.07 ± 0.21 lbs/day
4
vORF2 - 16 μg - Carbopol 1 dose
15
1.16 ± 0.26 lbs/day
5
rORF2 - 4 μg - Carbopol 1 dose
15
1.07 ± 0.26 lbs/day
6
rORF2 - 1 μg - Carbopol 2 doses
15
1.11 ± 0.26 lbs/day
7
rORF2 - 0.25 μg - Carbopol 2 doses
15
0.99 ± 0.44 lbs/day
8
KV > 8.0 log - Carbopol 2 doses
15
0.93 ± 0.33 lbs/day
9
Challenge Controls
14
0.88 ± 0.29 lbs/day
10
Strict Negative Controls
15
1.07 ± 0.23 lbs/day
vORF2 = isolated viral ORF2;
rORF2 = recombinant baculovirus expressed ORF2;
KV or killed whole cell virus = PCV2 virus grown in suitable cell culture
[0165] PVC2 serology results are presented below in Table 19. All ten (10) groups were seronegative for PCV2 on Day −3. On Day 14, PCV2 titers remained low for all ten (10) groups (range of 50-113). On Day 25, Group 8, which received the whole cell killed virus vaccine, had the highest PCV2 titer (4617), followed by Group 2, which received 16 ug vORF2-Carbopol, Group 4, which received as single dose of 16 ug vORF2-Carbopol, and Group 3, which received 16 ug rORF2-Carbopol, which had titers of 2507, 1920 and 1503 respectively. On Day 32 (one week post challenge), titers for Groups 1-6 and Group 8 ranged from 2360 to 7619; while Groups 7 (0.25 ug rORF2-Carbopol), 9 (Challenge Control), and 10 (Strict negative control) had titers of 382, 129 and 78 respectively. On Day 50 (day of necropsy), all ten (10) groups demonstrated high PCV2 titers (≧1257).
[0166] On Days 25, 32, and 50, Group 3, which received two doses of 16 ug rORF2-Carbopol had higher antibody titers than Group 1, which received two doses of 16 ug rORF2-IMS 1314. On Days 25, 32 and 50, Group 2, which received two doses of 16 ug vORF2 had higher titers than Group 4, which received only one does of the same vaccine. Groups 3, 5, 6, 7, which received decreasing levels of rORF2-Carbopol, of 16, 4, 1, and 0.25 ug respectively, demonstrated correspondingly decreasing antibody titers on Days 25 and 32.
[0000]
TABLE 19
Summary of Group PCV2 IFA Titers
Group
Treatment
Day -3
Day 14**
Day 25***
Day 32
Day 50****
1
rORF2—16 μg—
50
64
646
3326
4314
IMS 1314 2 doses
2
vORF2—16 μg—
50
110
2507
5627
4005
Carbopol 2 doses
3
rORF2—16 μg—
50
80
1503
5120
6720
Carbopol 2 doses
4
vORF2—16 μg—
50
113
1920
3720
1257
Carbopol 1 dose
5
rORF2—4 μg—
50
61
1867
3933
4533
Carbopol 1 dose
6
rORF2—1 μg—
50
70
490
2360
5740
Carbopol 2 doses
7
rORF2—0.25 μg—
50
73
63
382
5819
Carbopol 2 doses
8
KV > 8.0 log—Carbopol
50
97
4617
7619
10817
2 doses
9
Challenge Controls
50
53
50
129
4288
10
Strict Negative Controls
50
50
50
78
11205
vORF2 = isolated viral ORF2; rORF2 = recombinant baculovirus expressed ORF2; KV or killed whole cell virus = PCV2 virus grown in suitable cell culture
*For calculation purposes, a ≦ 100 IFA titer was designated as a titer of “50”; a ≧ 6400 IFA titer was designated as a titer of “12,800”.
**Day of Challenge
***Day of Necropsy
[0167] The results from the post-challenge clinical observations are presented below. Table 20 includes observations for Abnormal Behavior, Abnormal Respiration, Cough and Diarrhea. Table 21 includes the results from the Summary of Group Overall Incidence of Clinical Symptoms and Table 22 includes results from the Summary of Group Mortality Rates Post-challenge. The incidence of abnormal behavior, respiration and cough post-challenge were low in pigs receiving 16 ug rORF2-IMS 1314 (Group 1), 16 ug rORF2-Carbopol (Group 3), 1 ug rORF2-Carbopol (Group 6), 0.25 ug rORF2-Carbopol (Group 7), and in pigs in the Challenge Control Group (Group 9). The incidence of abnormal behavior respiration and cough post-challenge was zero in pigs receiving 16 ug vORF2-Carbopol (Group 2), a single dose of 16 ug vORF2-Carbopol (Group 4), 4 ug rORF2-Carbopol (Group 5), >8 log KV-Carbopol (Group 8), and in pigs in the strict negative control group (Group 10).
[0168] The overall incidence of clinical symptoms varied between groups. Pigs receiving 16 ug vORF2-Carbopol (Group 2), a single dose of 16 ug vORF2-Carbopol (Group 4), and pigs in the Strict negative control group (Group 10) had incidence rates of 0%; pigs receiving 16 ug rORF2-Carbopol (Group 3), and 1 ug rORF2-Carbopol (Group 6) had incidence rates of 6.7%; pigs receiving 16 ug rORF2-IMS 1314 (Group 1) had an overall incidence rate of 7.1%; pigs receiving 4 ug rORF2-Carbopol (Group 5), 0.25 ug rORF2-Carbopol (Group 7), and >8 log KV vaccine had incidence rates of 13.3%; and pigs in the Challenge Control Group (Group 9) had an incidence rate of 14.3%.
[0169] Overall mortality rates between groups varied as well. Group 8, which received 2 doses of KV vaccine had the highest mortality rate of 20.0%; followed by Group 9, the challenge control group, and Group 7, which received 0.25 ug rORF2-Carbopol and had mortality rates of 14.3% and 13.3% respectively. Group 4, which received one dose of 16 ug vORF2-Carbopol had a 6.7% mortality rate. All of the other Groups, 1, 2, 3, 5, 6, and 10 had a 0% mortality rate.
[0000]
TABLE 20
Summary of Group Observations for Abnormal Behavior, Abnormal
Respiration, and Cough Post-Challenge
Abnormal
Abnormal
Group
Treatment
N
Behavior 1
Behavior 2
Cough 3
1
rORF2 - 16 μg -
14
0/14
0/14
1/14
IMS 1314 2 doses
(0%)
(0%)
(7.1%)
2
vORF2 - 16 μg -
15
0/15
0/15
0/15
Carbopol 2 doses
(0%)
(0%)
(0%)
3
rORF2 - 16 μg -
15
0/15
0/15
1/15
Carbopol 2 doses
(0%)
(0%)
(6.7%)
4
vORF2 - 16 μg -
15
0/15
0/15
0/15
Carbopol 1 dose
(0%)
(0%)
(0%)
5
rORF2 - 4 μg -
15
1/15
1/15
0/15
Carbopol 1 dose
(6.7%)
(6.7%)
(0%)
6
rORF2 - 1 μg -
15
0/15
0/15
1/15
Carbopol 2 doses
(0%)
(0%)
(6.7%)
7
rORF2 - 0.25 μg -
15
0/15
1/15
1/15
Carbopol 2 doses
(0%)
(6.7%)
(06.7%)
8
KV > 8.0 log -
15
1/15
1/15
0/15
Carbopol 2 doses
(6.7%)
(6.7%)
(0%)
9
Challenge Controls
14
1/14
1/14
2/14
(7.1%)
(7.1%)
(14/3%)
10
Strict Negative
15
0/15
0/15
0/15
Controls
(0%)
(0%)
(0%)
1 Total number of pigs in each group that demonstrated any abnormal behavior for at least one day
2 Total number of pigs in each group that demonstrated any abnormal respiration for at least one day
3 Total number of pigs in each group that demonstrated a cough for at least one day
[0000]
TABLE 21
Summary of Group Overall Incidence of Clinical
Symptoms Post-Challenge
Incidence
of pigs
with Clinical
Incidence
Group
Treatment
N
Symptoms 1
Rate
1
rORF2 - 16 μg -
14
1
7.1%
IMS 1314 2 doses
2
vORF2 - 16 μg - Carbopol 2
15
0
0.0%
doses
3
rORF2 - 16 μg - Carbopol 2
15
1
6.7%
doses
4
vORF2 - 16 μg - Carbopol 1
15
0
0.0%
dose
5
rORF2 - 4 μg -
15
2
13.3%
Carbopol 1 dose
6
rORF2 - 1 μg -
15
1
6.7%
Carbopol 2 doses
7
rORF2 - 0.25 μg - Carbopol
15
2
13.3%
2 doses
8
KV > 8.0 log - Carbopol 2
15
2
13.3%
doses
9
Challenge Controls
14
2
14.3%
10
Strict Negative Controls
15
0
0.0%
vORF2 = isolated viral ORF2;
rORF2 = recombinant baculovirus expressed ORF2;
KV or killed whole cell virus = PCV2 virus grown in suitable cell culture
1 Total number of pigs in each group that demonstrated any clinical symptom for at least one day
[0000]
TABLE 22
Summary of Group Mortality Rates Post-Challenge
Dead
Post-
Group
Treatment
N
challenge
Mortality Rate
1
rORF2 - 16 μg -
14
0
0.0%
IMS 1314 2 doses
2
vORF2 - 16 μg - Carbopol 2
15
0
0.0%
doses
3
rORF2 - 16 μg - Carbopol 2
15
0
0.0%
doses
4
vORF2 - 16 μg - Carbopol 1
15
1
6.7%
dose
5
rORF2 - 4 μg -
15
0
0.0%
Carbopol 1 dose
6
rORF2 - 1 μg -
15
0
0.0%
Carbopol 2 doses
7
rORF2 - 0.25 μg - Carbopol 2
15
2
13.3%
doses
8
KV > 8.0 log - Carbopol 2
15
3
20.0%
doses
9
Challenge Controls
14
2
14.3%
10
Strict Negative Controls
15
0
0.0%
vORF2 = isolated viral ORF2;
rORF2 = recombinant baculovirus expressed ORF2;
KV or killed whole cell virus = PCV2 virus grown in suitable cell culture
[0170] The Summary of Group Mean Percentage Lung Lesions and Tentative Diagnosis is given below in Table 23. Group 9, the challenge control group, had the highest percentage lung lesions with a mean of 10.81±23.27%, followed by Group 7, which received 0.25 ug rORF2-Carbopol and had a mean of 6.57±24.74%, Group 5, which received 4 ug rORF2-Carbopol and had a mean of 2.88±8.88%, and Group 8, which received the KV vaccine and had a mean of 2.01±4.98%. The remaining six (6) groups had lower mean percentage lung lesions that ranged from 0.11±0.38% to 0.90±0.15%.
[0171] Tentative diagnosis of pneumonia varied among the groups. Group 3, which received two doses of 16 ug rORF2-Carbopol, had the lowest tentative diagnosis of pneumonia, with 13.3%. Group 9, the challenge control group, had 50% of the group tentatively diagnosed with pneumonia, followed by Group 10, the strict negative control group and Group 2, which received two doses of 16 ug vORF2-Carbopol, with 46.7% of 40% respectively, tentatively diagnosed with pneumonia.
[0172] Groups 1, 2, 3, 5, 9, and 10 had 0% of the group tentatively diagnosed as PCV2 infected; while Group 8, which received two doses if KV vaccine, had the highest group rate of tentative diagnosis of PCV2 infection, which 20%. Group 7, which received two doses of 0.25 ug rORF2-Carbopol, and Group 4, which received one dose of 16 ug vORF2-Carbopol had tentative group diagnoses of PCV2 infection in 13.3% and 6.7% of each group, respectively.
[0173] Gastric ulcers were only diagnosed in one pig in Group 7 (6.7%); while the other 9 groups remained free of gastric ulcers.
[0000]
TABLE 23
Summary of Group Mean % Lung Lesion and Tentative Diagnosis
No. Of pigs
that shed
Incidence
Group
Treatment
N
for at least one day
Rate
1
rORF2 - 16 μg -
15
0
0%
IMS 1314 2 doses
2
vORF2 - 16 μg -
15
1
6.7%
Carbopol 2 doses
3
rORF2 - 16 μg -
15
3
20.0%
Carbopol 2 doses
4
vORF2 - 16 μg -
15
2
13.3%
Carbopol 1 dose
5
rORF2 - 4 μg -
15
3
20.0%
Carbopol 1 dose
6
rORF2 - 1 μg -
15
6
40.0%
Carbopol 2 doses
7
rORF2 - 0.25 μg -
15
7
46.7%
Carbopol 2 doses
8
KV > 8.0 log - Carbopol
15
12
80%
2 doses
9
Challenge Controls
14
14
100.0%
10
Strict Negative Controls
15
14
93.3%
vORF2 = isolated viral ORF2;
rORF2 = recombinant baculovirus expressed ORF2;
KV or killed whole cell virus = PCV2 virus grown in suitable cell culture
[0174] The Summary of Group IHC Positive Incidence Results are shown below in Table 24. Group 1 (16 ug rORF2-IMS 1314) had the lowest group rate of IHC positive results with 0% of the pigs positive for PCV2, followed by Group 2 (16 ug vORF2-Carbopol) and Group 4 (single dose 16 ug vORF2-Carbopol), which had group IHC rates of 6.7% and 13.3% respectively. Group 9, the challenge control group, had the highest IHC positive incidence rate with 100% of the pigs positive for PCV2, followed by Group 10, the strict negative control group, and Group 8 (KV vaccine), with 93.3% and 80% of the pigs positive for PCV2, respectively.
[0000]
TABLE 24
Summary of Group IHC Positive Incidence Rate
No. Of pigs
that shed
Incidence
Group
Treatment
N
for at least one day
Rate
1
rORF2 - 16 μg -
15
0
0%
IMS 1314 2 doses
2
vORF2 - 16 μg -
15
1
6.7%
Carbopol 2 doses
3
rORF2 - 16 μg -
15
3
20.0%
Carbopol 2 doses
4
vORF2 - 16 μg -
15
2
13.3%
Carbopol 1 dose
5
rORF2 - 4 μg -
15
3
20.0%
Carbopol 1 dose
6
rORF2 - 1 μg -
15
6
40.0%
Carbopol 2 doses
7
rORF2 - 0.25 μg -
15
7
46.7%
Carbopol 2 doses
8
KV > 8.0 log - Carbopol
15
12
80%
2 doses
9
Challenge Controls
14
14
100.0%
10
Strict Negative Controls
15
14
93.3%
vORF2 = isolated viral ORF2;
rORF2 = recombinant baculovirus expressed ORF2;
KV or killed whole cell virus = PCV2 virus grown in suitable cell culture
Discussion
[0175] Seven PCV2 vaccines were evaluated in this example, which included a high dose (16 μg) of rORF2 antigen adjuvanted with IMS 1314 administered twice, a high dose (16 μg) of vORF2 antigen adjuvanted with Carbopol administered once to one group of pigs and twice to a second group of pigs, a high dose (16 μg) of rORF2 antigen adjuvanted with Carbopol administered twice, a 4 μg dose of rORF2 antigen adjuvanted with Carbopol administered twice, a 1 μg dose of rORF2 antigen adjuvanted with Carbopol administered twice, a low dose (0.25 μg) of rORF2 antigen adjuvanted with Carbopol administered twice, and a high dose (>8 log) of killed whole cell PCV2 vaccine adjuvanted with Carbopol. Overall, Group 1, which received two doses of 16 μg rORF2-IMS 1314, performed slightly better than Groups 2 through 7, which received vaccines containing various levels of either vORF2 or rORF2 antigen adjuvanted with Carbopol and much better than Group 8, which received two doses of killed whole cell PCV2 vaccine. Group 1 had the third highest ADWG (1.80±0.30 lbs/day), the lowest incidence of abnormal behavior (0%), the lowest incidence of abnormal respiration (0%), a low incidence of cough (7.1%), a low incidence of overall clinical symptoms (7.1%), was tied with three other groups for the lowest mortality rate (0%), the second lowest rate for mean % lung lesions (0.15±0.34%), the second lowest rate for pneumonia (21.4%) and the lowest incidence rate for positive IHC tissues (0%). Group 1 was, however, the only group in which injection site reactions were noted, which included 50% of the vaccinates 1 day after the second vaccination. The other vaccines administered to Groups through 7 performed better than the killed vaccine and nearly as well as the vaccine administered to Group 1.
[0176] Group 8, which received two doses of killed PCV2 vaccine adjuvanted with Carbopol, had the worst set of results for any vaccine group. Group 8 had the lowest ADWG (0.93±0.33 lbs/day), the second highest rate of abnormal behavior (6.7%), the highest rate of abnormal respiration (6.7%), was tied with three other groups for the highest overall incidence rate of clinical symptoms (13.3%), had the highest mortality rate of all groups (20%), and had the highest positive IHC rate (80%) of any vaccine group. There was concern that the killed whole cell PCV2 vaccine may not have been fully inactivated prior to administration to Group 8, which may explain this group's poor results. Unfortunately, definitive data was not available to confirm this concern. Overall, in the context of this example, a Conventional Killed PCV2 vaccine did not aid in the reduction of PCV2 associated disease.
[0177] As previously mentioned, no adverse events were associated with the test vaccines with exception of the vaccine adjuvanted with IMS 1314. Injection site reactions were noted in 50.0% of the pigs 1 day after the second vaccination with the vaccine formulated with IMS 1314 and in 28.6% of the pigs 2 days after the second vaccination. No reactions were noted in any pigs receiving Carbopol adjuvanted vaccines. Any further studies that include pigs vaccinated with IMS 1314 adjuvanted vaccines should continue to closely monitor pigs for injection site reactions.
[0178] All pigs were sero-negative for PCV2 on Day −3 and only Group 2 had a titer above 100 on Day 14. On Day 25 (day of challenge), Group 8 had the highest PCV2 antibody titer (4619), followed by Group 2 (2507). With the exception of Groups 7, 9 and 10, all groups demonstrated a strong antibody response by Day 32. By Day 50, all groups including Groups 7, 9 and 10 demonstrated a strong antibody response.
[0179] One of the hallmarks of late stage PCV2 infection and subsequent PMWS development is growth retardation in weaned pigs, and in severe cases, weight loss is noted. Average daily weight gain of groups is a quantitative method of demonstrating growth retardation or weight loss. In this example, there was not a large difference in ADWG between groups. Group 8 had the lowest ADWG of 0.88±0.29 lbs/day, while Group 4 had the highest ADWG of 1.16±0.26 lb/day. Within the context of this study there was not a sufficient difference between groups to base future vaccine efficacy on ADWG.
[0180] In addition to weight loss—dyspnea, leghargy, pallor of the skin and sometimes icterus are clinical symptoms associated with PMWS. In this example, abnormal behavior and abnormal respiration and cough were noted infrequently for each group. As evidenced in this study, this challenge model and challenge strain do not result in overwhelming clinical symptoms and this is not a strong parameter on which to base vaccine efficacy.
[0181] Overall, mortality rates were not high in this example and the lack of a high mortality rate in the challenge control group limits this parameter on which to base vaccine efficacy. Prior to Day 46, Groups 4 and 7 each had one out of fifteen pigs die, Group 9 had two out of fourteen pigs die and Group 8 had three out of fifteen pigs die. Due to the fact that Group 9, the challenge control group was not demonstrating PCV2 clinical symptoms and only two deaths had occurred in this group by Day 46, Porcine Respiratory and Reproductive Syndrome Virus (PRRSV) MLV vaccine was administered to all pigs on Day 46. Earlier studies had utilized INGELVAC® PRRS MLV as an immunostimulant to exasperate PCV2-associated PMWS disease and mortality rates were higher in these earlier studies. Two deaths occurred shortly after administering the PRRS vaccine on Day 46—Group 4 had one death on Day 46 and Group 7 had one death on Day 47—which were probably not associated with the administration of the PRRS vaccine. By Day 50, Group 8, which received two doses of killed vaccine, had the highest mortality rate (20%), followed by Group 9 (challenge control) and Group 7 (0.25 ug rORF2-Carbopol), with mortality rates of 14.3% and 13.3% respectively. Overall, administration of the PRRS vaccine to the challenge model late in the post-challenge observation phase of this example did not significantly increase mortality rates.
[0182] Gross lesions in pigs with PMWS secondary to PCV2 infection typically consist of generalized lymphadenopathy in combination with one or more of the following: (1) interstitial pneumonia with interlobular edema, (2) cutaneous pallor or icterus, (3) mottled atrophic livers, (4) gastric ulcers and (5) nephritis. At necropsy (Day 50), icterus, hepatitis, and nephritis were not noted in any groups. A gastric ulcer was noted in one Group 7 pig, but lymphadenopathy was not specifically examined for. Based on the presence of lesions that were consistent with PCV2 infection, three groups had at least one pig tentatively diagnosed with PCV2 (PMWS). Group 8, which received two doses of killed vaccine, had 20% tentatively diagnosed with PCV2, while Group 7 and Group 4 had 13.3% and 6.7%, respectively, tentatively diagnosed with PCV2. The mean % lung lesion scores varied between groups at necropsy. Groups 1, 2, 3, 4, 6 and 10 had low % lung lesion scores that ranged from 0.11±0.38% to 0.90±0.15%. As expected, Group 9, the challenge control group, had the highest mean % lung lesion score (10.81±23.27%). In four groups, the mean % lung lesion scores were elevated due to one to three pigs in each of these groups having very high lung lesion scores. The lung lesions were red/purple and consolidated. Typically, lung lesions associated with PMWS are described as tan, non-collapsible with interlobular edema. The lung lesions noted in this study were either not associated with PCV2 infection or a second pulmonary infectious agent may have been present. Within the context of this study, the % lung lesion scores probably do no reflect a true measure of the amount of lung infection due to PCV2. Likewise, tentative diagnosis of pneumonia may have been over-utilized as well. Any pigs with lung lesions, some as small as 0.10% were listed with a tentative diagnosis of pneumonia. In this example, there was no sufficient difference between groups with respect to gross lesions and % lung lesions on which to base vaccine efficacy.
[0183] IHC results showed the largest differences between groups. Group 1 (16 μg rORF2-IMS 1314) had the lowest positive IHC results for PCV2 antigen (0%); while Groups 9 and 10 had the highest positive IHC results with incidence rates of 100% and 93.3% respectively. Groups 3, 5, 6 and 7, which received 16, 4, 1 or 0.25 μg of rORF2 antigen, respectively, adjuvanted with Carbopol, had IHC positive rates of 20%, 20%, 40% and 46.7%, respectively. Group 2, which received two doses of 16 μg vORF2 adjuvanted with Carbopol had an IHC positive rate of 6.7%, while Group 4 which received only one dose of the same vaccine, had an IHC positive rate of 13.3%. Due to the objective nature of this test and the fact that IHC results correlated with expected results, IHC testing is probably one of the best parameters on which to base vaccine efficacy.
[0184] Thus in one aspect of the present invention, the Minimum Protective Dosage (MPD) of PCV2 rORF2 antigen adjuvanted with Carbopol in the CDCD pig model in the face of a PCV2 challenge is determined. Groups 3, 5, 6 and 7 each received two doses of rORF2 antigen adjuvanted with Carbopol, but the level of rORF2 antigen varied for each group. Groups 3, 5, 6 and 7 each received 16, 4, 1 or 0.25 μg of rORF2 antigen respectively. In general, decreasing the level of rORF2 antigen decreased PCV2 antibody titers, and increased the mortality rate, mean % lung lesions and the incidence of IHC positive tissues. Of the four groups receiving varying levels of rORF2-Carbopol, Groups 3 and 5, which received two doses of 16 or 4 μg of rORF2 antigen, respectively, each had an IHC positive rate of only 20%, and each had similar antibody titers. Overall, based on IHC positive results, the minimum protective dosage of rORF2 antigen administered twice is approximately 4 μg.
[0185] In another aspect of the present invention, the antigenicity of recombinant (rORF2) and VIDO R-1 (vORF2) PCV2 antigens were assessed. Group 2 received two doses of 16 μg vORF2 and Group 3 received two doses of 16 μg rORF2. Both vaccines were adjuvanted with Carbopol. Both vaccines were found to be safe and both had 0% mortality rate. Group 2 had a PCV2 antibody titer of 2507 on Day 25, while Group 3 had a PCV2 antibody titer of 1503. Group 3 had a lower mean % lung lesion score than Group 2 (0.11±0.38% vs. 0.90±0.15%), but Group 2 had a lower IHC positive incidence rate that Group 3 (6.7% vs. 20%). Overall, both vaccines had similar antigenicity, but vORF2 was associated with slightly better MC results.
[0186] In yet another aspect of the present invention, the suitability of two different adjuvants (Carbopol and IMS 1314) was determined. Groups 1 and 3 both received two doses of vaccine containing 16 ug of rORF2 antigen, but Group 1 received the antigen adjuvanted with IMS 1314 while Group 3 received the antigen adjuvanted with Carbopol. Both groups had essentially the same ADWG, essentially the same incidence of clinical signs post-challenge, the same mortality rate, and essentially the same mean % lung lesions; but Group 1 had an IHC positive rate of 0% while Group 3 had an IHC positive rate of 20%. However, Group 3, which received the vaccine adjuvanted with Carbopol had higher IFAT PCV2 titers on Days 25, 32 and 50 than Group 1, which received the vaccine adjuvanted with IMS 1314. Overall, although the PCV2 vaccine adjuvanted with IMS 1314 did provide better IHC results, it did not provide overwhelmingly better protection from PCV2 infection and did induce injection site reaction. Whereas the PCV2 vaccine adjuvanted with Carbopol performed nearly as well as the IMS 1314 adjuvanted vaccine, but was not associated with any adverse events.
[0187] In still another aspect of the present invention, the feasibility of PCV2 ORF2 as a 1 ml, 1 dose product was determined Groups 2 and 4 both received 16 μg of vORF2 vaccine adjuvanted with Carbopol on Day 0, but Group 2 received a second dose on Day 14. Group 4 had a slightly higher ADWG and a lower mean % lung lesions than Group 2, but Group 2 had higher IFAT PCV2 titers on Day 25, 32 and 50, and a slightly lower incidence rate of IHC positive tissues. All other results for these two groups were similar. Overall, one dose of vORF2 adjuvanted with Carbopol performed similar to two doses of the same vaccine.
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An improved method for recovering the protein expressed by open reading frame 2 from porcine circovirus type 2 is provided. The method generally involves the steps of transfecting recombinant virus containing open reading frame 2 coding sequences into cells contained in growth media, causing the virus to express open reading frame 2, and recovering the expressed protein in the supernate. This recovery should take place beginning approximately 5 days after infection of the cells in order to permit sufficient quantities of recombinant protein to be expressed and secreted from the cell into the growth media. Such methods avoid costly and time-consuming extraction procedures required to separate and recover the recombinant protein from within the cells.
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RELATED APPLICATIONS
The present invention was first described in and claims the benefit of U.S. Provisional Application No. 61/917,682, filed Dec. 18, 2013, the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a portable apparatus adapted to store and organize tools and tool elements on a stand having a rotatingly affixed display.
BACKGROUND OF THE INVENTION
As anyone who performs a lot of mechanical work will attest, nothing beats having the proper tool for a job. The proper tool can save time, save money, produce a higher quality job, reduce damage to equipment, and provide for the increased safety of the worker. One (1) tool that is found in many lines of work is that of the ratcheting socket wrench. The ratcheting socket wrench provides for quick removal and tightening of almost every style and size of nut or bolt with the use of interchangeable sockets. However, these interchangeable sockets are easily lost and misplaced due to their small size and ability to roll. Manufacturers have responded with carrying cases to hold such sockets; however, efforts to date have been large, unwieldy, time-consuming to use, and make it generally difficult to find the desired socket size. Accordingly, there exists a need for means by which sockets used with a ratcheting wrench can be easily stored and organized in order to address the problems as described above. The development of the socket organizer fulfills this need.
The present invention is an apparatus used for storing and organizing tool elements, such as sockets used with a ratchet wrench. The apparatus includes a central hub rotatingly affixed to a stand, where the central hub is provided with a plurality of compartments, formed by dividers, along the perimeter edge of the central hub. Magnetic material is used on interior surfaces of the compartments. Tool elements of varying lengths and sizes are then inserted in a standing fashion within the compartments such that they are arranged in a radial manner. The dividers are variable, enabling adjustment of the compartment so as to hold many tool elements of different lengths and sizes, including drive connections. The magnetic material is strong enough to hold the tool elements and tools in place easily, yet allow the user to pull the socket out from the compartment without too much effort. The central hub also comprises a magnetic material to hold tools onto a surface thereof. The hub itself can be easily rotated to display tool elements of varying sizes, and is provided with a detent mechanism to control the motion of the hub.
Prior art in this field consists of organizational socket case and tool holder devices that incorporate a magnetic structure to magnetically affix the device to a magnetized surface such as a tool chest. These devices suffer from the disadvantage of requiring a magnetized surface to which the device is to be affixed to. If users cannot avail themselves of such a surface then the prior art devices become mere organizational carrying cases. Some prior art devices have various sized socket holders to retain a variety of different size and shape tool elements, but these are fixed in that each compartment is a differing fixed size from the previous compartment. The present invention enables varying the compartment sized with the use of slidably engaged dividers. Another disadvantage of the prior art devices is that they require magnetically affixing tool elements that are specific to the configuration of the device, thereby limiting a user to a dedicated tool set for which the device stores and organizes. The present invention enables magnetic affixment of a variety of different tools and tool elements. These prior art devices further suffer from the inability to easily access the various tools and tool elements affixed thereto.
It is an objective of the present invention to provide an apparatus for storing and organizing tools and tool elements on a stand having a rotating assembly rotatingly affixed thereto.
It is a further objective of the present invention to enable effective display of, and efficient access to, each tool and tool element stored in and on the apparatus.
It is a further objective of the present invention to exploit the magnetic properties of tools and tool elements to magnetically affix them to the apparatus.
It is a further objective of the present invention to provide a portable apparatus for storing and organizing tools and tool elements without detracting from the utility provided by a stand-alone organizing apparatus.
It is a further objective of the present invention to provide a handle for ease of transport, the configuration of which will not detract form the functionality of the apparatus.
It is a further objective of the present invention to enable varying the compartment sizes into which the tool elements are retained.
It is a further objective of the present invention to provide a means to denote the type and size of tool for each compartment, which can be done permanently or temporarily.
It is a further objective of the present invention to enable temporary magnetic affixment of various tools to a surface of the apparatus.
It is a further objective of the present invention to provide a means to mechanically retain the rotating assembly in a desired position.
SUMMARY OF THE INVENTION
The present invention is an apparatus that provides a means for storing, organizing, and displaying tool elements, such as sockets. The apparatus includes a stand rotatingly engaged with a rotary assembly portion having a plurality of compartments for storing the tool elements. Each compartment incorporates magnetized portions to retain the tool elements while the rotary assembly is turned. The stand is configured to enable temporary or semi-permanent attachment of the apparatus to a flat surface, such as a workbench. The rotating assembly is configured to rotate within a range between zero degrees (0°) to at least three-hundred-sixty degrees (360°+). The rotating assembly stores each tool element in a compartment disposed about its perimeter edge so that each tool element may be accessed through an opening located on each compartment. Each compartment has a magnetic inner surface to retain each tool element placed therein.
Alternative embodiments of the present invention include a handle disposed on a top of the stand for ease of transport. Further embodiments enable variable sized compartments with use of divider portions slidingly engageable with the rotating assembly, where each divider preferably comprises a magnetic material. Further embodiments provide for indicia labeling, which may include adhesive-backed labels, molded relief-type characters, etc. Further embodiments have a magnetic member as part of the front panel of the rotating assembly to enable temporary magnetic attachment of other small tools to the face of the apparatus. Further embodiments include a plurality of detents and a ball plunger to index and mechanically retain the rotating assembly at desired positions.
Furthermore, the described features and advantages of the disclosure may be combined in various manners and embodiments as one skilled in the relevant art will recognize. The disclosure can be practiced without one (1) or more of the features and advantages described in a particular embodiment.
Further advantages of the present disclosure will become apparent from a consideration of the drawings and ensuing description.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present disclosure will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is a front perspective view of a tool element organizer 10 , according to a preferred embodiment of the present invention;
FIG. 2 is a top view of a rotary assembly portion 50 of the tool element organizer 10 , according to a preferred embodiment of the present invention;
FIG. 3 is a sectional view of the rotary assembly 50 taken along section line B-B (see FIG. 2 ), according to a preferred embodiment of the present invention; and,
FIG. 4 is a sectional view of a shaft portion 70 of the tool element organizer 10 taken along section line A-A (see FIG. 1 ), according to a preferred embodiment of the present invention.
DESCRIPTIVE KEY
10 tool element organizer
20 stand assembly
22 base plate
24 back plate
26 handle
28 mounting aperture
50 rotary assembly
51 a front panel
51 b rear panel
52 compartment
53 first magnet
54 divider
56 slot
58 indicia
60 floor panel
62 hub
64 second magnet
66 third magnet
70 shaft
71 first flange feature
73 bushing
74 second flange feature
75 detent
77 ball plunger
78 threaded aperture
100 tool element
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In accordance with the invention, the best mode is presented in terms of a preferred embodiment, herein depicted within FIGS. 1 through 4 . However, the disclosure is not limited to a single described embodiment and a person skilled in the art will appreciate that many other embodiments are possible without deviating from the basic concept of the disclosure and that any such work around will also fall under its scope. It is envisioned that other styles and configurations can be easily incorporated into the teachings of the present disclosure, and only one particular configuration may be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
The present invention describes a tool element organizer (herein described as the “apparatus”) 10 , which provides a means for storing and organizing tool elements 100 , particularly sockets, as used with a ratchet wrench. The apparatus 10 includes a ROLODEX®-style construction providing a rotary assembly portion 50 which further includes a plurality of compartments 52 for storing the tool elements 100 . Each compartment 52 is made using magnetic portions to retain the tool elements 100 while the rotary assembly 50 is turned.
Referring now to FIG. 1 , a front perspective view of the apparatus 10 , according to a preferred embodiment of the present invention, is disclosed. The apparatus 10 includes a stand assembly 20 and a rotating assembly 50 which is designed to store and magnetically retain a plurality of existing tool elements 100 .
The stand assembly 20 provides for temporary placement upon, or semi-permanent attachment to, a flat surface such as a work bench, shelf, or the like. The stand assembly 20 provides a unitary structure including a horizontal base plate 22 having an upwardly protruding vertical back plate 24 , and an integral oval-shaped handle 26 which is located at a top portion of the back plate 24 . The handle 26 provides a center opening portion being sized and shaped to allow insertion and grasping using a plurality of the user's fingers. The stand assembly 20 is envisioned to be made using durable plastic and metal materials.
The base plate 22 is to have substantial size and weight to stabilize the apparatus 10 against tipping during use. Additionally, the base plate 22 provides a plurality of mounting apertures 28 , preferably positioned at corner locations, allowing a user to secure the apparatus 10 in a semi-permanent manner to a flat surface using fasteners, if so desired. The back plate portion 24 provides rotating attachment at an intermediate location to the rotary assembly 50 via rotating hub 62 and shaft 70 portions (see FIG. 4 ). The handle 26 is envisioned to provide an oval-shaped aperture or similar ergonomic means of grasping and lifting to transport the apparatus 10 .
The rotary assembly 50 allows a user to access existing tool elements 100 contained within a plurality of compartment portions 52 positioned all along a perimeter edge. The tool elements 100 may be accessed through open top portions of each compartment 52 . Each compartment 52 provides magnetic inner surfaces to retain the tool elements 100 within while rotating the rotating assembly 50 , which may be rotated within a range between zero degrees (0°) to at least three-hundred-sixty degrees (360°+). The rotary assembly 50 includes circular front panel 51 a and rear panel 51 b portions being positioned vertically and parallel to each other, and each panel 51 a , 51 b having similar diameters. The sides of the compartments 52 are formed by inner-facing surfaces of the front 51 a and rear 51 b panels, a bottom surface comprising a floor panel 60 (see FIG. 3 ), and selectively positioned removable dividers 54 . The tool elements 100 are retained within the compartments 52 via a plurality of magnets 53 , 54 , 64 (see FIGS. 2 and 3 ).
The rotating assembly 50 is envisioned to utilize a plurality of indicia 58 upon an outer surface portion of the front panel 51 a , located adjacent to each compartment 52 , to provide identification of the contents. The indicia 58 may include adhesive-backed paper labels, molded-in relief-type characters, pre-printed symbols, or the like, which allow a user to identify and/or write upon to describe the contents.
Referring now to FIGS. 2 and 3 , top and sectional views of the rotary assembly portion 50 of the apparatus 10 , according to a preferred embodiment of the present invention, are disclosed. The rotating assembly 50 provides a plurality of compartments 52 along a perimeter edge portion. Each compartment 52 is envisioned to be rectangular in shape and may be selectively sized via variably positioned divider portions 54 . The side surfaces of the compartments 52 are formed by the front 51 a and rear 51 b panels, further comprising a plurality of equally-spaced and adhesively bonded first magnets 53 . The first magnets 53 are generally rectangular in shape and separated from each other by parallel linear slots 56 . The slots 56 are arranged perpendicular to the perimeter edge of the panels 51 a , 51 b and having a width so as to allow sliding insertion of the dividers 54 therein at desired locations. The selective insertion of the dividers 54 within the slots 56 allows a user to create a compartment 52 having a desired length for storing a particular number of tool elements 100 or other related items.
As previously described, the front 51 a and rear 51 b panels are partially covered by the first magnet portions 53 . The first magnets 53 are envisioned to be sections of polymer magnet sheet material or an equivalent magnetic material. In a similar manner, the floor panel 60 is to include a plurality of adhesively bonded second magnets 64 made using a similar material as the first magnets 53 . Finally, the dividers 54 are envisioned being made of a permanent magnet material or may be made using a plastic base material having adhesively bonded sections of polymer magnetic sheet, in a similar manner as the aforementioned first panel 51 a , second panel 51 b , and floor panel 60 portions.
Drive tool elements 100 of varying lengths and sizes are envisioned to be inserted into the compartments 52 in a standing fashion to conserve space. The apparatus 10 is capable of holding many tool elements of different lengths, different sizes, and different drive connection sizes such as one-eighth (⅛), one-quarter (¼), one-half (½), and three-quarters (¾) inch. However, it is also envisioned that the apparatus 10 could be introduced in several models which each correspond to a particular drive connection, and as such should not be interpreted as a limiting factor of the apparatus 10 . The front 51 a is envisioned to provide at least one (1) large third magnet 66 along an outer surface for temporary magnetic attachment of other small tools such as drive extensions, drive adapters, wrenches, screwdrivers, and the like. The third magnet 66 is envisioned to be made of a similar bonded polymer magnetic material as the first 53 and second 64 magnets.
The previously described magnetic portions 53 , 54 , 63 within the compartments 52 are to apply enough magnetic force to hold the tool elements 100 in place, but allow the user to remove a tool element 100 with reasonable effort.
Referring now to FIG. 4 , a sectional view of a rotating shaft portion 70 of the apparatus 10 taken along section line A-A (see FIG. 1 ), according to a preferred embodiment of the present invention, is disclosed. The front panel 51 a and rear panel 51 b portions are connected to each other along a center line by an integral cylindrical hub portion 62 . The hub 62 provides a means to attach the rotating assembly 50 to the back plate portion 24 of the stand assembly 20 . The hub 62 comprises a hollow cylindrical form that provides securement of a front end of a shaft 70 , which has a rearwardly extending rear end portion that passes through a bushing 73 via a slip-fit. The bushing 73 is permanently mounted within the back plate 24 providing a means to rotate the rotating assembly 50 and shaft 70 portions. It is envisioned that the shaft 70 includes integral retaining first flange features 71 which extend perpendicularly from each end portion. The bushing 73 is envisioned to be a self-lubricating bronze bushing or equivalent bearing component, and is secured to the back plate 24 via integral second flange features 74 that extend perpendicularly at each end portion.
The apparatus 10 further provides a means to index and mechanically retain the rotating assembly 50 at a desired position via a plurality of detents 75 and a ball plunger 77 . The detents 75 provide a plurality of equally-spaced circular impressions arranged in a circular pattern being molded-in or machined into a rearward surface of the rear panel 51 b . The detents 75 work in conjunction with the ball plunger 77 , which is threadingly installed within the back plate 22 at a corresponding location so as to align with the circular pattern of the detents 75 , thereby allowing engagement between the detents 75 and ball plunger 77 to retain a position of the rotating assembly 50 . The spring-loaded nature of the ball plunger 77 allows a user to motion the rotating assembly 50 from one (1) detent 75 to another with minimal force being applied.
It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The preferred embodiment of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the apparatus 10 , it would be installed as indicated in FIG. 1 .
The method of preparing the apparatus 10 for use may be achieved by performing the following steps: procuring a model of the apparatus 10 being suitable for storing tool elements 100 of an intended number of tool elements 100 , or a particular drive size; mounting the apparatus 10 to a flat surface such as a work bench or shelf, if so desired, using the mounting aperture portions 28 in the base plate 22 and fasteners, or; utilizing the handle 26 to grasp and transport the apparatus 10 to a job site, as needed; loading the apparatus 10 with existing tool elements 100 by rotating the rotating assembly 50 until a particular compartment 52 is positioned near a top position of the rotating assembly 50 , being retained in position by engagement of the ball plunger 77 and detent 75 portions; inserting dividers 54 in a selective manner within slot portions 56 to obtain a compartment 52 having a desired length; loading the compartment 52 with tool elements 100 , other small tools, and miscellaneous items, as desired; rotating the rotating assembly 50 to another loading position until the ball plunger 77 and detent 75 engage; repeating the insertion of dividers 54 , loading of tool elements 100 , and the rotating process for a desired number of compartments 52 ; applying indicia 58 , if utilizing label-type indicia 58 , along the front panel 51 a adjacent to each loaded compartment 52 to identify the corresponding contents; and, affixing desired drive accessories 102 and various small tools such as drive extensions, drive adapters, wrenches, screwdrivers, and the like, to the large third magnet 66 located upon the front panel 51 a . The apparatus 10 is now ready for use.
The method of utilizing the apparatus 10 may be achieved by performing the following steps: locating and obtaining a desired tool element 100 stored within the apparatus 10 by rotating the rotating assembly 50 until positioning a compartment 52 containing the desired tool element 100 at a top position; securing the rotating assembly 50 via engagement of the ball plunger 77 within a detent 75 ; extracting the desired tool element 100 ; detaching other drive accessories 102 from the third magnet 66 , as needed; and, utilizing the apparatus 10 to acquire tool elements 100 and drive accessories 102 to complete a task in a timely manner.
The foregoing descriptions of specific embodiments have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit to the precise forms disclosed and many modifications and variations are possible in light of the above teachings. The embodiments were chosen and described in order to best explain principles and practical application to enable others skilled in the art to best utilize the various embodiments with various modifications as are suited to the particular use contemplated.
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A socket organizer includes a planar member having a plurality of recessions to receive various sized tool elements, such as sockets. A portion of the planar member is magnetized to enable the device the ability to securely, but removably, retain each socket when placed into an individual recession. The planar member is rotatingly secured to a support stand. A mechanical connection between the planar member and support stand is provided with a series of detents to enable a user to rotate the planar member to a desired position for access to a particular socket held within the device.
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This invention relates to non-electric blasting caps initiated by the heat produced by the ignition of an explosive gas mixture. In one aspect, this invention relates to non-electric blasting caps containing a porous ignition charge, initiatable in response to action of explosive energy of an explosive gas mixture together with conduit means in contact with the porous ignition charge for employing a confined stream of the explosive gas in ignition position within the blasting cap for the responsive initiation. A further aspect of this invention relates to a detonator system, including a plurality of blasting caps above described, together with means for emplacing an explosive gas mixture in ignition relationship with a responsively initiatable ignition charge(s) for the detonation of one or more main charges. A still further object of this invention relates to methods for making a porous ignition charge, making a non-electrically initiated blasting cap and initiating a non-electrically initiated blasting cap for the initiation of a main charge. Other aspects will be apparent in light of the accompanying disclosure and the appended claims.
BACKGROUND OF THE INVENTION
Non-electric blasting caps initiatable by explosive energy from the detonation of an explosive gas mixture are disclosed and claimed in U.S. Pat. No. 3,885,499 to Hurley. These blasting caps contain an open space adjacent the ignition charge, a first conduit extending from outside the blasting cap into the open space in open communication with the ignition charge so as to convey the explosive gas as a confined stream into the open space for responsive ignition of the ignition charge; and a second conduit extending from the open space to the outside of the shell so that a stream of the explosive gas mixture can be continuously passed from the first conduit through the open space and through the second conduit to purge and charge the system for the detonation and responsive ignition of the ignition charge.
In the embodiments illustrated in the above patent, the cap shell is elongated and closed, including at one end a plug type closure member spaced from the ignition charge to form the requisite open space. Both conduits are plastic and thin walled for flexibility purposes. The first conduit extends into the shell through the end closure member and the second conduit extends from the open space either through the plug end closure or through the side of the cap shell.
SUMMARY OF THE INVENTION
This invention is concerned with non-electric blasting caps essentially of the type above described but which do not require an open space between the ignition charge and the plug closure member.
In accordance with the invention, a non-electrically initiated blasting cap is provided which comprises: a closed shell, including a plug closure therefor; an ignition charge in said shell substantially contiguous with said plug closure and initiatable in response to action of explosive energy of an explosive gas mixture, and sufficiently porous and permeable for flow of a gas stream through the interstices thereof; a first conduit means extending from outside said shell through said plug closure and opening into contiguous contact with said ignition charge so as to convey an explosive gas mixture as a confined stream into initiating position in said interstices for responsive initiation of said ignition charge; and a second conduit means extending from continuous contact with said ignition charge to the outside of said shell, whereby a stream of said explosive gas can be continuously passed from said first conduit means through the interstices of said ignition charge and through said second conduit means to purge and charge said porous ignition charge and thereafter explosive gas in said first conduit means can be ignited for preparation of resulting explosive energy within the interstices of said porous ignition charge for initiation of same.
In a preferred embodiment, the closed shell is elongated, having a base charge in the integrally closed end of the shell, a primer charge in direct operative communication with the base charge, a porous ignition charge in operative contact with the primer charge, with or without a delay charge intermediate the primer and ignition charges, wherein the plug closure substantially fills the cross-section of the shell and has a first and a second passageway therethrough to allow gas to be introduced into and to exit from the closed shell. Further, and in preferred practice, the porous ignition charge alone or together with a delay charge substantially fills the cross-section of the closed shell between the primer charge and the plug closure, has interconnected pores and is initiatable in response to action of explosive energy of an explosive gas mixture, wherein, in turn, the primer charge is detonatable in operative response to the heat produced by the ignition charge or the ignition charge and delay charge, and the base charge is detonatable in response to the detonation of the primer charge, and wherein a delay charge might be included intermediate to the primer and ignition charges, said delay charge would be detonatable in operative response to the heat produced by the ignition charge.
Further, in accordance with the invention, a detonator system is provided for detonation of one or more main charges comprising a plurality of spaced apart non-electrically initiated blasting caps above described, wherein the first passageway of the first of said plurality is connected with a source of explosive gas mixture and means for igniting said explosive gas mixture, and the second passageway of the first of said plurality is connected with the first passageway of the second of said plurality and thereby in series to provide for purging and charging action of the porous ignition charge in each of said blasting caps by flow of the explosive gas mixture in series flow therethrough and subsequently for ignition of said explosive gas mixture to propagate an explosive reaction front in series through each of said blasting caps in said plurality. In addition, the invention includes a method for making a porous ignition charge, a method for making a blasting cap containing a porous ignition charge, and a method for initiating a non-electric blasting cap for the initiation of a main explosive charge.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated with reference to the drawings of which:
FIG. 1 illustrates a zero delay type blasting cap of the invention, including a pair of conduits supported in an ignition plug end closure for ingress and egress of the explosive gas mixture during the purging and charging operation, and thereafter for ingress and explosive energy from ignition of the explosive gas mixture;
FIG. 2 is a delay type blasting cap otherwise the same as that of FIG. 1;
FIG. 3 is the same as FIGS. 1 or 2 except that in lieu of the egress conduit, an open passageway is disposed in the side wall of the shell for egress of the explosive gas mixture during the purging and charging operation;
FIG. 4 illustrates a plurality of any of the blasting caps of FIGS. 1 and 2 as elements of a detonator system of the invention;
FIG. 5 is the same as FIG. 4 except that it illustrates a plurality of blasting caps of FIG. 3;
FIG. 6 illustrates an embodiment of the blasting system of the invention including a plurality of blasting caps of either or both of FIGS. 1 and 2 supported for detonation of a series of separate main explosive charges. Like parts in the drawings are designated by like numbers.
FIGS. 4-6 are particularly illustrative of the method for initiating non-electric blasting caps for the initiation of main explosive charges.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, elongated cup-shaped shell 10 of zero delay type blasting cap 9 is integrally closed at bottom end 11 and is closed at the opposite end 12 by ignition plug end closure 13. Base explosive charge 14, primer charge 16 and porous ignition charge 17 extend in that order in shell 10 from bottom end 11 toward closure plug 13, and face 18 of porous ignition charge 17 is in substantial contiguous contact with face 13' of plug 13. Although charge 17 can be referred to as an initiator or ignition charge, hereinafter, it will be described as porous ignition charge 17.
A first tube 19 extends from outside shell 10 through plug closure 13 into communication with porous ignition charge 17. A second tube 21 extends through plug 13 from a point in communication with porous ignition charge 17 to a point outside shell 10.
Base charge 14 is detonatable in response to detonation of primer charge 16 and primer charge 16 is detonatable in response to the heat output of porous ignition charge 17. Base charge 14 is any suitable high explosive charge such as PETN, RDX, Tetryl, or the like, with adequate explosive energy output to produce detonation of a main explosive charge in detonating relationship therewith. Exemplary of primer charge 16 is diazodinitrophenol, often a diazodinitrophenol system of the well known type including a top layer for ignition in response to ignition of the porous ignition charge 17 and an underlying higher-density layer detonatable in response to ignition of the top layer. Further exemplary primer charges 16 are diazodinitrophenol/potassium chlorate, lead azide, mercury fulminate, lead styphnate, barium styphnate, potassium dinitrobenzfuroxyl and mannitol hexanitrate tetracene.
Porous ignition charge 17 may be a porous agglomeration of particles made from an ignition powder; a permeable mat-like pad of fibrous particles of ignition material; a pellet of minute spheres of ignition material, attached to one another at their contact surfaces to prevent transport of the spheres into the gas conduits during charging or handling; or a sponge-like pellet of ignition material, with connected porosity to produce permeability. Porous ignition charge 17 must be permeable for flow of a gas stream therethrough, and initiatable in response to action of explosive energy of an explosive gas mixture. Examples of materials which can be used for porous ignition charge 17 are lead/selenium, lead-tin/selenium, tin/selenium, red lead/boron, lead monoxide/boron, lead oxide/manganese, lead monoxide/silicon, and lead/tellurium.
By the term "explosive energy" is meant the heat and flame produced by the detonation or deflagration of an explosive gas mixture.
Tube 19 is generally a plastic tube, as for example, 0.103 inch OD by 0.060 inch ID and formed from polyethylene; and confines a stream of the explosive gas mixture for flow into porous ignition charge 17, and tube 21 is the same, or similar in design and composition to tube 19. Tube 21, in direct contact with porous ignition charge 17, serves to convey a stream of explosive gas mixture from porous ignition charge 17, during the purging and charging operation and, as an element of the initiation system of the invention, to direct propagating explosive energy to the succeeding blasting cap in the system.
In the operation of blasting cap assembly 9, a stream of an explosive gas mixture such as a mixture of oxygen with a fuel such as manufactured gas, acetylene, hydrogen, or hydrogen/methane, is passed through tube 19 into porous ignition charge 17 and is thus emplaced so that, upon ignition, the resulting explosive energy propagates into initiation relationship with porous ignition charge 17. Prior to initiation of porous ignition charge 17, enough of the gas, which is initially present in the interconnected pores of charge 17, must be replaced by the explosive gas mixture from tube 19 to insure reliable initiation. This is accomplished by passing a stream of the explosive gas through tube 19, porous ignition charge 17 and then tube 21 to purge the pores of charge 17 free from such initially present gas.
FIG. 2 illustrates another embodiment, which is the same as that of FIG. 1 except that the blasting cap 9' is of the delay type and contains a delay charge 22 intermediate the porous ignition charge 17 and the primer charge 16. Often porous ignition charge 17 of FIG. 2 differs in composition from that of FIG. 1 to the extent necessary to assure a sufficiently hot ignition for delay fuse 23, which is conventionally disposed as a core in a swaged metal tube 24 in ignitable relationship with porous ignition charge 17 and in detonating relationship with primer 16. Often, in a delay cap system such as that of FIG. 2, a wafer type charge (not specifically shown) which has a higher heat of reaction than that of porous ignition charge 17 and serves as a supplemental source of heat for ignition of the delay fuse, is positioned subjacent porous ignition charge 17. Such wafer type charges are generally utilized in combination with longer burning and hence less ignition-sensitive delay charges, as disclosed in U.S. Pat. No. 3,776,135.
FIG. 3 illustrates a blasting cap 8 which is similar to the blasting caps of FIGS. 1 and 2 except that in lieu of the tube 21, a conduit or passageway 26, extends from open communication with porous ignition charge 17 through a side wall of shell 10.
Referring to FIG. 4, a series of five blasting caps A-E inclusive, which can be any of blasting caps 9 and 9' of FIGS. 1 and 2, each for being disposed in detonating relationship with a booster or main explosive charge (neither shown), are in series with the discharge line from a gas mixing and ignition system 27. Gas mixing and ignition system 27 comprises fuel gas supply 28, connecting through line 29, gas flow control meter 31, and line 30, with gas mixing/ignition chamber 32 and oxidizer gas supply 33, connecting through line 34, flow control meter 36, and line 37 with gas mixing/ignition chamber 32.
In operation of the system 27, a suitable fuel gas, generally a manufactured gas, or a mixture of hydrogen and methane, is passed from supply 28 via line 29, through flow meter 31 which in turn controls the requisite rate of flow and pressure of fuel gas through line 30 to mixing chamber 32 for mixing therein with oxidizer gas from supply 33. Similarly the oxidizing gas is passed from supply 33 via line 34, through flow meter 36 which in turn controls the requisite rate of flow and pressure of oxidizer gas through line 37 in the required proportions for the mixing step in chamber 32. The relative proportions of fuel and oxidizer are predetermined to provide an explosive gas mixture which is then ignited in chamber 32 by a spark generated by action of spark plug 39 operatively extending into chamber 32 for that purpose.
Conduit 38 extends from chamber 32 and connects through a suitable collar, or sleeve-type connector 38a with inlet tube 19 of a first blasting cap 9 of the series A-E to convey flow of the explosive gas mixture from chamber 32 through the tube member 19, porous ignition charge 17 and exit flow tube 21, and in series through each of the successive caps B-E to thereby purge each porous ignition charge 17 of substantially all gas other than that from line 38 and in turn to charge each porous ignition charge 17 with the explosive gas mixture. Tube 21 of each of blasting caps 4A-D connects with tube 19 of the succeeding blasting cap of the Series B-E by any suitable means, such as by a plastic collar, or sleeve, connector 20.
During the purging and charging operation, the stream of explosive gas mixture from line 38 is passed in series through tube 19, porous ignition charge 17 and tube 21 of each of caps A-E; and the flow of explosive gas through the series A-E is maintained for a time duration sufficient to complete the requisite purging and charging of all blasting cap ignition charges 17, generally for a period of at least about one minute, but often from five to ten minutes, depending upon the flow variables involved.
Upon completion of the purging and charging action and with the flow of the explosive gas mixture in line 38 stopped, the ignitor member 39 is actuated, and, by action of the spark, the explosive gas mixture thus emplaced for ignition and responsive initiation of the porous ignition charge, is ignited. Check valve system 35 in chamber 32 precludes back pressure flow of explosive energy into the upstream flow and supply stream. The explosive reaction wave front then travels, confined in line 38 and each of the tubes 19 and 21, through each porous ignition charge 17 in series A-E.
Occasionally, one or more of the tubes 19 and 21 may fail to confine the explosive energy, in which event the reaction rate of the particular explosive gas is sufficiently high to permit the explosive reaction wave front to travel ahead of the tube breakage so that the latter does not preclude series travel of the wave front through the series of caps.
FIG. 5 illustrates another embodiment of the detonator system of the invention which is the same as that in FIG. 4 except that blasting caps 8 of FIG. 3 are in lieu of those of FIGS. 1 or 2. In the embodiment of FIG. 5, a continuous stream of an explosive gas mixture from chamber 32 is passed through line 38 as a manifold supply connecting by suitable connector means, such as a collar or sleeve 25, with each of the caps A-E respectively to supply a stream of explosive gas mixture through each tube 19 into each corresponding porous ignition charge 17A-E. Instead of the series type purging and charging action of FIG. 4, the explosive gas mixture from each porous ignition charge 17 is discharged therefrom through the conduit, or opening, 26 in a side wall of each cap assembly. As in FIG. 4, after the requisite purging and charging period, the explosive gas mixture in line 38 is ignited by action of spark generation means in chamber 32. The explosive reaction wave front then travels along line 38 through each tube 19, to, in each instance, emplace the resulting explosive energy in initiating contact with the ignition charge.
Referring to FIG. 6, each of the separate bore holes 41, in earth formation 40, of FIGS. 6A-C is loaded with any suitable cap-insensitive main explosive charge 42 such as an aqueous gel type explosive, prills/fuel oil, or the like. A pair of suitable boosters 43 is embedded in each of the main explosive masses. Each booster is cap-sensitive and is in detonating relationship with main explosive charge 42 adjacent thereto, and is initiated by action of a blasting cap system of the invention such as that of FIG. 4.
Thus in each bore hole 41 of FIG. 6, two booster units 43, e.g., each 500 grams of PETN, tetryl or the like, are embedded and spaced apart, in main explosive charge 42 to provide for detonation of the main explosive charge 42 along its entire length. Each booster unit 43 contains a blasting cap 9 or 9' of FIGS. 1 or 2, respectively. The explosive gas mixture from chamber 32 (not shown) is supplied via line 38 and passed in series through the entire plurality of blasting caps 9 and/or 9' in the separate booster charges in the three bore holes via tubes 19 and 21 of each blasting cap, as illustrated with reference to FIG. 4. The flow of explosive gas mixture from line 38 in series through the entire plurality of blasting caps in the bore holes 41A-C is continued until each porous ignition charge 17 is substantially free from initially present gas, after which the flow of the explosive gas mixture stream is terminated or continued as desired, followed by ignition of the gas in chamber 32 and travel of the explosive reaction wave front in series through each of the blasting caps in initiation relationship with the main explosive charge therein. Dependent on whether a main charge is reliably cap-sensitive, a booster charge(s) may not be required, in which event one or more of the blasting caps are embedded directly in the main charge, and are charged with gas and initiated.
The system of FIG. 6 containing delay caps regulates the burning time of each delay charge and hence, the delay between shots in each bore hole including, when desired, a progressively longer delay time along the entire series of boosters in the bore holes of FIG. 6.
Although the invention is specifically illustrated with reference to delay and nondelay type blasting caps utilizing a porous ignition charge in combination with primer and base charges, with or without an intermediate delay charge, it is to be understood that the invention is applicable to initiation devices in which the ignition charge is the only charge in the device, or is utilized with one or more additional charges, exemplary of which initiating devices are those of the deflagrating or squib type.
A non-electric blasting cap 9 containing a porous ignition charge, as shown in FIG. 1, is made by initially providing elongated cup-shaped shell 10 which is integrally closed at bottom end 11. Base explosive charge 14 and primer charge 16 are placed in the shell 10, with base explosive charge 14 in contact with the inner surface of bottom end 11 and primer charge 16 resting thereon. Where a delay type, non-electric blasting cap with porous ignition charge is desired, as shown in FIG. 2, the delay charge or fuse assembly 22 is placed in shell 10 upon and in contact with primer charge 16. The porous ignition charge 17 may be prepared by initially forming a suitable ignition powder into a pellet, i.e., by pressing the powder within a cylindrical press mold, with sufficient pressure to consolidate the ignition powder. The compressed pellet is then removed from the press mold and cut into small fragments. These fragments are then screened to provide a predetermined size range, free of fine particles and dust, preferably with a maximum cross-sectional dimension less than about 0.187 inch, for flow of a fluid therethrough. The fragments are then placed in shell 10, thereby having a portion thereof in direct contact with primer charge 16 or delay charge 22, if present. The charge fragments are placed in shell 10 to a predetermined height, after which, ignition plug end closure 13, containing tubes 19 and 21, is forced into shell 10 through end 12 until contact is made by face 13' of plug 13 with face 18 of porous ignition charge 17. A standardized fluid flow test is then made on each cap to detect any leakage or blockage of the passageways within the cap.
EXAMPLE
Six non-electric blasting caps containing porous ignition charges were made in accordance with the method of this invention. These six blasting caps were of the delay type containing a base charge, primer charge, delay charge and porous ignition charge as shown in FIG. 2. Each cap was made with a cylindrical aluminum shell having a length of 2.01 in., an I.D. of from 0.249 in. to 0.256 in. and an O.D. of 0.288 in. A base charge 14, which consisted of PETN weighing 0.4 gm., was placed through end 12 into shell 10 in contact with the inner face of bottom end 11. The PETN was placed in the shell as a loose powder and then pressed in the shell. The primer charge 16 consisted of a cylindrical pellet of diazodinitrophenol, weighing 0.29 gm., and was placed through end 12 onto and in contact with base charge 14. The combined height of base charge 14 and primer charge 16 was approximately 0.9 in. The delay charge 22 consisted of a 2 gm. pressed cylindrical pellet of, (weight basis), lead, 46.9%, tin, 8.3%, selenium, 11.6%, lead oxide, 32.2%, and boron, 1.0%, having a length of 0.4 in. This pellet, designed to provide a delay time of 300-400 milliseconds, was placed through end 12 into cap 10 upon and in contact with primer charge 16, to provide a combined base, primer, and delay charge height of 1.3 inches. The porous ignition charge 17 was prepared from an ignition powder consisting of (weight basis) lead, 68.4%, selenium, 26.6%, potassium perchlorate, 2.2%, aluminum, 1.1%, and snow floss, 1.7%. The ignition powder was formed into a 0.250 in. O.D. 0.25 in. pellet by placing the powder into a cylindrical mold and subjecting said powder to a pressure of 3000 p.s.i. The pellet was then cut with a razor blade into small irregular fragments. The desired size range was obtained by retrieving the fragments which passed through a #4 sieve (U.S.S.S.) and were retained on a #8 sieve (U.S.S.S.). The fragments were then loosely placed in shell 10 to a total column height of approximately 1.8 in. for each cap. The closure plug assembly 13, which was 0.45 in. long, was then forced into shell 10 until contact was made by inner face 13' of plug assembly 13 with outer face 18 of porous ignition charge 17. Closure plug assembly 13 contained two 12 in. long tubes 19 and 21 made of low density polyethylene and having an 0.103 in. O.D. and 0.060 in. I.D., which were bonded to plug assembly 13 and had terminal ends 19', within the passageways of plug assembly 13, which were in contact with porous ignition charge 17. The plug assembly 13 was then affixed to the shell 10 by crimping shell 10 around its exterior along the portion adjacent to plug assembly 13.
A test for circuit continuity was then separately performed on each of the six caps by passing nitrogen gas at 50 p.s.i.g. through tube 19, and measuring the exit flow from tube 21.
A stream of gas, comprising, on a volume basis, 50% methane and 50% hydrogen, at an approximate rate of 25 liters (S.T.P.) per minute at 40 p.s.i.g., was mixed with a separate stream of oxygen at a rate of 59 liters (S.T.P.) per minute at 40 p.s.i.g. through 10 feet of 0.25 in. O.D. by 0.120 in. I.D. polyethylene tubing to form an explosive gas mixture as the combined stream. The oxygen constituted approximately 71% of the combined stream, which was passed through each individual cap for approximately 0.25 minute to purge and charge the tubing circuit, including porous ignition charge 17, thereby replacing the air which originally filled the tubing circuit, with the explosive gas mixture. After charging, the resulting explosive gas mixture was in each instance ignited upstream from the individual caps by a spark, whereupon the explosive energy associated with the detonation front, which passed through tube 19 and into porous ignition charge 17, initiated each ignition charge. Each of the six caps fired successfully.
As will be evident to those skilled in the art, various modifications can be made in the light of the foregoing disclosure and discussion, without departing from the spirit or scope of the disclosure or from the scope of the claims.
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A non-electrically initiated blasting cap containing a porous ignition charge which is permeable for flow of a gas stream therethrough and initiatable in response to explosive energy of an explosive gas mixture, including conduit means for emplacing a confined stream of the explosive gas in position within the blasting cap for the responsive initiation.
Also provided is a system, including a plurality of the above blasting caps spaced apart for detonation of one or more main charges, together with additional conduit means for conveying the explosive gas to the plurality of blasting caps for the emplacement, and means for ignition of the thus emplaced explosive gas.
Method is provided for making a blasting cap containing a porous ignition charge, making a porous ignition charge and initiating a non-electric blasting cap for the initiation of a main explosive charge.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 11/340,676, filed Jan. 27, 2006, which is a continuation-in-part of U.S. patent application Ser. No. 10/219,260, filed Aug. 16, 2002, the entire disclosure of which is incorporated into the 11/340,676 application by reference.
FIELD OF THE INVENTION
This invention relates to a novel architecture for a CMOS-based image sensor, and in particular to an architecture suitable for use at ultra-low voltages (eg below 1V).
BACKGROUND OF THE INVENTION
CMOS-based image sensors have a wide range of potential applications since they may be integrated into a number of electronic products such as personal computers, cellular telephones, personal digital assistants and many others. CMOS active pixel sensors (APS) exploit the mature CMOS industry and can compete with charge coupled devices for low power, high levels of integration and functionality.
In recent years much effort has been made into reducing the required voltage supply to facilitate the incorporation of APS devices in portable applications such as mobile phones, and personal digital assistants which all need to minimize power consumption in order to maximize battery life. However, if the voltage supply goes below 1V, this has an enormous impact on the signal-to-noise ratio and the dynamic range of the pixels, not only because of the lower allowable signal voltages, but also because of the presence of larger noise voltages due to lower currents. In order to maximize the signal-to-noise ratio and dynamic range of the pixel, the signals have to be as large as possible, preferably from rail-to-rail, and so the pixel has to be equipped with a rail-to-rail input as well as a rail-to-rail output stage.
PRIOR ART
FIG. 1( a ) shows the structure of a conventional APS design. In this structure the highest available output voltage V out is limited by the V T drop of the NMOS reset transistor M 1 and the source follower M 2 , and therefore the maximum available output swing is only V DD −2V T −V Dsat and this significantly limits the dynamic range of the CMOS APS of FIG. 1( a ) as is shown in FIG. 1( b ). The APS shown in FIG. 1( a ) cannot function at a supply voltage of 1V or below, or at least cannot function without very complex output circuits.
The voltage output of the active pixel sensor element will have a slope which depends on the illumination intensity with the slope increasing with increasing intensity. The slope, and thus the intensity, may be extracted from the output using known double sampling (DS) or correlated double sampling (CDS) techniques. FIG. 5 illustrates a conventional CDS technique in which the voltage difference is measured over a fixed time interval. A disadvantage with a conventional CDS technique, however, is that it requires an analog-to-digital converter (ADC) capable of a very fine degree of resolution, which is quite difficult to achieve in an ultra low voltage environment. For example, with an APS capable of operating at low voltages as described further herein, at 1V operation the output swing is only 0.55V and to achieve 8-bits resolution the ADC needs to have a resolution of 2 mV. This implies that the practical dynamic range of an APS is governed not only by the APS architecture itself, but also by the readout method.
SUMMARY OF THE INVENTION
According to the present invention there is provided an optical sensor comprising at least one pixel wherein the pixel generates an output voltage that changes at a rate dependent on the light intensity incident on the pixel, and wherein means are provided for measuring the time for the pixel output voltage to change from a first predefined level to a second predefined level so as to produce an output indicative of the incident light intensity.
According to still further aspect the present invention also provides a method of generating an output from a pixel of an optical sensor wherein the pixel generates an output voltage that changes at a rate dependent on the light intensity incident on the pixel, the method comprising measuring the time for the pixel output voltage to change from a first predefined level to a second predefined level.
BRIEF DESCRIPTION OF THE DRAWINGS
Some embodiments of the invention will now be described by way of example and with reference to the accompanying drawings, in which:
FIGS. 1( a ) and ( b ) illustrate (a) a conventional APS architecture and (b) the available output voltage swing,
FIGS. 2( a ), ( b ) and ( c ) show (a) the architecture of a CMOS APS, (b) the available output voltage swing and (c) the same structure with the reset transistor changed to NMOSFET and the photodiode connected to the power supply,
FIGS. 3( a ) and ( b ) show outputs from a CMOS APS and, in FIG. 3( b ) the output from the prior art by way of comparison,
FIGS. 4( a ), ( b ), ( c ) and ( d ) show cross-sectional views of four possible structures of the CMOS APS, (a) on bulk silicon with light coming from the top, (b) on SOI with light coming from the top, (c) on SOI with light coming from the bottom, and (d) on bulk silicon with light coming from the bottom after thinning the silicon substrate
FIG. 5 illustrates a conventional readout methodology, and
FIG. 6 illustrates a readout methodology according to an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring firstly to FIG. 2( a ) a CMOS APS will now be described. It will be understood that FIG. 2( a ) shows just one pixel and in use an array of pixels may be provided. In comparison with the conventional APS architecture shown in FIG. 1( a ) it will be noted that the NMOS reset transistor M 1 of the prior art has been replaced by a PMOSFET reset transistor M 1 . This allows the input node to go all the way to V DD when the chip is reset. After reset, the photodiode will discharge N 1 at a rate that is proportional to the incident light intensity. This signal is amplified by the source follower M 2 and arrives at the node V outn . As in the prior art M 3 is a NMOS transmission gate that is provided to allow the signal to pass upon application of a row select signal. In this signal path there will be an inevitable drop V T due to the source follower M 2 , and to compensate for this a complementary signal path is provided comprising a PMOS common drain amplifier M 5 and an associated PMOS transmission gate M 4 . This complementary signal path produces an output V outp and the two outputs (V outn and V outp ) are combined to give the pixel output V out .
As mentioned above, a PMOS reset transistor is used to eliminate the threshold voltage drop between V DD and the node N 1 . In addition, two complementary source followers M 2 and M 5 are used to amplify the signal on node N 1 and the two complementary paths are combined to give the pixel output.
The input and output swing of the NMOS source follower M 2 is given by:
V dsat +V TN <V Ninput <V DD
V dsat <V Noutput <V DD −V TN
Where V Ninput and V Noutput are the input and output swings of the node N 1 respectively. V TN is the threshold voltage of the N-type source follower M 2 and V dsat is the voltage across the current source.
The input swing of the PMOS source follower M 5 is given by:
0 <V Pinput <V DD −V dsat −V TP
V TP <V Poutput <V DD −V dsat
In order to ensure a full rail-to-rail input, the supply voltage V DD has to be at least V TN +V TP +2V dsat . At the same time, the available output swing is close to rail-to-rail:
V dsat <V output <V DD −V dsat
This maximum available output swing is shown schematically in FIG. 2( b ) and it will be seen from a simple comparison of FIGS. 1( b ) and 2 ( b ) that the architecture of the present invention, at least in its preferred forms, provides for a much greater output swing. In particular this allows the minimum supply voltage to be reduced, for example to as low as 1.2V in 0.25 μm CMOS technology where typically V TN =0.4V, V TP =0.6V and V dsat =0.1V. Furthermore if the bias transistors are operated in the triode or weak inversion mode, the supply voltage can be even lower.
FIG. 2( c ) shows the complementary structure derived from the pixel architecture given in FIG. 2( b ) with the photodiode connected to the power supply voltage and the reset transistor replaced by an NMOSFET connected to ground.
FIG. 3 illustrates experimental outputs from a CMOS APS using the TSMC [Taiwan Semiconductor Manufacturing Company]0.25 μm CMOS process with 5 metal and 1 polysilicon layer. FIG. 3( a ) shows the outputs of the two complementary signal paths at a 1V supply voltage, while the output signal after their combination is shown in FIG. 3( b ). FIG. 3( b ) also shows a conventional trace from a prior art design (this is the lower trace in FIG. 3( b )). It can be seen from FIG. 3( b ) that the design of the CMOS APS is capable of working at a 1V supply voltage, whereas the conventional prior art design is incapable of so doing.
It will also be understood that in the CMOS APA of FIG. 2( a ) the reset transistor could be a NMOSFET transistor, in which case source follower M 2 would be PMOS, and complementary source follower M 5 would be NMOS.
An active pixel sensor could be implemented through bulk silicon technology, but could also be implemented using silicon-on-insulator (SOI) technology. FIG. 4( a ) shows an example of a device manufactured using bulk silicon technology and FIG. 4( b ) shows and example of a device manufactured using SOI technology. SOI technology uses a thin layer of silicon on an insulator and all active devices are fabricated in the thin layer. Compared to bulk technology SOI technology has a number of advantages including: better isolation between pixels leading to smaller interference between pixels; SOI CMOS technology does not require a separate well for the PMOSFET and can thus provide a higher fill-factor because the transistors in the pixel can be packed closer together; and SOI can further reduce the power consumption due to the smaller loading that has to be driven.
In FIG. 4( a ) and FIG. 4( b ) light is incident on the top of the sensor. However, light could also be incident from the bottom as shown in FIG. 4( c ) in which the active pixel sensor is implemented on a transparent substrate such as sapphire. Alternatively, the back side of the device could be made transparent by forming it to be very thin by polishing as shown in FIG. 4( d ).
The voltage output of the active pixel sensor element will have a slope which depends on the illumination intensity with the slope increasing with increasing intensity. The slope, and thus the intensity, may be extracted from the output using known double sampling (DS) or correlated double sampling (CDS) techniques. FIG. 5 illustrates a conventional CDS technique in which the voltage difference is measured over a fixed time interval. A disadvantage with a conventional CDS technique, however, is that it requires an analog-to-digital converter (ADC) capable of a very fine degree of resolution, which is quite difficult to achieve in an ultra low voltage environment. For example, even with an APS according to an embodiment of the invention, at 1V operation the output swing is only 0.55V and to achieve 8-bits resolution the ADC needs to have a resolution of 2 mV. This implies that the practical dynamic range of an APS is governed not only by the APS architecture itself, but also by the readout method.
FIG. 6 illustrates a novel readout methodology that may preferably be used in place of a conventional CDS technique. In the method of FIG. 6 two fixed voltages V a and V b are defined and the time taken for the pixel output to drop from V a to V b is measured. This time is inversely proportional to the illumination intensity. In this method, the dynamic range depends on the conversion speed of the ADC rather than its resolution and this is easier to control with precision, especially in an ultra low voltage environment. This novel methodology is particularly suited for use with CMOS active pixel sensors as described above but could be used with other forms of sensors. The design is particularly suitable for use with sensors capable of use at ultra low voltages (eg below 1V).
It should also be noted that while in the above examples the output voltage will fall at a rate dependent on the incident light intensity, it is also possible to reconfigure the sensor circuit so that the output voltage increases at a rate dependent on the incident light intensity. For example, looking at FIG. 2( a ) rather than having the diode connected to ground and the reset transistor to V dd , this could be reversed with the reset transistor connected to ground and the diode to V dd as is shown in FIG. 2( c ).
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A pixel element for an image sensor comprising, a photodiode and a reset transistor coupled to an input node, wherein said reset transistor is a PMOSFET coupled between said input node and the supply voltage, and wherein said pixel further comprises parallel complementary signal paths.
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BACKGROUND
[0001] A ‘torque-on-demand’ (TOD) four wheel drive system automatically applies torque to the front wheels when the rear wheels slip. An overrunning clutch can provide a low cost method for TOD. Such a system is explained in U.S. Pat. No. 6,602,159 and provides either TOD or full lock four wheel drive (4WD). In such a system, the front axle is always turning which adds parasitic drag to the vehicle, increasing fuel consumption. It is desirable to provide a mode that allows the front axle to be stopped, i.e. two wheel drive mode (2WD). Another undesirable feature of the current system using an overrunning clutch to provide TOD is that a drag brake must be used for clutch control which increases fuel consumption.
[0002] Referring to FIG. 1 , a prior art four wheel drive control device 8 with TOD mode is shown. The control device 8 comprises a through shaft 1 delivering torque to the rear wheels, a sprocket 3 capable of driving the front wheels through a chain 2 , an inner race 4 fitted over the shaft 1 , a slipper 5 between the sprocket 3 and the inner race 4 , and a brake 6 capable of causing drag torque on the slipper 5 by way of an actuator ring 6 A which is keyed into the slipper 5 . The inner race 4 has multiple axially oriented recesses 9 disposed around it's outer periphery and the slipper 5 has multiple recesses 10 disposed around it's inner periphery aligned with the recesses 9 in the inner race 4 to form pockets into which rollers 7 are placed. The slipper 5 is circumferentially discontinuous by virtue of an axial cut 11 . The slipper 5 is generally loose in the bore of the sprocket 3 . In conditions without wheel slip, the drive ratio to the front wheels is different to the rear such that the sprocket 3 rotates faster than the shaft 1 . The friction of the slipper 5 in the sprocket 3 would tend to rotate the slipper 5 relative to the sprocket 3 , but the friction of the drag brake 6 is greater than the slipper drag preventing such relative rotation. If the rear wheels slip, the sprocket 3 will tend to rotate slower than the shaft 1 because the vehicle speed reduces. The slipper drag is now in the same direction as the drag from the brake 6 causing the slipper 5 to rotate relative to the sprocket 3 . Such relative rotation causes the rollers 7 to climb the sides of the recesses 9 , 10 in the inner race 3 and the slipper 5 . The slipper 5 expands in diameter as the rollers 7 climb in the recesses 9 , 10 causing the slipper 5 to lock in the sprocket 3 and thereby transfer torque to the front wheels. Since the drag brake torque reverses in reverse rotation, the identical functions occur in reverse rotation. Removing the drag brake torque causes the slipper 5 to lock unconditionally. A substantial drag is required from the drag brake, which increases fuel consumption.
SUMMARY
[0003] The present invention provides a “torque-on-demand” four wheel drive system comprising a slipper clutch or roller clutch positioned between a first rotatable component and a second rotatable component. The clutch comprises a first tubular component having a first axial slot and a second tubular component having a second axial slot. A control pin extends through and is axially moveable within the first and second slots. One of the first or second slots has a constant circumferential width W and the other of the first and second slots has at least first and second portions along its axial length with the first and second portions having different circumferential widths. Axial movement of the control pin along the slots changes the clutch between 2WD and 4WD/TOD modes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a cross section through a plane perpendicular to the axis of the main shaft illustrating the principle of the bidirectional slipper clutch with drag brake providing TOD operation.
[0005] FIG. 2 is a cross section through a plane containing the axis of the main shaft of a slipper clutch assembly that is a first embodiment of the present invention.
[0006] FIG. 3 is a radially inward view along the line 3 - 3 in FIG. 2 .
[0007] FIG. 4 is a schematic diagram of the mode select device for the slipper clutch assembly of FIG. 2 .
[0008] FIG. 5 is a cross section through a plane containing the axis of the main shaft of a roller clutch assembly that is a second embodiment of the present invention.
[0009] FIG. 6 is a cross section through a plane containing the axis of the main shaft of a self contained slipper clutch that is a third embodiment of the present invention.
[0010] FIG. 7 is a cross section through a plane containing the axis of the main shaft of a self contained slipper clutch that is a fourth embodiment of the present invention.
[0011] FIG. 8 is a cross section through a plane containing the axis of the main shaft of a self contained slipper clutch that is a fifth embodiment of the present invention.
[0012] FIG. 9 is a radial view along the line to the main shaft showing the slot profiles of the device in FIG. 8 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] The present invention will be described with reference to the accompanying drawing figures wherein like numbers represent like elements throughout. Certain terminology, for example, “lop”, “bottom”, “right”, “left”, “front”, “frontward”, “forward”, “back”, “rear” and “rearward”, is used in the following description for relative descriptive clarity only and is not intended to be limiting.
[0014] Referring to FIGS. 2 and 3 , a slipper clutch assembly 20 that is a first embodiment of the present invention is shown. The slipper clutch assembly 20 generally includes an inner tube 22 rotationally fixed to the inner race 4 and outer tube 24 rotationally fixed to slipper 5 . The inner tube 22 has an axial slot 26 and the outer tube 24 has an axial slot 30 overlying the inner tube axial slot 26 . A pin 28 extends through both axial slots 26 and 30 and is moveable along the axis of the shaft 1 by an actuator plate 29 . The inner tube axial slot 26 has a uniform width W. As illustrated in FIG. 3 , the outer tube slot 30 has variable widths. Namely, the outer tube slot 30 has a first portion 32 that is substantially equal to the width W of the inner tube slot 26 ; a second portion 34 that is wider than the inner tube slot 26 in both circumferential directions; a third portion 36 that is wider than the inner tube slot 26 in one circumferential direction and a forth portion 38 that is wider than the inner tube slot 26 in the opposite circumferential direction.
[0015] When the pin 28 is located in the first portion 32 of the outer tube slot 30 , the recesses 9 , 10 of the inner race 4 and slipper 5 are aligned so that the rollers 7 cannot climb up the sides of the recesses 9 , 10 , preventing the slipper 5 from locking. This prevents torque from being transmitted to the front wheels, thereby providing a 2 wheel drive mode. The second portion 34 of the slot 30 allows relative rotation between the inner race 4 and the slipper 5 in both directions to provide fill freedom to unconditionally lock the slipper 5 . When the pin 28 is in the third portion 36 of the slot 30 , the system provides a forward TOD mode wherein locking is prevented when the sprocket 3 overruns the shaft 1 in forward and locks when the sprocket 3 is slower than the shaft 1 . The fourth slot portion 38 provides a reverse TOD position in which the free and locking directions are reversed from that of the forward TOD mode. Various mechanisms may be utilized to provide the axial motion of the actuator plate 29 to select the desired operating mode.
[0016] Referring to FIG. 4 , an illustrative mechanism 40 for axially moving the actuator plate 29 is shown. The mechanism 40 includes a gearmotor that turns a sector plate 42 to select the mode of the transfer case. A hi-low shift fork 44 is moved by the sector plate 42 as well as the slipper clutch control fork 46 . The slipper clutch control fork 46 moves the actuator plate 29 . A spring loaded solenoid 48 moves the pivot point 49 of a sector plate follower 47 . When the transfer case is in TOD mode, it is in forward mode unless the solenoid 48 is actuated to move it to the TOD reverse mode.
[0017] Referring to FIG. 5 , a roller clutch assembly 50 that is a second embodiment of the present invention is shown. The roller clutch assembly 50 includes an outer race 52 that is press fitted into the sprocket 3 . The outer race 52 is formed with a plurality of axial recesses on its inner periphery similar to the recesses 10 described in the previous embodiment. The outer race 52 also includes an axial slot 54 having a variable configuration similar to the configuration of the outer tube slot 30 of FIG. 3 , with portions 32 , 34 , 36 , 38 . Rollers 7 are placed between the outer race recesses and the shaft 1 . The rollers 7 are held in location by a cage 56 . The cage 56 is rotationally fixed to an inner tube 58 having an axial slot 57 with a configuration similar to inner tube slot 26 . The rotational position of the cage 56 , and thereby the rollers 7 , relative to the outer race 52 is determined by the axial location of pin 28 which is controlled by the actual actuator 29 . For 2WD operation, the pin 28 is retained in the slot portion 32 such that the cage 56 maintains its relative position to the outer race 52 and the rollers 7 are held centered in the outer race recesses. When locking is desired in a mode, the pin 28 is moved axially along the slots 52 , 56 , such that the outer race slot portions 34 , 36 , 38 provide freedom for relative rotation between the outer race 52 and cage 56 such that the rollers 7 climb the sides of the recesses and lock against the shaft 1 functionally similar to the FIG. 2 arrangement.
[0018] Referring to FIG. 6 , a self contained slipper clutch assembly 60 that is a third embodiment of the present invention is shown. The slipper clutch assembly 60 includes an inner race 4 and a slipper 5 . The inner race 4 includes splines 62 axially alignable and engageable with splines 64 on the slipper 5 . While splines are described, other interlocking features may also be utilized. When the splines 62 and 64 are axially aligned, the splines 62 and 64 engage one another such that there is no relative rotation between the inner race 4 and slipper 5 . As such, the recesses 9 , 10 are maintained in alignment and the assembly 60 is prevented from locking. This provides 2WD mode. A stack of wave springs, 65 , 66 , holds the splines 62 , 64 engaged. An axial actuator plate 67 is aligned with and contacts the slipper 5 and the wave springs 65 , 66 . A shift fork 68 or the lice is utilized to move the actuator plate 67 against the slipper S and wave springs 65 , 66 to achieve the 4WD and TOD modes. Initial movement of the actuator plate 67 to the right causes the splines 62 and 64 to disengage as the weak wave spring 65 in the stack collapses. Once the splines 62 and 64 are disengaged, the inner race 4 and slipper 5 are free to rotate relative to one another in both directions. This provides an unconditional, full lock operation. Further movement of the shift fork 68 , and thereby the actuator plate 67 , causes a higher force to develop as the stiffer wave springs 66 collapse. The higher force causes a drag torque higher than the slipper friction to put the system into TOD mode similar to the function of the device described in FIG. 1 . A cup 69 holds the sprocket 3 in a fixed axial location.
[0019] Referring to FIG. 7 , a self contained slipper clutch assembly 70 that is a fourth embodiment of the present invention is shown. The clutch assembly 70 is similar to that shown in FIG. 6 and includes an inner race 4 and slipper 5 , with an interengaging feature 72 , for example, splines, therebetween. An axial actuator plate 73 is moved against the slipper 5 in a manner similar to the previous embodiment to achieve the various modes of operation. To reduce the frictional wear between the slipper 5 and the sprocket 3 when the slipper 5 rotates relative to the sprocket 3 , a pair of conical plain bearings 75 is positioned between the slipper 5 and tapered surfaces 78 of the sprocket 3 and support the sprocket 3 away from the rotating slipper 5 . The plain bearings 75 are loaded by springs 76 and 77 , which allow the plain bearings 75 to back away as the slipper S expands to lock the clutch. The plain bearings 75 do not interfere with the locking action of the clutch. Ball bearings can be used instead of plain bearings. A spacer 79 may also be provided to position the rollers 7 . FIG. 7 also illustrates an alternative construction of the device of FIG. 6 where the wave springs 74 are located in the cup 69 .
[0020] Referring to FIGS. 8 and 9 , a self contained slipper clutch assembly 80 that is a fifth embodiment of the present invention is shown. The clutch assembly 80 is similar to that shown in FIG. 2 and includes an inner race 4 and slipper 5 . Rather than providing independent tubes, the inner race 4 and slipper 5 are each provided with an axially extending flange 82 and 84 , respectively. Each flange 82 , 84 includes a respective slot 83 , 85 with a pin 28 extending therethrough. An actuator plate 29 is axially moveable to move the pin 28 within the slots. Referring to FIG. 9 , slipper slot 85 has a constant width W similar to slot 26 while the inner race slot 83 includes a first portion 86 with a width substantially equal to the slipper slot width W and a second portion 87 with an expanded width in both circumferential directions.
[0021] The actuator plate 29 is moveable between two actuator positions. In the right position in which the pin 28 is in inner race slot portion 86 , the inner race 4 and slipper 5 are closely aligned to prevent the clutch from locking to provide 2WD operation. When the pin 28 is moved to the left position aligned with the inner race slot portion 87 (as shown), there is freedom for the clutch to lock in either direction. This position allows for either full lock or TOD. To change between full lock and TOD, a drag band 88 is provided about a disc member 89 adjacent the second position of the actuator plate 29 . When the drag band 88 is engaged, the actuator plate 29 , through the pin 28 applies the drag band torque to the slipper 5 by way of the pin 28 and slot 85 to operate the clutch in TOD mode. The clutch assembly 80 may also include conical bearings 75 similar to those described in the previous embodiment. A roller clutch similar to that shown in FIG. 5 can also incorporate the feature of the present embodiment be providing the cage with a slot similar to 83 and the race has a slot similar to 85 .
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A “torque-on-demand” (“TOD”) four wheel drive system comprising a slipper clutch or roller clutch positioned between a first rotatable component and a second rotatable component. The clutch comprises a first tubular component having a first axial slot and a second tubular component having a second axial slot. A control pin extends through and is axially moveable within the first and second slots. One of the first or second slots has a constant circumferntial width W and the other of the first and second slots has at least first and second portions along its axial length with the first and second portions having different circumferential widths. Axial movement of the control pin along the slots changes the clutch between 2WD and 4WD/TOD modes.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to an endpiece body for a safety ski binding and relates specifically to an endpiece body including an automatically adjustable sole holder.
2. Description of Related Art
An endpiece body has already been described in Austrian Patent Specification No. 375,269. In this endpiece body, the sole holder, which can be turned in a horizontal plane, can also be pivoted to a limited extent in a vertical plane on a transverse pivot which penetrates through the bolt. The flat rear side of the sole holder is acted upon via a piston by the release spring, which attempts to pivot the lever arm of the sole holder remote from the spring against the upper side of the ski.
This endpiece body has the disadvantage that the sole thickness may only have a slight clearance to enable the sole holder to provide satisfactory fixing. In addition, manufacturing the sole holder is difficult insofar as a bore which runs at an oblique angle to the upper and lower boundary surface and is roughly in the shape of an elongated hole in plan view penetrates through this sole holder.
German Offenlegungsschrift No. 1,943,973 describes another endpiece body. This endpiece body can be pivoted about a pivot running perpendicularly to the upper side of the ski and is fastened in the travel position by means of an adjustable catch device. On the side opposite the catch device with respect to the pivoting axis, the endpiece body has a vertical bore in which a sleeve having an internal thread is located. Screwed into this sleeve is a further threaded sleeve through which a screw bolt supporting a sole holder penetrates. Located between the nut of the screw bolt and the second threaded sleeve is a helical spring which presses down the sole holder.
If there is snow beneath the sole, the sole holder is lifted and the compression spring supporting the screw bolt is compressed slightly. This endpiece body is also complicated in its construction.
In FIGS. 7 and 8 of German Offenlegungsschrift No. 2,259,819, a front endpiece is shown in which a sole holder which is under the effect of a spring pressing it upward is displaceably guided on a bolt. In two diametrically opposite areas, the bore of the sole holder has threaded segments which extend over about 90°. The bolt is flattened on two sides and has between the flattened areas threaded segments which likewise extend over about 90°. By turning the bolt through 90°, the threaded segments of bolt and bore can be released from one another for the adjusting operation (see FIG. 8) and can be brought into engagement again with one another for fixing the sole holder in position (see FIG. 7). Automatic adjustment of the sole holder is thus not possible in this embodiment. On the contrary, the position of the sole holder desired in each case must be set manually, as described.
SUMMARY OF THE INVENTION
According it is an object of the invention to remove the disadvantages of the known embodiments and to create an endpiece body which on the one hand is simple in its construction and on the other hand permits automatic setting of the sole holder even if the thickness of the sole varies within prescribed tolerance limits (see at present Austrian Standard Specification ONORM S 4035 or West German Standard Specification DIN 7880, part 1: 19±1 mm for adults, and ONORM S 4036 or DIN 7880, part 2: 15±2 mm for children).
Based on an endpiece body according to the present invention, this object is achieved according to the invention. By means of present invention, automatic adaption of the distance of the sole holder from the lower section of the housing or the supporting body or the upper side of the ski is ensured even if ski boots having soles of different thicknesses are inserted into the endpiece body.
Further according to the present invention, the overall height of the endpiece body is reduced, especially since part of the length of the compression spring is located inside the sole holder.
Further according to the present invention, it is ensured that on the one hand the sole holder is pressed with adequate force against the inserted ski boot, but that this pressure is not so great that an effect on the pretension of the release spring is caused.
Further according to the present invention, the sole holder is secured in position in the endpiece body in a simple manner.
Further the construction according to the invention can be advantageously used in various types of endpiece bodies.
The present invention thus relates to the use of an endpiece body according to the invention in a safety ski binding having a compensating lever as described, for example, in Austrian Patent Specification No. 368,396 and which enables friction forces which additionally occur at the sole holder in the event of a backward twisting fall to be compensated. In this endpiece body, although an elastic element is arranged between the sole holder and the compensating lever, this elastic element is merely used to permit a pivoting movement of the compensating lever without the sole holder changing its vertical position. The vertical position of the release lever is not affected by the elastic element. The arrangement of a helical spring is especially favorable for manufacturing reasons.
Further according to the present invention, the sole holder is secured against swinging out laterally.
Further according to the present invention, it is expressed that the measure according to the invention can also be used advantageously in heel endpieces.
The distance between the sole holder and the underside of the housing, which distance is automatically set in each case by the ski boot via the helical spring, is essentially determined by the present invention.
The set position of the sole holder is ensured by the present invention.
It follows from the present invention that the principle according to the invention can also be used in front endpieces which are known per se and in which the housing supporting the sole holder is mounted on a bearing block. Accordingly, the bolt which forms the pivoting axis for the housing and is under the effect of the helical spring is mounted in an axially displaceable manner in the bearing block.
In contrast thereto, a front endpiece may be provided in which the bolt which forms the pivoting axis for the housing, as likewise known, is secured in the bearing block against axial displacement and in which the housing is displaceably guided on the bolt in a vertical direction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical longitudinal center section of a front endpiece of a ski binding embodying the teachings of a first embodiment of the present invention;
FIG. 1a depicts the endpiece of FIG. 1 at the beginning of a rearward fall;
FIG. 1b depicts the endpiece of FIG. 1 during a rearward fall and before the release movement begins;
FIG. 1c depicts the endpiece of FIG. 1 showing an enlarged view of the bolt and sole holding means;
FIG. 2 is a partially sectioned plan view of the endpiece illustrated in FIG. 1;
FIGS. 3 and 4 are partially sectioned side views of the endpiece illustrated in FIG. 1 with inserted thin and thick soles, respectively;
FIG. 5 is a vertical longitudinal center section of a front endpiece of a ski binding embodying the teachings of a second embodiment of the present invention;
FIG. 6 is a longitudinal center section of a front endpiece of a ski binding embodying the teachings of a third embodiment of the present invention;
FIG. 6a is an enlarged section along the line VIa-VI a in FIG. 6;
FIG. 6b is a variant of the endpiece illustrated in FIG. 6a;
FIG. 7 is a partially sectioned side view of the endpiece illustrated in FIG. 6 with an inserted sole;
FIGS. 8 and 9 illustrate a partially sectioned side view of a heel holding endpiece embodying the teachings of a fourth embodiment of the present invention in a state of rest and during the entering operation;
FIGS. 10 and 11 are vertical longitudinal center sections of front endpieces embodying the teachings of a fifth embodiment of the present invention;
FIGS. 12 and 13 are vertical longitudinal center sections of front endpieces embodying the teachings of a sixth embodiment of the present invention; and
FIG. 14 is a plan view of the endpiece illustrated in FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An endpiece body shown in FIGS. 1-4 is designed as a front endpiece and is designated overall by 1. Endpiece 1 has a housing 2 which can be fixed in a known manner by means of screws (not shown) to the upper side of a ski (not shown) and in which a supporting body 3 is arranged which is roughly angular in longitudinal section. Of the latter, one leg 3a is arranged substantially parallel to the upper side of the ski. The other leg 3b runs vertically relative to the upper side of the ski and carries at its upper end a pivot 4 which runs in the transverse direction of the ski and parallel to the upper side of the ski. A bell-crank lever 5 is mounted on this pivot 4. Recessed in the leg 5a of the bell-crank lever 5 running parallel to the leg 3a of the supporting body 3 is a vertical bore 5c through which a bolt 6 penetrates whose head 6a rests on the leg 5a. The lower end of the bolt 6 is guided in a bore 3c of the leg 3a. The bore 3c is located in a cup-shaped bulge 3d of the leg 3a. The lower end of the bolt 6 is provided with a widened section 6b which limits the displacement travel of the bolt 6 and thus the pivoting angle of the bell-crank lever 5.
The bolt 6 penetrates through the stepped bore 7a of a sole holder 7 which, when a ski boot is not inserted, rests on the bulge 3d of the leg 3a, as shown in FIG. 1. Furthermore, the bolt 6 is surrounded by a helical spring 8 which, with its lower end, is arranged in the stepped bore 7a and, with the other, upper end, is supported against the underside of the leg 5a, for example by a lock washer 9 in betweeen which engages into a groove of the bolt 6. Clearance enabling the bell-crank lever 5 to pivot is present between the lock washer 9 and the underside of the leg 5a.
The remaining construction 3a of the front endpiece 1 is of a known type. Thus, the leg 3a of the supporting body 3, at a lateral distance from the vertical longitudinal center plane of the front endpiece 1, carries two vertical pivots 10 on which lateral bell-crank levers 11 are mounted, of which one leg serves to laterally hold the sole 12a, 12'a of a boot 12, 12' inserted into the front endpiece 1 as shown in FIGS. 3 and 4.
A release spring 13 extending in the longitudinal direction of the endpiece 1, is accommodated in the housing 2. The pretension of the release spring 13 can be set by means of a sleeve 14 having an internal thread. This sleeve 14 is screwed onto the threaded section of a tie rod 15 which penetrates centrally through the release spring 13. Supported on a collar of the sleeve 14 is a further sleeve 16 which performs the function of a spring plate. On its end adjacent to the ski boot, the tie rod 15 carries a slide 17. A pull toward the ski tip is exerted on the slide 17 by the release spring 13 via the tie rod 15. The slide 17 acts on each of the two lateral bell-crank levers 11 and, via the latter, the bell-crank lever 5.
In FIG. 1, the front endpiece 1 is represented before insertion of the ski boot. If the ski boot is to be inserted, the tip of the sole 12a or 12'a, tapered roughly in a wedge shape, is inserted obliquely from above into the gap between the leg 3a of the supporting body 3 and the sole holder 7. The ski boot 12 or 12' is then kicked downward so that it rests with its sole 12a or 12'a on the leg 3a or on a base plate 18, as shown in FIGS. 3 and 4. As a result, the sole holder 7 is lifted against the force of the helical spring 8 in accordance with the thickness of the sole 12a or 12'a. This position of the sole holder 7 is shown in FIG. 3 when a ski boot is used whose sole 12 has a thickness h 1 and in FIG. 4 when a ski boot is used whose sole 12'a has a thickness h 2 .
The front endpiece 1' shown in FIG. 5 is very similar to endpiece 1 described above. It differs from the latter merely in that the head 6'a of the bolt 6' is mounted in the housing 2' itself and that the release spring 13' accommodated in the housing 2' only acts on the two lateral bell-crank levers 11', which are intended for laterally holding the sole. Although this embodiment is slightly simpler in its construction than the embodiment described above, it has the disadvantage that friction forces which occur at the sole holder in the event of a twisting fall backward are not compensated in it.
The front endpiece 1" according to FIGS. 6 and 7 essentially corresponds to the front endpiece 1 according to FIGS. 1-4. It differs from the latter merely in that the bolt 6", in the region of the half of its peripheral surface facing away from the release spring 13", is provided with ribs 6"c which run normal to the bolt axis and in the peripheral direction of the bolt 6" and are roughly crescent-shaped in plan view and opposite which are located corresponding grooves 7"b in the associated half of the roughly elliptical bore of the sole holder 7". The side of the sole holder 7" facing the release spring 13" is acted upon by a leaf spring 20 fixed with one end to the supporting body 3", as a result of which the ribs 6"c are disengaged from the grooves 7"b of the sole holder 7", as shown in FIG. 6.
If, however, the ski boot 12", with its sole 12"a, is inserted into the front endpiece 1", the leaf spring 20--after the sole holder 7" has automatically adapted itself to the thickness of the sole 12"a--is bent back and the ribs 6"c of the bolt 6" engage into the grooves 7"b of the sole holder 7", which is thereby secured in its vertical position relative to the base plate 18", as shown in FIG. 7.
FIG. 6a illustrates to an enlarged scale the configuration of the ribs 6"c of the bolt 6" and the grooves 7"b of the sole holder 7". Here, it should be noted that the sole holder 7" can be displaced in the vertical direction relative to the bolt 6".
The variant of a sole holder 7 IV according to FIG. 6b differs from the above described embodiment that the bolt 6 IV following the ribs 6 IV c, is laterally flattened and the sole holder 7 IV has guide sections corresponding to the flattened sections. The sole holder 7 IV is thereby secured against swinging out laterally.
In contrast to the exemplary embodiments described above in connection with FIGS. 1-7, FIGS. 8 and 9 refer to an endpiece body which is desgined as a heel holder 30. This heel holder 30 has a bearing block 31 which can be displaced on a guide rail 32 in the longitudinal direction of the ski and can be locked in a known manner in the position selected by means of a catch device (not shown). Located in the bearing block 31 at the end remote from the sole holder 7'" is a transverse pivot 33 on which the housing 2'", approximately U-shaped in cross section and carrying a tread spur 35 and the sole holder 7'", is pivotably mounted. Fixed in the housing 2'" is a pivot 36 which forms the pivoting axis for a release lever 37. The heel holder 30 can be opened at will in a known manner by a transversely running pin 38 which is attached to the release lever 37 and penetrates through elongated holes (not shown) in the housing 2'".
Fixed in the housing 2'" is a bolt 6'" which runs approximately normal to the guide rail 32 in the position according to FIG. 8 and on which the sole holder 7'" is displaceably guided. The sole holder 7'" is pressed by the helical spring 8'" toward the upper side of the heel 12'".
The remaining components of the heel holder 30 are of a known type of construction, for which reason the arrangement of the release spring, the control lever, the spring fork and the cam allocated to the control lever is not dealt with in greater detail.
Whereas in the design of the endpiece body as a front endpiece, as illustrated in FIGS. 1-7 and 10-14, the sole holder is lifted during the entering operation by the sole tip tapered in a wedge shape, this is not possible in a heel holder 30 as shown in FIGS. 8 and 9. Here, during the entering operation, the ski boot already inserted into the front endpiece and the housing 2'" mounted on the transverse pivot 33 and supporting the sole holder 7'" executes oppositely directed pivoting movements by which the heel 12'" of the ski boot is inserted in a sloping position into the gap between the sole holder 7'" and the tread spur 35, as shown in FIG. 9. As a result, the sole holder 7'" is lifted slightly against the force of the helical spring 8'". Consequently, it is also possible to fasten with the heel holder 30 heels whose height exceeds the currently permissible distance between the tread spur 35 and the sole holder 7'" (see the standard specifications cited above.
The front endpiece 1 V according to FIGS. 10 and 11, in contrast to the front endpieces described above has a bearing block 31 V which is to be fixed on the upper side of the ski and in which the bolt 6 V is mounted in a vertically displaceable manner. The bearing block 31 V has in its lower area a truncated-cone-shaped recess 40, open at the bottom, into which the lower end of the bolt 6 V protrudes. Arranged on this end is the helical spring 8 V , which is supported with one end against the roof 40a of the recess 40 and with its other end against a washer 41 which is slipped onto the bolt 6 V and is riveted to the latter.
The rest of the construction of the front endpiece 1 V is known per se (see French patent specification No. 2,537,442). Thus the bolt 6 V has on its upper end a head 6 V a which is used for mounting the housing 2 V which is provided with a sole holder 7 V at its rear end. The housing 2 V can not only be pivoted laterally about the bolt 6 V but can also be pivoted vertically, especially as the underside of the head 6 V a is of conical design.
During the entering operation, the end of the sole 12 V a of the ski boot 12 V is pushed beneath the sole holder 7 V and then the ski boot is pivoted toward the ski. As a result, the housing 2 V is lifted slightly and the helical spring 8 V is compressed, as shown in FIG. 11. It is therefore not necessary to set the height of the housing 2 V manually.
The front endpiece 1 VI shown in FIGS. 12 and 13 essentially consists of a bearing block 31 VI and a housing 2 VI supporting the sole holder 7 VI and accommodating the release spring 13 VI . The bolt 6 VI is displaceably mounted in the housing 2 VI against the force of the helical spring 8 VI . In its center area, the bolt 6 VI has an annular groove 6 VI d which is defined by a collar 6 VI e and into which an extension 31 VI a of the bearing block 31 VI radially engages. The bearing bore for the upper end of the bolt 6 VI is recessed in the housing 2 VI itself, whereas the lower bearing bore, designed as a stepped bore 2 VI b, is located in an extension 2 VI a of the housing 2 VI .
The helical spring 8 VI is arranged on the tapered, lower end 6 VI f of the bolt 6 VI adjoining the collar 6 VI e. The upper end of the helical spring 8 VI is supported on the collar 6 VI e of the bolt 6 VI , whereas the lower end is supported by the step of the stepped bore 2 VI b in the extension 2 VI a of the housing 2 VI and is surrounded by this extension 2 VI a.
In the housing 2 VI , a threaded pin 34 running in the transverse direction of the front endpiece 1 VI is rotatably mounted in its center area but is secured against axial displacement. In its two end areas, the threaded pin 34 has oppositely directed threaded sections which engage into nuts (not shown). The latter are rotatably mounted in levers (not visible) which laterally enclose the sole 12 VI a. These levers merely serve to laterally fasten the sole 12 VI a. However, they cannot be swung out laterally in the event of a twisting fall by the skier. On the contrary, the lateral swing-out movement is effected by the housing 2 VI in the event of a twisting fall.
The remaining constructional elements of the front endpiece 1 VI are known (see French Patent Specification No. 2,556,602) and are not a subject matter of the present invention, for which reason their description is dispensed with.
FIG. 14 represents a variant of the embodiment in FIGS. 12 and 13. This variant is distinguished by the fact that a smooth bolt 34' and not a threaded pin penetrates through the two levers 50a, 50b which laterally enclose the sole 12 VI a. The levers 50a, 50b are mounted on vertical pivots 51a, 51b which are anchored with their lower ends in the housing 2 VI . At a distance from the two vertical pivots 51a, 51b, stepped bores 52a, 52b running in the transverse direction are recessed in the levers 50a, 50b, which stepped bores 52a, 52b merge into conical widened sections 53a, 53b toward the vertical longitudinal center plane of the front endpiece. Helical springs 54a, 54b are accommodated in the two stepped bores 52a, 52b. Each helical spring 54a or 54b is supported with one end against the step of the stepped bore 52a or 52 b and with the other end against a washer 55a or 55b which is riveted onto the end of the bolt 34'.
In this embodiment too, the housing 2 VI is pivoted about the bolt 6 VI in the event of a twisting fall by the skier, whereas the two levers 50a, 50b essentially do not change their position relative to the housing 2 VI .
Various changes to the exemplary embodiments shown are possible without leaving the scope of the invention. For example, the sole holder, in the rest position, need not necessarily be supported on the supporting body or on the housing; on the contrary, it can also be supported on a washer or on an intermediate sleeve which surrounds the bolt with clearance and rests on the supporting body or on the housing. Furthermore, it is possible to design the sole holder roughly in a V-shape in plan view. In this case, the two legs of the V exert a downward pressure on the sole to both sides of the vertical longitudinal center plane of the ski boot. Finally, the spring elements, which in all exemplary embodiments are shown as helical springs, can be formed by disk spring stacks, or plastic or rubber elements. In this case, the pretension of the spring elements is 5°-90° of the pretension of the release spring.
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An endpiece for a safety ski binding attached to a ski, the endpiece comprising an elongated housing for disposition on the ski in the longitudinal direction of the ski; a lever pivotably mounted to the housing, the lever including a first end having a bolt opening and a second end; a sole holder for exerting a downward force on the sole of a ski boot, and having a portion disposed beneath the lever, the sole holder also having an elongated bore extending substantially perpendicular to the longitudinal axis of the ski; a bolt extending through the bolt opening and the bore, the sole holder vertically slidable on the bolt; a first spring disposed between the housing and the sole holder for urging the sole holder toward the ski; and a second spring for exerting a force on the second end of the lever for resisting rotational movement of the first and of the lever away from the ski.
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FIELD OF THE INVENTION
The present invention relates generally to Graylock type pipe connectors, and more particularly to an apparatus for remotely assembling and disassembling such a connector.
BACKGROUND OF THE INVENTION
Graylock type connectors are well known in the art and have been disclosed in a number of patents, including U.S. Pat. No. 3,403,931 (Crain et al) and U.S. Pat. No. 3,680,188 (Mason et al). Connectors of this type provide a pressure seal which is made by wedging a metal seal ring between two hubs that are in turn held together by two semicircular clamps. Four studs are highly torqued to draw the clamps together to provide a compression seal with the seal ring. Such connectors are ASME code approved as closure mechanisms to seal a pressure containing system such as a pressure vessel consisting principally of a closed length of pipe.
The standard Graylock system for large pressure vessels, however, is not easily assembled or disassembled and is not suitable for remote handling. Clamp alignment, insertion and removal of studs and nuts, and the application of torque to the nut require a manual effort. Large, high pressure connectors are heavy and difficult to assemble or disassemble. Thus, there is a need to provide an apparatus with the capability of assembling and disassembling these connectors remotely.
Various remote controlled devices have also been disclosed in the prior art for connecting a pipe to another structure. Examples of such miscellaneous devices are disclosed in the following U.S. Pat. Nos.: No. 3,754,780 (Pogonowski); No. 3,845,973 (Houot): No. 4,185,856 (McCaskill); and No. 4,191,256 (Croy et al). However, none of these devices are suitable for use with a Graylock type connector.
SUMMARY OF THE INVENTION
In accordance with the present invention, an apparatus for remotely assembling and disasembling a connector between a pipe and a closure for the pipe is provided. The connector is a Graylock type connector which includes an angled flange on the end of the pipe and an angled flange on the end of the connector. Two semicircular collars surround the flanges so that an interior peripheral cam groove rests against both flanges. A nut and bolt means extends through the two collars at each side in order to draw the collars together. A sealing ring is located between the pipe and the closure. This sealing ring is compressed between the pipe and the closure as the camming action of the cam groove on the collar draws the pipe and closure toward one another.
In order to operate such a connector remotely, a base is provided with a receptacle in which the closure is received with the flange of the closure uppermost and horizontally disposed and with the sealing ring resting on the flange. A positioning means is then provided for moving the pipe into position vertically above the closure with the flange of the pipe immediately adjacent and concentric with the flange of the closure. A moving means for each collar is also provided for reciprocally removing each collar horizontally from a position free of the closure to a position such that the interior cam groove contacts the two flanges. Finally, a tensioning means is provided for automatically tightening and loosening the nut and bolt means in each side of the collars to cause the seal ring to be compressed to seal the pipe to the closure and to cause the seal ring to be released from compression.
In the preferred embodiment of the present invention, the moving means for each collar includes a support for the collars, a pair of guides on the base parallel to the movement of the collar, and the guide follower for guiding the support for movement along the guides. Conveniently, the guides are V shaped tracks and the guide followers are wheels with a peripheral V shaped groove to mate with the V shaped track. A hydraulic actuator is also preferably used for each collar which is attached between the support and the base.
In the preferred embodiment, the nut and bolt means also preferably includes an elongate shaft portion at each side of the collars which extends externally of the collars during tensioning. The tensioning means then includes a removable sleeve which is located around each shaft portion between the associated collar and a reaction surface of the nut and bolt means. Thus, by removal of the sleeve, the collars are allowed to slide apart along the nut and bolt means sufficiently for the pipe to clear the collars. Preferably, the sleeve has a C shaped cross section. An arm is attached to the sleeve at one end and to a pivot means at the other end. This pivot means is attached to the base for pivotal movement of the sleeve away from the shaft portion. A stop means for limiting the pivotal movement of the arm and a travel means for allowing the arm to move parallel to the shaft portion are also preferably provided.
It is thus an advantage of the present invention to facilitate assembly and disassembly of a common pressure vessel closure to the extent that remote operation is possible.
It is also an object to the present invention to use a closure mechanism which is ASME code approved and is suitable for pressure rating in excess of those possible with other remote closure devices.
Other features and objects of the present invention are stated in or apparent from a detailed description of a presently preferred embodiment of the invention found hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of a remotely operated pipe connector according to the present invention.
FIG. 2 is a cross sectional elevation view of the remotely operated pipe connector depicted in FIG. 1 taken along the line 2--2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings in which like numerals represent like elements throughout the two views, a presently preferred embodiment of a remotely operated pipe connector 10 is depicted in FIGS. 1 and 2. Pipe connector 10 is used to join a pipe 12 having a suitably closed end 14 and an open end 16 to a closure 18 for open end 16. In order to accomplish this, a Graylock type connector 20 is employed.
Connector 20 comprises a blind hub 22 which includes a suitable flange 24. Flange 24 has an angled camming surface 26 as is well known in the art. Connector 20 also includes a vessel hub 28 having a flange 30 provided with an angled camming surface 32. Conveniently, vessel hub 28 is simply welded to open end 16 of pipe 14 as shown by weld 34.
Connector 20 further includes a pair of semicircular clampaing collars 36 having an interior peripheral cam groove 38. As shown in FIG. 2, cam groove 38 includes angled cammed surfaces 40 and 42 which respectively engage camming surfaces 26 and 32 during joining.
Located between blind hub 22 and vessel hub 28 and resting on the interior portions of respective flanges 24 and 30 is a sealing ring 44. Sealing ring 44 is compressed between flanges 24 and 30 to provide a sealing of the joint between blind hub 22 and vessel hub 28. This compressive action is caused by the drawing together of clamping collars 36 in a radial direction relative to pipe 12 which results through the action of camming surfaces 26, 32, 40, and 42 on the axial movement of blind hub 22 and vessel hub 28 toward one another. The drawing together of clamping collars 36 is accomplished through a nut and bolt means 46. These nut and bolt means are tightened to a high torque in order to provide the necessary compressive forces.
Remotely operated pipe connector device 10 is specifically designed to perform the assembling and disassembling operations of connector 20 remotely. Pipe connector device 10 is particularly useful where pipe 12 is a relatively large, high pressure, pressure vessel which is heavy and thus makes the assembly and disassembly of a suitable sized connector 20 quite difficult. Pipe connector device 10 includes a base 50 in which a receptacle 52 is provided. As shown, receptacle 52 is particularly designed to secure closure 18 to base 50 by bolting with flange 24 horizontal and uppermost. Where access is provided to the interior of pipe 12 through closure 18 as shown, base 50 preferably also includes an aperture 54 therethrough.
Mounted on the top surface of base 50 are V shaped tracks 56 and 58. As shown best in FIG. 1, tracks 56 and 58 extend from one side of base 50 to the other. As also shown in FIG. 1, each clamping collar 36 is mounted on a support 60. Each support 60 has a pair of depending walls 62. Suitably mounted to each wall 62 is a pair of wheels 64. Only one wheel 64 of each pair is shown, with the other wheel of the pair located beneath the adjacent clamping collar 36. Each wheel 64 has a V shaped groove 66 along the periphery thereof which rides on an adjacent track 56 or 58. Thus, supports 60 are mounted for horizontal movement relative to base 50.
Also attached to base 50 intermediate tracks 56 and 58 is a bracket 68 associated with each clamping collar 36. Each bracket 68 includes a horizontal plate 70 which is suitably attached to base 50 and a vertical plate 72 located at the far end of horizontal plate 70.
Extending horizontally from vertical plate 72 at the vertical position of the associated clamping collar 36 is a mounting means 74. Mounting means 74 is used to pivotally mount a hydraulic actuator 76 to vertical plate 72 such that hydraulic actuator 76 can pivot about a horizontal axis as shown. The other end of hydraulic actuator 76 is attached to a similar mounting means 78. Mounting means 78 is securely attached to a pusher 80. Pusher 80 includes a bottom plate (not shown), a top plate 82, and a middle plate 84 all of which are mechanically clamped to an associated clamping collar 36. Thus, by actuation of hydraulic actuator 76, an associated clamping collar 36 is appropriately moved along tracks 56 and 58 with support 60.
As mentioned above, a nut and bolt means 46 is provided for drawing clamping collars 36 together. In the present invention, nut and bolt means 46 on each side of clamping collars 36 includes a pair of elongate shafts 90, one on top of the other, which extend through the sides of clamping collars 36. As shown more clearly with respect to the upper elongate shafts 90, a nut 92 is securely threaded on one end of elongate shaft 90 on the outside of the associated clamping collar 36. On the other side of the associated clamping collar, elongate shaft 90 extends through a C shaped sleeve 94. At the end of sleeve 94 adjacent the associated clamping collar 36, a spherical washer 96 is provided which engages a mating surface of clamping collar 36. At the other end of sleeve 94, sleeve 94 engages a hydraulically actuated stud tensioner 98. Stud tensioner 98 is designed to rotate a nut contained therein on the threaded end of elongate shaft 90.
It should be appreciated that sleeve 94 is removable from elongate shaft 90 when elongate shaft 90 is not tensioned. Sleeve 90 is thus pivotally mounted to base 50 by use of an arm 100 which is suitably attached to sleeve 94 as by welding. The lower end of arm 100 is mounted about a pivot shaft 102. The lower end of arm 100 is also horizontally movable along pivot shaft 102 to allow sleeve 94 some horizontal movement as well. Pivot shaft 102 is mounted to base 50 by a suitable bracket 104. Also mounted to bracket 104 is a stop means 106 which engages arm 100 after arm 100 has pivoted sufficiently to move sleeve 94 out of the way of the horizontal movement of clamping collars 36.
In order to bring pipe 12 into position relative to closure 18 mounted on receptacle 52 of base 50, a suitable positioning means is provided. For example, an overhead crane 110 is suitably attached to an eyelet 112 which is secured to closed end 14 of pipe 12. By use of overhead crane 110, pipe 12 is suitably positioned with flange 30 immediately adjacent flange 24 of blind hub 22.
In operation, pipe connector device 10 functions in the following manner. Initially, nut and bolt means 46 is loosened and sleeves 94 have been pivoted away from associated shafts 90 so that clamping collars 36 are pulled back away from blind hub 22. This leaves a large clearance space. The sealing ring 44 is positioned on blind hub 22 adjacent flange 24. With the clerance provided between clamping collars 36, overhead crane 110 or the like is suitably used to position pipe 12 over blind hub 22. Pipe 12 is positioned so that flange 30 of vessel hub 28 is immediately adjacent flange 24 of blind hub 22 and concentric therewith.
Once pipe 12 is in position, hydraulic actuators 76 are actuated remotely in order to move clamping collars 36 toward respective flanges 24 and 30. It should be appreciated that clamping collars 36 move smoothly and horizontally because clamping collars 36 are attached to respective supports 60 which ride on wheels 64 along tracks 56 and 58. Hydraulic actuators 76 move clamping collars 36 into contact with respective flanges 24 and 30. It should be appreciated that as clamping collars 36 move, clamping collars 36 also freely move along elongate shafts 90 adjacent the respective sleeves 94.
At this time, clamping collars 36 are in contact with both blind hub 22 and vessel hub 28 such that cam surfaces 40 and 42 contact, respectively, caming surface 26 and caming surface 32. Next, sleeves 94 are rotated into position by arm 100 relative to pivot shaft 102. In this manner, sleeves 94 are located between the respective side of clamping collars 36 and respective stud tensioners 98.
Once all four sleeves 94 are in position, hydraulic stud tensioners 98 are actuated. Initially, this causes a small longitudinal movement of each sleeve 94 toward respective clamping collars 36 as spherical washer 96 is received in a corresponding concavity in clamping collars 36. It should be appreciated that this longitudinal movement of sleeves 94 is readily accommodated despite the attachment of arm 100 thereto because arm 100 is movable along pivot shaft 102. As the stud tensioners continue to tighten the nut located therein around the end of elongate shaft 90, the adjacent sides of clamping collars 36 are drawn toward one another resulting in the drawing of blind hub 22 and vessel hub 28 toward one another as well. This is caused by the camming action of camming surfaces 26 and 32 relative to cam surfaces 40 and 42. As blind hub 22 and vessel hub 28 are drawn toward one another, sealing ring 44 is compressed to form the high pressure seal between flange 24 and flange 30. It should be appreciated that stud tensioners 98 supply sufficient force to the nut contained therein to achieve a high torque on the nut and the necessary compressive force on sealing ring 44. After this high load is achieved, pipe 12 is ready to be used as a pressure vessel or the like.
After pipe 12 has been used as a pressure vessel or the like, pipe connector device 10 is also used to disconnect pipe 12 from blind nut 22. This is accomplished by reversing the action of stud tensioners 98 to loosen the nuts contained therein and relieve any tension on elongate shafts 90. After this is accomplished, sleeves 94 are moved slightly longitudinally in order to clear spherical washers 96 and pivoted free from elongate shafts 90. Sleeves 94 are finally positioned with arm 100 against stop means 106 to hold sleeves 94 in a position which does not interfere with further movements of clamping collars 36.
Once sleeves 94 are free of elongate shafts 90, hydraulic actuators 76 are actuated to pull clamping collars 36 away from one another. It should be appreciated that hydraulic actuators 76 supply sufficient force to break the seal and to thereafter withdraw clamping collas 36 away from one another as support 60 rides along wheels 64 on tracks 56 and 58, resepctively. Pipe 12 can then be moved as desired by overhead crane 110.
It should be appreciated that the present invention permits the largest Graylock closure system to be used with ease. In addition, it should also be appreciated that the present invention with slight modification to receptacle 52 and base 50 can be used to form a connection between two pipes as well as a connection between a pipe and a closure as described above. It should further be appreciated that the exact positioning of pipe 12 relative to closure 18 is not critical as the sealing ring 44 has tapered surfaces that center the pipe and closure exerting a compressive force on sealing ring 44.
While the present invention has been described with respect to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that variations and modifications can be effected within the scope and spirit of the invention.
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An apparatus for remotely assembling and disassembling a Graylock type coctor between a pipe and a closure for the pipe includes a base and a receptacle on the base for the closure. The pipe is moved into position vertically above the closure by a suitable positioning device such that the flange on the pipe is immediately adjacent and concentric with the flange on the closure. A moving device then moves two semicircular collars from a position free of the closure to a position such that the interior cam groove of each collar contacts the two flanges. Finally, a tensioning device automatically allows remote tightening and loosening of a nut and bolt assembly on each side of the collar to cause a seal ring located between the flanges to be compressed and to seal the closure. Release of the pipe and the connector is accomplished in the reverse order. Preferably, the nut and bolt assembly includes an elongate shaft portion on which a removable sleeve is located.
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BACKGROUND OF THE INVENTION
A user service center facilitates a communication between a user and an agent at the user service center. Many times, a user service center can accept connections from more users than the user service center employs agents. When this happens, the user service center typically has the excess users wait until an agent becomes available.
SUMMARY OF THE INVENTION
In one embodiment, a method of managing calls at a user service center includes determining whether an identifier associated with a user qualifies the user for priority access to an agent at a user service center based on a previous interaction with the user service center, and if so, the method provides for giving priority access to the user to interact with the agent.
In another embodiment, the method includes, during the previous interaction, providing the user with an option of selecting a later timeslot from a plurality of timeslots to complete the interaction with the user service center during the later timeslot. The method may further include, using the identifier, associating the user with a priority access queue during the later timeslot.
In another embodiment, the method may also include providing the plurality of timeslots to the user, the plurality of timeslots associated with at least one of an estimated low volume user-to-agent interaction period, a high idle-agent-to-active-agent ratio time period, a period with a high number of active agents, an economically efficient period, a period leveraging resources of an outside center, and a new time slot designated for priority access. The method may further include providing the user with a notification to initiate the interaction during the later timeslot with the user service center, the notification being provided at a time associated with the later timeslot. The method may also include periodically providing the notification during the later timeslot until such a time the user initiates the interaction.
The method may also include during the previous interaction, creating and, if necessary, providing the identifier to the user, the identifier providing the user with priority access to the user service center at a timeslot to continue the previous interaction. The method may further include mapping the identifier to a priority access mechanism associated with the timeslot.
The identifier may include a relative priority identifier that identifies a relative priority of the user with respect to other users associated with respective identifiers qualifying the other users with priority access to the user service center. The interaction may be at least one of the following: a phone call, live instant messaging, real-time text messaging, video-chat, remote assistance, and other online interaction.
The identifier may be associated with a timeslot to continue the previous interaction during which the user may receive priority access to the user service center, but not during other timeslots. The method may further include, for each timeslot, providing a restricted number of identifiers qualifying users for priority access to the user service center.
The restricted number may be selected in a manner that prevents an overflow of interactions during the timeslot based on a predetermined estimated volume of interactions expected to be received during the timeslot.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing will be apparent from the following more particular description of example 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 embodiments of the present invention.
FIGS. 1A-1B are a block diagrams illustrating an example embodiment of a user service center configured to employ delayed priority access.
FIG. 2 is a flow diagram illustrating an example embodiment of granting priority access to user and identifying a user with priority access.
FIG. 3A is a block diagram illustrating an example embodiment of an implementation of priority access.
FIG. 3B is a block diagram illustrating another example embodiment of implementing priority access to agents. The identifier determination module receives
FIG. 4 illustrates a computer network or similar digital processing environment in which embodiments of the present invention may be implemented.
FIG. 5 is a diagram of the internal structure of a computer (e.g., client processor/device or server computers) in the computer system of FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
A description of example embodiments of the invention follows.
FIG. 1A is a block diagram 100 illustrating an example embodiment of a user service center 108 configured to employ delayed priority access. Many user service centers 108 , such as a call service center or a chat service center, have peak load times when more callers or users access the user service center 108 than agents available at the user service center 108 . As a result, many users have to wait to speak to an agent at the user service center 108 . At other times of the day, fewer callers access the system than agents available at the user service center 108 . As a result, agents can be idle at those off-peak load times. Ideally, users of the user service center 108 would call in a uniformly distributed pattern during the day. In this manner, agents are neither overloaded nor idle, and users would have much smaller wait times.
In one embodiment, the delayed priority access system addresses this problem by redistributing the user calls into the uniformly distributed pattern throughout the day. It should be understood that the user service center 108 may employ telephone communications, and/or other modes of communications such as text messaging, instant messaging, online chat, providing remote service, and video chat. While descriptions herein refer to telephone communications as the mode of communication between a user 102 and the user service center 108 , other modes of communications are also applicable to the described system and method.
A user 102 can call the user service center 108 using a client device 104 . Examples of the client device 104 include a mobile phone, mobile device, computer, laptop, automobile, appliances, a wearable computer, a computing enabled accessory, or a kiosk. The client device can further be employed to begin the interaction offline, and only connect to the network when necessary. Upon calling the user service center 108 , the client device 104 transmits an identifier 106 to the user service center 108 to an identifier determination module 110 . The identifier 106 is a token that the user service center 108 previously issued or determined. The user service center 108 issues or determines the identifier 106 during a previous interaction with the user. In the previous interaction, the user 102 elects to call the user service center 108 back during a nonpeak hour in exchange for priority access during the off-peak hour. The user service center 108 associates the identifier 106 with the user 102 , either by generating a new identifier 108 or by determining a pre-existing identifier of the user 102 . The identifier 106 can be, for example, a phone number of the user 102 (e.g., as determined by caller ID), an account number of the user 102 , personally identifiable information of the user 102 , or a number and/or code generated by the user service center 108 . The user service center 108 transmits the number and/or code to the user 102 during the previous interaction. The client device 104 can transmit the number and/or code either in an automated manner or after user input of the number and/or code in the present interaction. Other examples of the identifier 106 can include automatic numbering information (ANI), a user identification mechanism (e.g., a username or account number), a special key or code that the user 102 can enter, or a hotline for users with higher priority (e.g. dialed number identification service (DNIS)).
The user service center 108 , upon receiving the identifier 106 at the identifier determination module 110 , determines whether the user 102 associated with the identifier 106 is qualified for priority access to agents. If the identifier determination module 110 determines that the identifier 106 either is nonexistent or does not qualify the user 102 for priority access, the identifier determination module 110 routes call data 120 to a normal access line 112 . The normal access line 112 can optionally include a queue 116 . After waiting in the queue 116 , the user 102 is connected to one of the agents 118 at the user service center 108 .
On the other hand, if the identifier determination module 110 determines that the identifier 106 is qualified for priority access, the identifier determination module 110 routes the call data 120 to a priority access path 114 . The priority access path 114 then gives the user 102 priority access to one of the agents 118 . Priority access can be implemented in a variety of ways, such as by providing a priority queue 115 with a higher priority along the priority access path 114 , or specific pool of agents primarily serving users with priority access. The priority access time window can be determined by a statistical analysis of call load times during a typical day. In another embodiment, where the specific pool of agents is employed to handle priority access calls, the calls can be scheduled based on the number of agents available during a specific time slot.
FIG. 1B is a block diagram 150 illustrating another example embodiment of a user service center 108 configured to employ delayed priority access. The embodiment illustrated in FIG. 1B is similar to the embodiment illustrated in FIG. 1A . However, FIG. 1B illustrates a second user 152 and an Nth user 162 communicating with the user service center 108 .
The second user 152 transmits a second identifier 156 to the identifier determination module 110 at the user service center. If the identifier determination module 110 determines that the second identifier 156 either is nonexistent or does not qualify the second user 152 for priority access, the identifier determination module 110 routes call data 120 to the normal access line 112 . After waiting in the queue 116 , the second user 152 is connected to one of the agents 118 at the user service center 108 .
On the other hand, if the identifier determination module 110 determines that the second identifier 156 is qualified for priority access, the identifier determination module 110 routes the call data 158 to a priority access path 114 . The priority access path 114 then gives the second user 152 priority access to one of the agents 118 .
Similarly, the Nth user 162 transmits a Nth identifier 166 to the identifier determination module 110 at the user service center. If the identifier determination module 110 determines that the Nth identifier 166 either is nonexistent or does not qualify the Nth user 162 for priority access, the identifier determination module 110 routes call data 120 to the normal access line 112 . After waiting in the queue 116 , the Nth user 162 is connected to one of the agents 118 at the user service center 108 .
On the other hand, if the identifier determination module 110 determines that the Nth identifier 162 is qualified for priority access, the identifier determination module 110 routes the call data 168 to a priority access path 114 . The priority access path 114 then gives the Nth user 162 priority access to one of the agents 118 .
FIG. 2 is a flow diagram 200 illustrating an example embodiment of granting priority access to user and identifying a user with priority access. After the process begins ( 202 ), the user service center prompts the user for the identifier, or it retrieves the identifier automatically ( 204 ). The user can be prompted to enter an identifier, such as a username, account number, or number assigned to the user, such as the number assigned during a previous phone call. The user service center can retrieve the identifier automatically by using caller ID or ANI. Next, the user service center determines whether the identifier is associated with a user that qualifies for priority access ( 206 ). If the user does qualify for priority access, the user service center grants priority access ( 208 ).
If the identifier is not associated with a user qualifying for priority access, the user service center prompts the user and determines whether the user selects to complete the interaction in a later time slot ( 210 ). If the user does select to complete the interaction in a later time slot ( 210 ), the user service center associates an identifier of the user with a later time slot ( 212 ). Otherwise, the user service center places the user in a waiting mechanism/queue until an agent is available ( 214 ).
The identifier does not necessarily have to be retrieved by the user service center or entered by the user. In the event that no identifier is retrieved or entered, the user service center recognizes that the user is not authorized for priority access and the user service center prompts user to select completing interaction a later time slot ( 210 ).
FIG. 3A is a block diagram 300 illustrating an example embodiment of an implementation of priority access. The identifier determination module receives the identifier 106 and, at a decision block 302 , determines whether the identifier 106 indicates priority access. If the identifier does not indicate the user is authorized for priority access, the call is routed into a normal access line 112 , which can include a queue 304 , before the user is routed to one of the agents 118 . On the other hand, if the identifier indicates the user is authorized for priority access, then the call is routed to a priority access path 114 which skips the queue 304 and gives more direct access to the agents 118 .
FIG. 3B is a block diagram 310 illustrating another example embodiment of implementing priority access to agents. The identifier determination module receives the identifier 106 at the decision block 302 . The decision block 302 determines whether the identifier indicates whether the user is authorized for priority access. If the identifier does not indicate the user is authorized for priority access, then the call is routed onto the normal access line 112 and then into a queue 304 , which is then routed to a regular agent pool 318 b . If the decision block determines that the identifier does indicate the user is authorized for priority access, then the call is routed onto the priority access path 114 and into a priority agent pool 318 a . The priority agent pool 318 a is a pool of agents that are available to priority users to improve service to authorized users.
Embodiments or aspects of the present invention may be implemented in the form of hardware, software, or firmware. If implemented in software, the software may be any form of software capable of performing operations consistent with the example embodiments disclosed herein. The software may be stored in any non-transient computer readable medium, such as RAM, ROM, magnetic disk, or optical disk. When loaded and executed by processor(s), the processor(s) are configured to perform operations consistent with the example embodiments disclosed herein. The processor(s) may be any form of processor(s) capable of being configured to execute operations as disclosed herein.
FIG. 4 illustrates a computer network or similar digital processing environment in which embodiments of the present invention may be implemented.
Client computer(s)/devices 50 and server computer(s) 60 provide processing, storage, and input/output devices executing application programs and the like. Client computer(s)/devices 50 can be the client device 104 . Client computer(s)/devices 50 can also be linked through communications network 70 to other computing devices, including other client devices/processes 50 and server computer(s) 60 . Communications network 70 can be part of a remote access network, a global network (e.g., the Internet), a worldwide collection of computers, Local area or Wide area networks, and gateways that currently use respective protocols (TCP/IP, Bluetooth, etc.) to communicate with one another. Other electronic device/computer network architectures are suitable.
FIG. 5 is a diagram of the internal structure of a computer (e.g., client processor/device 50 or server computers 60 ) in the computer system of FIG. 4 . Each computer 50 , 60 contains system bus 79 , where a bus is a set of hardware lines used for data transfer among the components of a computer or processing system. Bus 79 is essentially a shared conduit that connects different elements of a computer system (e.g., processor, disk storage, memory, input/output ports, network ports, etc.) that enables the transfer of information between the elements. Attached to system bus 79 is I/O device interface 82 for connecting various input and output devices (e.g., keyboard, mouse, displays, printers, speakers, etc.) to the computer 50 , 60 . Network interface 86 allows the computer to connect to various other devices attached to a network (e.g., network 70 of FIG. 4 ). The computer 50 , 60 can employ the network interface 86 to leverage the disk storage 95 and memory 90 of another computer 50 , 60 connected to the network 70 as its own storage and/or memory. Memory 90 provides volatile storage for computer software instructions 92 and data 94 used to implement an embodiment of the present invention (e.g., priority access in a user service center code detailed above). Disk storage 95 provides non-volatile storage for computer software instructions 92 and data 94 used to implement an embodiment of the present invention. Central processor unit 84 is also attached to system bus 79 and provides for the execution of computer instructions.
In one embodiment, the processor routines 92 and data 94 are a computer program product (generally referenced 92 ), including a computer readable medium (e.g., a removable storage medium such as one or more DVD-ROM's, CD-ROM's, diskettes, tapes, etc.) that provides at least a portion of the software instructions for the invention system. Computer program product 92 can be installed by any suitable software installation procedure, as is well known in the art. In another embodiment, at least a portion of the software instructions may also be downloaded over a cable, communication and/or wireless connection. In other embodiments, the invention programs are a computer program propagated signal product 107 embodied on a propagated signal on a propagation medium (e.g., a radio wave, an infrared wave, a laser wave, a sound wave, or an electrical wave propagated over a global network such as the Internet, or other network(s)). Such carrier medium or signals provide at least a portion of the software instructions for the present invention routines/program 92 .
In alternate embodiments, the propagated signal is an analog carrier wave or digital signal carried on the propagated medium. For example, the propagated signal may be a digitized signal propagated over a global network (e.g., the Internet), a telecommunications network, or other network. In one embodiment, the propagated signal is a signal that is transmitted over the propagation medium over a period of time, such as the instructions for a software application sent in packets over a network over a period of milliseconds, seconds, minutes, or longer. In another embodiment, the computer readable medium of computer program product 92 is a propagation medium that the computer system 50 may receive and read, such as by receiving the propagation medium and identifying a propagated signal embodied in the propagation medium, as described above for computer program propagated signal product.
Generally speaking, the term “carrier medium” or transient carrier encompasses the foregoing transient signals, propagated signals, propagated medium, storage medium and the like.
While this invention has been particularly shown and described with references to example 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 user service center facilitates communication between a user and an agent at the user service center. At peak use times, the user service center is connected to a surplus of users with respect to its number of agents, and the user service center has the users wait to communicate with an agent. In one embodiment, the system and method described herein give the user the option to reconnect with the user service center at a later, off-peak, time. In exchange, the user is granted an identifier indicating priority access to an agent at the off-peak time. In this way, the user does not have to wait to communicate with an agent during the subsequent communication during the off-peak time.
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BACKGROUND OF THE INVENTION
The field of the present invention is storage and display racks.
Storage and display racks for retail goods are required to be sturdy and yet open to properly provide access to and full display of products. Such shelving can be subject to hundreds of pounds of product. It is also frequently advantageous to have displays movable for featuring a product, restocking and the like.
Adequate storage and display racks, when not custom made, are frequently of formed metal sheet fabricated with stiffening corrugations or understructure. Such designs are characteristically not easily modified without changing dies and the like. The structures are frequently a compromise of design parameters between flimsy and excessively heavy. Using metal sheet also is not acoustically desirable. Shelving on rollers can further complicate such deficiencies.
Plastic shelving has been available as well. Such shelving frequently requires complicated assembly and can also suffer from lack of structural rigidity. Because of molding requirements, design changes and size modifications are difficult to accomplish.
BRIEF DESCRIPTION OF THE INVENTION
The present invention is directed to a rack for storage or display. Corner supports and side supports are employed with side rails through a pin and socket arrangement to form a structural perimeter. A plate is positioned on and attached to the supports.
In a first specific and separate aspect of the present invention, the corner supports include pins extending at 90° with a base bifurcating this angle. The side supports include such pins at 180° and also have a base extending laterally in one direction. Thus, a solid support is provided by the corner and side supports with side rails spanning between supports for a rigid plate. In a further detail, the side rails may also provide support for the rigid plate. Where mobility is desirable, casters may be associated with the support attachment bases.
In a second specific and separate aspect of the present invention, the supports again include bases extending inwardly to support a plate. The supports are associated with side rails through a rigid pin and socket connection preventing rotation of the rails relative to the supports. The side rails include a channel to receive the edge of the plate to resist flexure and bending. It is possible to affix the channels to the plate for even further rigidity. The side panels may conveniently be extrusions of thin wall tubing with an appropriate cross section to define the channel, to define sockets so as to be capable of rigid coupling with the supports and to form a rigid support structure about the channel.
In a third specific and separate aspect of the present invention, any of the foregoing structures may be provided with vertical sockets for receiving elongate columns. Multiple layers of shelving may then be accommodated.
Accordingly, it is an object of the present invention to provide improved racks having substantial utility for storage and display. Other and further objects and advantages will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a multiple level rack.
FIG. 2 is an exploded perspective view of a panel with a plate partially removed for clarity.
FIG. 3 is a perspective view of a side rail.
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 3.
FIG. 5 is a plan view of a corner support with a panel shown in phantom.
FIG. 6 is a cross-sectional view taken along line 6--6 of FIG. 5.
FIG. 7 is a cross-sectional view taken along line 7--7 of FIG. 5.
FIG. 8 is a cross-sectional view taken along line 8--8 of FIG. 5.
FIG. 9 is a side view taken along line 9--9 of FIG. 5.
FIG. 10 is a cross-sectional view taken along line 10--10 of FIG. 5.
FIG. 11 is plan view of a side support with the portion of a panel shown in phantom.
FIG. 12 is a side view taken along line 12--12 of FIG. 11.
FIG. 13 is an end view taken along line 13--13 of FIG. 11.
FIG. 14 ms a cross-sectional view taken along line 14--14 of FIG. 11.
FIG. 15 is a cross-sectional view taken along line 15--15 of FIG. 11.
FIG. 16 is a cross-sectional view taken along line 16--16 of FIG. 11.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning in detail to the drawings, FIG. 1 illustrates an assembled rack, generally designated 10 having four decks. Each deck 12 is identically arranged but for the casters 14 associated with the lowermost deck 12. Elongate columns 16 are formed of angle members which extend from deck to deck. Also, elongate columns 18 extend from deck to deck. These columns 18 are formed by solid rods or tubes. The columns 16 and 18 are associated with vertically oriented sockets 20 and 22, respectively, which are found both top and bottom of each deck, reference being made to FIG. 2.
At the corners of each deck 12, corner supports 24 are identically arranged. Each corner support, reference being made to FIGS. 5 through 10, includes a body 26 arranged generally in a 90° angle. It is in the body 26 that the vertically oriented sockets 20 are arranged top and bottom. At the end of each leg of the body 26 is a pin 28. Each pin 28 includes a T section formed by an outer wall 30 and a horizontal plate 32. At the outer end of the pin 28 an end wall 34 abuts against the T section. This end wall 34 includes a lower section 36 having an inclined edge 38. An upper section 40 extends to a vertical edge 42 partway along the horizontal plate 32 as can best be seen in FIG. 6. Additional lower sections 36 may be spaced along the pin 28 beneath the horizontal plate 32. At the inner end of each pin 28 an upper section 44 having a vertical edge 46 almost aligned with the vertical edge 42 is provided.
An attachment base 48 extends inwardly from the body 26, bifurcating the angle defined by the pins 28. The attachment base 48 includes a flat upper surface 50 having glue relief grooves 52 in the surface thereof. Recessed cavities 54 are also arranged in the corners of the attachment base 48. A supporting wall 56 and supporting ribs 58 provide strength and rigidity to the attachment base 48. The supporting ribs 58 extend to circular supports 60 aligned with the recessed cavities 54 about holes 62. Extending inwardly from the body 26 are lugs 64.
In addition to the corner supports, side supports 66 are employed. The side supports 66 are designed much like the corner supports 24 except that the pins 28 extend at 180° from a straight body 68. Much of the structure is common between the side supports 66 and the corner supports 24. The same reference numbers denote similar structures in each. Repetition of description here is avoided. Extending from the attachment base 48 is a pin 70. The pin 70 receives a rectangular tube 72 (see FIG. 2).
Connecting the pins 28 and 70 are side rails 74. The side rails 74 are extruded thin wall rigid tubes. The cross section of such a tube is illustrated in FIG. 4. The side rails 74 each have a socket at each end defined by the interior of the cavity. The cross-sectional profile is shown to include a channel 76. This channel 76 is similarly dimensioned to the open area defined by each lug 64 in association with the flat upper surface 50 and the wall of the body 26 or body 68. A shelf 78 extends outwardly from beneath the channel 76 and is supported by an angled portion 80. A rim 82 is defined by the portion of the side rail 74 extending upwardly above the channel 76.
Arranged in the channel 76 of each of the side rails 74 and beneath the lugs 64 is a plate 84. The plate is rigid, made of plywood, medium density fiberboard, hardboard, particleboard, plastic panels, foam composite panels, corrugated plastic or cardboard panels or other composite combination thereof. With each deck 12 fully assembled, the plate 84 is retained by these elements.
In assembling any deck 12 of the rack, glue is used. Glue is employed on the attachment bases 48 and may be used on the pins 28 and 70. The size of the rack may also be selected from a wide variety of sizes because of modular construction. None, one or more side supports 66 may be employed to alter the width of each deck 12. The number of decks 12 also determines size in terms of height. The casters 14 and the elongate columns 18 provide additional support as added sections are included. The size of the deck 12 may also be conveniently determined by selecting the lengths of the extruded side rails 74. Their lengths are easily accomplished by selecting and sawing or cutting the extrusion. The panel 84 must be cut to the appropriate size as well as the rectangular tube 72. The elongate columns 16 and 18 may also be varied at the time of fabrication or later to determine the ultimate height of storage area between decks 12.
The overall strength of the decks is exceptional. Even central bending is accommodated by the rectangular tube 72 or the attachment bases 48. As the bases attempt to rotate downwardly, the bodies 26 and 68 both further engage the plate 84 as well as transmit displacement to the side rails 74. Because of the shapes of the side rails 74 and the associated pins 28 and 70, the side rails also attempt to rotate but are restrained by the plate 84. Thus, increased rigidity is experienced.
Thus, a rolling, in-store merchandise display rack is disclosed which is safe, stable, capable of holding heavy loads and easy to assemble without the use of tools. While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore is not to be restricted except in the spirit of the appended claims.
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A rack for display and storage having multiple decks with each deck including corner supports, side supports and a supported plate. In addition, extruded side rails connect the several supports. Elongate columns make multiple decks possible. Casters under the lowermost deck provide a rolling feature to the structure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to conduit couplings, and in particular to a fluid-tight, pull-out resistant coupling for buried conduits for telecommunication lines and related applications.
2. Description of the Related Art
Various types of transmission lines and cables are commonly enclosed in conduits for protection. Such transmission lines can transmit electrical power or signals over, for example, electrical conductors or fiber optic cables. Conduits can be installed in various structures and can also be buried below grade. For example, fiber optic cables have come into widespread use in telecommunications, particularly in long distance telecommunication networks. Many of these fiber optic cables are being installed underground within protective conduits.
In fiber optic cable networks, the conduits can serve two purposes. First of all, fiber optic lines are often pulled through buried conduits by means of pulling devices driven by air pressure and connected to the fiber optic cable ends for pulling same through the buried conduits. Such installation methods can effectively install relatively long fiber optic cable runs. However, the buried conduits must be relatively fluid-tight to maintain the necessary air pressures over significant distances. Secondly, the conduits protect the fiber optic cable runs from the elements, such as ground water.
The conduit sections are commonly made of high density polyethylene (HDPE) for its properties of strength, impermeability, corrosion-resistance and moderate cost. Relatively permanent conduit runs can be formed with this material.
A common problem encountered in buried fiber optic cable network design relates to coupling the HDPE conduit sections. Strong, tight connections of the individual conduit sections are necessary to maintain the integrity of the system under adverse environmental conditions. Preferably the connections should be able to withstand internal air pressure encountered when the cables are installed and a tendency of the conduit section ends to pull away from the couplings.
The Thompson, Jr. U.S. Pat. No. 5,180,197 discloses a pipe jointing system with a rigid outer layer and an elastomeric inner layer. The elastomeric inner layer includes opposing sets of sawtooth ridges for engaging conduit section ends in sealing relationships therewith. However, the pipe jointing system of the Thompson, Jr. '197 patent lacks end-mounted lock nuts for securing the conduit section ends to the coupling and preventing pull-out of same.
Heretofore there has not been available a conduit coupling with the advantages and features of the present invention. The conduit coupling of the present invention addresses some of the problems encountered in installing buried fiber optic cable networks.
SUMMARY OF THE INVENTION
In the practice of the present invention, a coupling is provided for conduit sections. The coupling includes a body with an outer, rigid casing and an inner, resilient core. The core includes a plurality of annular ridges for engaging the conduit sections in sealing relationships. A pair of lock nuts are threadably mounted on the casing and each receives a gripper ring with annular ridges for engaging the conduit in a clamping relationship to resist pull-out.
OBJECTS AND ADVANTAGES OF THE INVENTION
The principle objects and advantages of the present invention include: providing a conduit coupling; providing such a conduit coupling which utilizes a rigid outer casing and an elastomeric core; providing such a conduit coupling with a pair of end-mounted lock nuts; providing such a conduit coupling with gripper rings received within the lock nuts; providing such a conduit coupling which is adapted for coupling a pair of conduit sections in a fluid-tight relationship; providing such a conduit coupling which is adapted to resist pull-out; providing such a conduit coupling which is particularly well adapted for use in connection with buried conduits; providing such a conduit coupling which is particularly well adapted for buried fiber optic cable networks; and providing such a conduit coupling which is economical to manufacture, efficient in operation, capable of a long operating life and particularly well adapted for the proposed usage thereof.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention.
The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a conduit coupling embodying the present invention.
FIG. 2 is an enlarged, longitudinal, cross-sectional view thereof.
FIG. 3 is an end elevational view of a lock nut thereof.
FIG. 4 is an end elevational view of a gripper ring thereof.
FIG. 5 is an end elevational view of a body thereof.
FIG. 6 is a perspective view of a modified gripper ring thereof.
FIG. 7a is a side elevational view of the conduit coupling showing a first step of a first assembly procedure.
FIG. 7b is a side elevational view of the conduit coupling showing a second step of the first assembly procedure.
FIG. 7c is a side elevational view of the conduit coupling showing a third step of the first assembly procedure.
FIG. 8a is a side elevational view of the conduit coupling showing a first step of a second assembly procedure.
FIG. 8b is a side elevational view of the conduit coupling showing a second step of the second assembly procedure.
FIG. 8c is a side elevational view of the conduit coupling showing a third step of the second assembly procedure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
I. Introduction and Environment
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, the words "upwardly", "downwardly", "rightwardly" and "leftwardly" will refer to directions in the drawings to which reference is made. The words "inwardly" and "outwardly" will refer to directions toward and away from, respectively, the geometric center of the embodiment being described and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof and words of a similar import.
Referring to the drawings in more detail, the reference numeral 2 generally designates a conduit coupling for conduit sections 4 each having an end 4a. Without limitation on the generality of useful applications of the coupling 2, it is particularly well suited for fluid-tight applications. For example, fiber optic cables and other communications lines are commonly run through buried conduits. High density polyethylene (HDPE) material is commonly used for the buried conduits, sections of which can be joined by the coupling 2. However, the coupling 2 could also be utilized with other materials and in other applications.
The conduit coupling 2 generally comprises a body 6, a lock nut 8 and a gripper ring 10.
II. Body 6
The body 6 includes an external casing 12 with opposite ends 12a, an outer surface 12b, external threading 12c adjacent the ends 12a, and a medial section 12d between the external threading 12c. A plurality of longitudinally-extending, radially-spaced grips 12e protrude outwardly from the casing outer surface 12b. A casing bore 12f extends between the casing ends 12a. The casing 12 preferably comprises a relatively rigid material, such as polyvinylchloride (PVC).
A core 14 is fixedly secured within the casing bore 12f and includes opposite ends 14a which are generally flush with the casing ends 12a and thus form respective body ends 6a. The core 14 includes a passage 14b between and open at the core ends 14a. A medial, annular stop ring or lip 14c projects inwardly into the core passage 14b approximately midway between the core ends 14a.
A plurality of annular, sawtooth-shaped ridges 14d are positioned in generally parallel, spaced relation on each side of the stop ring or lip 14c and project inwardly into the core passage 14b. Each ridge 14d includes an annular edge 14e formed by the intersection of a proximate face 14f lying generally in a plane perpendicular to a longitudinal axis 16 and a distal face 14g which slopes proximally and inwardly to the ridge edge 14e. The core 14 preferably comprises a suitable elastomeric material, such as urethane.
III. Lock Nut 8
The lock nut 8 includes proximate and distal ends 8a,b and a lock nut passage 8c extending between and open at the ends 8a,b. The passage 8c includes an internally threaded proximate section 8d and a frusto-conical, distally converging distal section 8e. The lock nut passage 8c includes a proximate inside diameter ID. 1 and a lesser, distal inside diameter ID.2. The lock nut passage proximate and distal sections 8d,e are open at the lock nut proximate and distal end 8a,b respectively.
The lock nut 8 includes an outer surface 8f with a generally cylindrical proximate portion 8g having a plurality of grips 8h projecting outwardly therefrom and a frusto-conical, distally-converging outer surface distal portion 8i terminating at the lock nut distal end 8b.
IV. Gripper Ring 10
The gripper ring 10 includes proximate and distal ends 10a,b and a gripper ring passage 10c extending therebetween and open thereat. The gripper ring 10 has a frusto-conical, distally-converging outer surface 10d. The gripper ring 10 includes a proximate outside diameter OD.1 and a lesser, distal outside diameter OD.2. A plurality of annular ridges project inwardly into the gripper ring passage 10c and each includes an annular edge 10f. The gripper ring ridges 10e have configurations similar to the body core ridges 14d with proximate faces 10g generally perpendicular to the longitudinal axis 16 and distal faces 10h sloping inwardly and proximally from the ring passage 10c to the respective ridge edges 10f. The gripper ring 10 includes an expansion/contraction slot 10i extending between its ends 10a,b and open at the passage 10c and the outer surface 10d.
V. Modified Gripper Ring 110
A modified gripper ring 110 is shown in FIG. 6 and includes proximate and distal ends 110a,b and a passage 110c extending therebetween. A plurality of channels 110d extend longitudinally between the longitudinal gripper ring ends 110a,b and open into the passage 110c. The channels 110d are positioned in radially-spaced relation. The modified gripper ring 110 includes a plurality of ridges 110e which extend between respective adjacent pairs of channels 110d and have cross-sectional configurations similar to the ridges 10e. The channels 110d facilitate manufacture of the gripper ring 110 by reducing the amount of material required, and are particularly useful in connection with modified gripper rings 110 having relatively small-diameter passages 110c.
VI. Assembly and Operation
A first assembly method is shown in FIGS. 7a,b,c and involves the following steps:
1. The lock nuts 8 are loosened on the body 6 until a predetermined length (e.g., approximately one inch) of external threading 12c is exposed on each side.
2. An annular mark 18 is placed on each conduit section 4 a predetermined distance from its end 4a. For example, the marks 18 can be located approximately 31/2 inches from the ends 4a for mounting a typical conduit coupling 2.
3. The conduit section ends 4a are pushed into the lock nuts 8, through the gripper rings and into engagement with the core lip or stop ring 14c on either side.
4. The lock nuts 8 are then tightened. For example, a relatively secure application can be formed by tightening the lock nuts 8 by hand, and then tightening each of them one additional revolution with the aid of an appropriate wrench or other tool.
FIGS. 8a,b,c illustrate an alternative installation method involving the following steps:
1. The lock nuts 8 and the gripper rings 10 are slid over the conduit sections 4 and positioned in spaced relation from their respective ends 4a.
2. Annular marks 20 are then placed on each conduit section 4, for example, approximately two inches from their respective ends 4a.
3. Each conduit end 4a is then pushed into a respective body end 6a and into engagement with a respective side of the core lip or stop ring 14c.
4. The gripper rings 10 are then pushed proximally until their respective proximate ends 10a engage the body ends 6a.
5. The lock nuts 8 are then hand-tightened, and receive one additional revolution each applied mechanically to effect a secure coupling.
In operation, a relatively tight coupling engagement is formed between the conduit sections 4 and the conduit coupling 2. The sawtooth configurations of the core ridges 14d and the gripper ring ridges 10e cooperate to effectively resist pull-out of the conduit sections 4.
It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown. For example, the coupling 2 could be reconfigured for connecting a single conduit section 4 to another type of fitting or to a piece of equipment or other component in a system. Other fitting configurations could also be formed, such as T-connectors, Y-connectors, four-way connectors, etc.
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A conduit coupling for conduit sections includes a body with a rigid, outer casing and an elastomeric inner core. The core includes a passage with annular ridges for sealing the coupling on the conduit. A pair of lock nuts are mounted on the casing ends and each receives a gripper ring with gripper ring ridges for engaging the conduit. The lock nuts are threadably mounted on the casing for tightening the gripper rings against the conduit sections to resist pull-out.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a detaching driving mechanism for a comber.
2. Description of the Related Art
The lap combing cycle of a comber includes the steps of combing the front end of a lap gripped at the rear end thereof by a nipper of a combing cylinder, advancing the nipper to move the combed fleece to detaching rollers, and reversing the detaching rollers in synchronism with the advancement of the nipper. This action reverses fleece pulled out from the lap in the preceding combing cycle so that the fleece combed in the present combing cycle overlaps the fleece combed in the preceding combing cycle, rotating the detaching rollers in the normal direction to pull off the combed fleece combed in the present combing cycle from the nipper, and combing the rear end of the fleece with a top comb. The rotation of the detaching rollers in the normal and reverse directions is transferred from the cylinder shaft to synchronize the same therewith. That, is the detaching rollers are stopped or slightly rotated during the first half of a full turn of the cylinder shaft, and are rotated in the normal direction immediately after the rotation in the reverse direction during the second half of a full turn of the cylinder shaft.
Such a reciprocating rotational motion of the detaching rollers is produced by combining a constant-speed rotative input and a variable-speed rotative input applied to a differential gear mechanism connected to the input shaft of the detaching roller unit. The variable-speed rotative input is applied by an input means employing a cam (Japanese Examined Patent Publication (Kokoku) No. 44-17573) or an input means employing a linkage (Japanese Examined Patent Publication (Kokoku) Nos. 43-10728 and 53-15178).
The input means employing a cam can obtain an ideal curve of motion for piecing and pulling a fleece by properly designing the cam surface of the cam. Nevertheless, the cam groove of the cam is quickly abraded because the inertia of driving members for transmitting the motion of a cam follower to the detaching roller unit is concentrated on the line of contact of the cam follower and the cam groove when reversing and accelerating the detaching rollers, which produces the advancing and reversing motions, and the mechanism is also expensive because the width and shape of the cam groove must have a precise accuracy.
When the components of the input means employing a cam are operated at high operating speed, to improve the productivity, a large impact of the cam and the cam follower, when changing the direction of rotation of the detaching rollers from the reverse direction to the normal direction generates noise and vibrations, accelerates the abrasion of the cam surface, shortens the lifetime of the machine, and deteriorates the quality of the combed slivers. Therefore, the input means employing a cam is unable to operate at a high operating speed, and the productive efficiency of a machine employing such an input means is unsatisfactory.
Although a comber employing an input means using a linkage, namely, a camless comber, is able to operate at a relatively high operating speed, only motion curves H and J as shown in FIGS. 7 and 8 are possible, and thus the fleece delivered by the feed roller of the nipper cannot be fully drafted because a portion A of the curve of motion shown in the drawing, in particular, can be formed only with a large radius of curvature, and severe noise and shocks are liable to be generated. Moreover, the parts are abraded quickly and are liable to be damaged because, in a portion B in which the rotation direction is changed from the reverse direction to the normal direction, the motion of the change is sudden. Consequently, the quality of slivers of long fibers is unsatisfactory.
SUMMARY OF THE INVENTION
An object of the present invention is to enable a camless comber capable of operating at a high operating speed to obtain an ideal curve of motion which is equal to that obtained by a cam comber, by providing the camless comber with a novel linkage.
As shown in FIG. 1, by way of example, a constant-speed rotating motion R of a drive is transmitted through a V belt 2 and a driving pulley 1 to two driving systems D 1 and D 2 . The driving system D 1 converts the constant-speed rotating motion into a variable-speed rotating motion by a crank mechanism C 1 and a quadric crank mechanism L comprising links 26, 29 and 34, and transmits the variable-speed rotating motion through a shaft 35 to the input gear 39 of a differential gear mechanism G. The other driving system D 2 transmits the constant-speed rotating motion R through a crank mechanism C 2 to swing a swing lever 50 for a swing motion on a fixed pin 15 pivotally supporting the swing lever 50 at one end thereof. The swing motion of the swing lever 50 is transmitted through a lever and links to the planet gear unit of the differential gear mechanism, to reciprocate the planet gear unit. A connecting link 18 has one end pivotally joined to the swinging end of the swing lever 50 by a crank pin 17 and the other end pivotally jointed to the swinging end of a lever 20 pivotally supported on a joint pin 19. As shown in FIG. 3, a dead point on a line passing one terminal end b19 of the locus of circular motion of the lever 20 and the pin 15 supporting the swing lever 50 is located near the terminating end of the pin 17 on the swinging end of the swing lever 50, the pin 23 on the lever 20 is connected to the planet gear unit of the differential gear mechanism is connected by connecting link, and a dead point on a line passing a position b42 of the shaft 42 of the planet gear unit farthest from the pin 21 and the pin 21 on the lever 20 is located at the terminating end of the locus of circular reciprocating motion of a joint pin 23 on the swinging end of the lever 20.
A combined motion produced by combining the motion of the swing lever 50 in a dead zone of the swing motion and the motion of the lever 20 in a dead zone of the swing motion is transmitted to the planet gear unit of the differential gear mechanism to obtain a motion curve K having a bottom section equal to the sine curve of the original motion, and an upper section having a small radius of curvature representing a rapid reduction of the motion as shown in FIG. 5 is obtained for one cycle of operation of the swing lever 50.
The motion curve K is combined with a curve M produced by the driving system D 1 to obtain a motion curve N shown in FIG. 6.
The motion curve N of the detaching rollers has a section B of an unchanged sine curve for a reverse feed, and a section A having an ideal curve having a small radius of curvature for completing the forward feed of the fleece.
As apparent from FIG. 6, since the section B of the motion curve N of detaching rollers driven by the detaching roller driving mechanism of the present invention for a reverse feed deviates little from a sine curve, compared with motion curves H and J of the detaching rollers driven by the conventional detaching roller driving mechanism, a sudden change of motion of the detaching rollers can be avoided, so that noise and an exposure of component parts to impact can be avoided, and thus the abrasion of the component parts can be suppressed and damage to the same can be avoided. Since the radius of curvature of the section A is far smaller than that of the corresponding section of the curve of motion of the detaching rollers driven by the conventional detaching roller driving mechanism, the length L 3 of the fleece delivered during the rotation of the cylinder shaft from an angular position P 0 corresponding to the start of a forward feed to an angular position P 1 corresponding to the foremost position of the nipper, namely, the termination of the delivery of the fleece, is longer than the length (L 1 , L 2 ) of the fleece delivered during the same period by the detaching rollers driven by the conventional detaching roller driving mechanism, so that the fleece fed by the feed roller of the nipper can be fully combed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an essential portion of a detaching roller driving mechanism embodying the present invention;
FIG. 2 is a side elevation of the essential portion shown in FIG. 1;
FIG. 3 is a diagram of assistance in explaining the motion of a driving system (D 2 ) included in the detaching roller driving mechanism embodying the present invention;
FIG. 4 is a diagram of assistance in explaining the motion of another driving system (D 1 ) included in the detaching roller driving mechanism embodying the present invention;
FIG. 5 is a graph showing a curve representing the feed motion of detaching rollers driven by the detaching roller driving mechanism embodying the present invention;
FIG. 6 is a graph comparatively showing a curve representing the feed motion of detaching rollers driven by the detaching roller driving mechanism embodying the present invention, and curves representing the feed motions of detaching rollers driven by conventional detaching roller driving mechanism; and
FIGS. 7 and 8 are graphs showing curves of the feed motion of the detaching rollers of a conventional camless comber.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIGS. 1 and 2, a driving pulley 1 is connected to a drive, not shown, by a V belt 2. The pulley 1 is fixed to a driving shaft 3. A pinion 4 mounted on the driving shaft 3 engages a gear 5 mounted on a cylinder shaft 6 and a gear 8 mounted on an intermediate shaft 7. The intermediate gear 8 engages a gear 9 mounted on a crankshaft 10. The gears 5 and 9 have the same tooth number. The constant-speed rotating motion R of the driving pulley 1 is transmitted through the cylinder shaft 6 to a driving system D 1 and through the crankshaft 10 to a driving system D 2 .
Driving system D 1
A gear 25 and eccentric cams 31 are fixed to the cylinder shaft 6, and links 26 are supported rotatably on the cylinder shaft 6. A shaft 27 is supported on the free ends of the links 26. A gear 28 and links 29 are supported rotatably on the shaft 27. A pin 30 is fixed to the free ends of links 32 combined with the eccentric cams 31. The links 29, links 34 and a gear 33 are supported rotatably on the pin 30. A shaft 35 is supported for rotation in bearings, not shown, at a fixed position. Gears 26 and 27 are mounted fixedly on the shaft 35, and links 34 are mounted on the shaft 35 for swing motion relative to the shaft 35. The gears 25, 28, 33 and 36 are in continuous mesh, in that order. A gear 37 is in mesh with a gear 39.
Driving system D 2
A crankshaft 10 is fixedly provided with a crank 11, and a crank pin 12 revolves around the crankshaft 10 when the crankshaft 10 is rotated.
A block 16 is fixed to a frame, not shown, and a pin 15 is supported on the block 16. A swing lever 50 is supported for a swing motion on the pin 15. A connecting rod 13 has one end joined to the crank 11 by the crank pin 12 and the other end joined to the swing lever 50 by a joint pin 14.
When the crank 11 is turned, the swing lever 50 swings on the pin 15 so that the joint pin 14 and a joint pin 17 reciprocate between positions a14 and d14 and between positions a17 and d17, respectively, as shown in FIG. 3.
A block 22 is fixed to a frame, not shown, and supports a shaft 21. A lever 20 is supported pivotally on the pin 21 for a swing motion, and joint pins 19 and 23 are attached to the free ends of the lever 20. A connecting link 18 has one end pivotally joined to the joint pin 17 and the other end pivotally joined to the joint pin 19. A connecting rod 24 has one end pivotally joined to the joint pin 23 and the other end pivotally joined to the shaft 42 of a differential gear mechanism.
The joint pins 19 and 23, and the shaft 42 reciprocate between positions b19 and d19, between positions b23 and d23, and between positions b42 and d42, respectively.
The values of l 1 and l 2 (FIG. 2) are determined selectively to determine the radius of curvature of a section A of a curve of motion. For example, when the values of l 1 and l 2 are increased and the sizes of the related members are changed accordingly, the radius of curvature of the section A increases, and thus the curvature of the curve is reduced.
Differential Gear Mechanism G
A shaft 38 is supported for rotation in bearings, not shown, at a fixed position. Levers 41 are fixed to the shaft 38, and shafts 42 and 43 are supported fixedly on the levers 41. Gears 39 and 40 are supported rotatably on the shaft 38. A gear 44 is supported rotatably on the shaft 42, and the end of the connecting rod 24 is joined pivotally to the shaft 42. A gear 45 is supported rotatably on the shaft 43. Gears 39 and 44, gears 44 and 45 and gears 45 and 40 are meshed, respectively. The gears 39 and 45 are separated from each other. The gear 40 is in engagement with gears 46 and 47 fixedly mounted respectively on detaching rollers 48 and 49.
Action of the Driving System D 1
When the eccentric cams 31 rotate together with the cylinder shaft 6 in the direction of an arrow A 1 (FIG. 1), the pin 30 reciprocates between positions f30 and h30 as the centers of the eccentric cams 31 revolves through angular positions f31, g31, h31 and f31, whereby the shaft 27 is reciprocated between positions f27 and h27. The rotation of the cylinder shaft 6 is transmitted through the gears 25, 28, 33, 36, 37, 39, 44, 45 and 40 to the gears 46 and 47 to rotate the detaching rollers 48 and 49.
If the shaft 42 does not move, the surface feed distance of the detaching rollers 48 and 49 varies along a curve M (FIG. 5) with the rotation of the cylinder shaft 6.
Driving System D 2
The crankshaft 10 rotates at a rotating speed equal to that of the cylinder shaft 6 in a direction indicated by an arrow A 2 (FIG. 1) opposite to that of rotation of the cylinder shaft 6. As shown in FIG. 3, when the crankshaft 10 is rotated in the direction of the arrow A 2 to turn the crank pin 12 through angular positions a12, b12, c12, d12, e12 and a12, the joint pin 14 is reciprocated between positions a14 and d14 via positions b14, c14, d14 and e14, the joint pin 17 is reciprocated between positions a17 and d17 via positions b17, c17, d17 and e17, the joint pin 19 moves through positions a19, b19, c19, d19, e19, b19, a19, b19, c19 and d19, in that order, and the joint pin 23 moves according to the movement of the joint pin 19. At the same time, the shaft is reciprocated between positions b42 and d42.
When the difference between the respective lengths of the crank 11 and the connecting rod 13 is relatively small, the joint pin 14 moves at a relatively low speed in the vicinity of the position a14, and moves at a relatively high speed from a position after the position c14 to the position e14. When the crank 11 is at the angular position b12, the positions b19 and b17 and the pin 15 are aligned to locate the lever 20 at the dead point thereof, and the pin 21 and the position b23 and b42 are aligned to locate the shaft 42 at the dead point thereof.
Accordingly, while the crank 11 is turning from the position e12 via the position a12 to the position c12, the joint pin 23 moves from the position e23 via the position b23 to the c23, and the shaft 42 moves slightly in the vicinity of the position b42 and remains substantially stationary.
While the crank 11 moves from the position c12 via the position d12 to the position e12, the joint pin moves from the position c23 via the position d23 to the position e23, and the shaft 42 reciprocates between the positions b42 and d42.
The gear 44 is supported rotatably on the shaft 42, and the differential gear mechanism G comprises the gears 39, 44, 45 and 40. Therefore, the gear 40 is moved at a fixed speed ratio by the shaft 42 when the gear 39 is fixed, and the gears 46 and 47 is rotated by the gear 40 to rotate the detaching rollers 48 and 49. The surface feed distance of the detaching rollers 48 and 49 varies along a curve K (FIG. 5) during one full turn of the crank 11.
Composite Action of the Driving Systems
The driving systems D 1 and D 2 were interlocked so that the substantially horizontal section of the curve M representing the variation of the surface feed distance of the detaching rollers 48 and 49 as driven by the driving system D 1 and the substantially horizontal section of the curve K representing the variation of the surface feed distance of the detaching rollers 48 and 49 as driven by the driving system D 2 coincide with each other as shown in FIG. 5 to obtain a curve N by combining the curves M and K.
When the radius of curvature of a section B of the curve N is maintained equal to that of the corresponding section of the curve K (sine curve) to reduce the angle between slopes before and after reversing and to increase the stopping time of the shaft 42, the radius of curvature of a section of the curve K corresponding to a section A of the curve N can be reduced.
When the length of the lever 41 is reduced without changing the position of the shaft 38, the radius of curvature during the reverse operation is substantially the same, the angle between the slopes respectively in the normal operation and the reverse operation can be reduced, and thus the surface feed distance of the detaching rollers during rotation in the normal direction is increased.
The same effect and function can be obtained when the center distance between the pin 21 and the shaft 42 is fixed and the length of the lever 20 is increased.
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A differential gear mechanism for driving a detaching roller of a comber includes two driving systems. One of the driving systems converts constant-speed rotational motion into variable-speed rotational motion through a crank mechanism and a quadric crank mechanism. The variable-speed rotational motion is transmitted to the input shaft of the differential mechanism. The other driving system converts constant-speed rotational motion into swing motion by a crank mechanism, converts the swing motion into reciprocating motion by way of connecting rods and linkage, and transmits the reciprocating motion to a planet pinion of the differential gear mechanism. The feed motion curve of the detaching roller produced by the differential gear mechanism is an ideal curve similar to that obtained by an ideally designed cam comber.
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BACKGROUND OF THE INVENTION
The present invention relates to an automatic film loading camera capable of loading a patrone while a film end is wound around the patrone.
In cameras, with the advancement of automatic film loading techniques, an automatic loading mechanism has been widely employed. According to this mechanism, the rear cover of a camera is opened to put a patrone in a patrone chamber, the distal end of a film is extracted, and the rear cover is closed. Thereafter, when a shutter button is depressed, the film is automatically fed to the first frame. Recently, automatic film loading cameras capable of loading a film while the film end is wound around a patrone have been proposed. For example, Japanese Patent Laid-Open (Kokai) No. 62-165636 discloses a camera wherein a patrone is rotated by a patrone rotating mechanism in a direction to loosen a film, and the film end is guided to an exposing section along a guide surface formed on the inner surface of a patrone chamber. In addition, Japanese Patent Laid-Open (Kokai) No. 62-201428 discloses a camera in which the patrone rotating mechanism has an eccentric mechanism.
According to the former system, however, if a film end has a strong curling tendency, the film end is not necessarily inserted in the exposing section. In the latter system, since the eccentric mechanism is used, the number of components is increased, and the system is complicated.
SUMMARY OF THE INVENTION
The present invention has been made in consideration of the above situation, and has as its object to provide an automatic film loading camera capable of reliably loading a film with a simple construction.
In order to achieve the above object, there is provided an automatic film lading camera comprising a patrone chamber for housing a patrone, a rotating shaft which is engaged with a winding shaft of the patrone so as to rotate the winding shaft when the patrone is housed in the patrone chamber, detecting means for detecting an extraction state of a leader portion of a film, and rotating shaft driving means for rotating the rotating shaft in a direction to rewind the film upon loading of the patrone so as to rewind the film when the film is extracted by a predetermined length or more, and rotating the rotating shaft in a direction to wind up the film after the film is rewound to a predetermined position, wherein a film end is guided to an exposing section by rotating the patrone in the direction to wind up the film upon rotation of the rotating shaft in the film wind-up direction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing an automatic film loading camera according to an embodiment of the present invention;
FIG. 2 is a view showing a positional relationship between a leader end detecting switch, a patrone detecting switch, and a patrone;
FIGS. 3A and 3A are schematic diagrams showing a patrone chamber in a state wherein a lid of a patrone chamber and a cover of a camera main body are attached;
FIGS. 4A to 7B are views for explaining an operation of the embodiment;
FIG. 8 is a block diagram showing a control system of the embodiment;
FIG. 9 is a flow chart for explaining an operation of the control system; and
FIGS. 10 and 11 are schematic diagrams showing other embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described below with reference to the accompanying drawings.
FIG. 1 is a schematic top diagram of an automatic film loading camera according to an embodiment of the present invention, from which a cover of a camera main body is detached.
Referring to FIG. 1, reference numeral 1 denotes a camera main body; 2, a film exposing section; 3, a film take-up chamber; 4, photographing lens; 5, a shutter; 6, a film take-up reel; and 7, a film guide.
Reference numeral 8 denotes a patrone chamber in which a patrone 9 is housed; 10, a DX contact for detecting DX data appended to the patrone 9; 11, a leader end detecting switch for detecting the end of a leader L of a film; and 12, a patrone detecting switch for detecting the presence/absence of a patrone. The switches 11 and 12 are arranged below the patrone 9, as shown in FIG. 2. The leader end detecting switch 11 is turned on when a contact 11a is urged by an edge portion of a film. Therefore, when only the leader L of a film is extracted from the patrone 9, the switch 11 is OFF. When the film is further extracted, the switch 11 is turned on. When the patrone 9 is loaded in the patrone chamber 8, the patrone detecting switch 12 is ON. When the patrone 9 is not loaded, the switch 12 is OFF.
In addition, referring to FIG. 1, reference numeral 13 denotes a patrone press member for fixing the patrone 9 in position and preventing reversal of the patrone; 14, a patrone ratchet for guiding the distal end of a film to the film exposing section 2; 15, a film feed roller pair; 16, a photodiode; and 17, a film feed detecting LED. The photodiode 16 and the LED 17 are arranged at a position corresponding to the perforations of the leader L of a film. The photodiode 16 outputs pulse signals of a number corresponding to that of perforations passing therethrough. With this operation, the feed amount of a film can be detected (for example, in a 35-mm film, eight perforations correspond to one frame).
FIGS. 3A and 3B are views showing the patrone chamber 8 in a state wherein a cover 1a of the camera main body is attached, in which FIG. 3A is a side view and FIG. 3B is a plan view. A rewinding shaft 20 to be engaged with a spool (winding shaft) of the patrone 9 is arranged at the bottom portion of the patrone chamber 8. Reference numeral 21 denotes a lid of the patrone chamber 8; 22, a patrone press spring mounted on the lid 21; 23a and 23b, lock portions of the lid 21; 24a and 24b, lock pawls respectively engaged with grooves 23c of the lock portions 23a and 23b to lock the lid 21; 24c, a lock button; and 25, an opening cover for positioning a patrone upon loading.
FIG. 4A is a plan view showing the patrone chamber with the cover of the camera main body being detached. In FIGS. 4A to 7B, the wall of the patrone chamber is omitted.
Referring to FIG. 4A, reference numeral 24 denotes a lock lever having the lock pawls 24a and 24b and the lock button 24c. The lock lever 24 is guided by a guide pin 26 and can be moved in the lateral direction in FIG. 4A. The lock lever 24, however, is normally biased by a spring 27 in the right direction in FIG. 4A. Reference numeral 28 denotes a stop lever for stopping the lock lever 24 at an opening position. A stop lever 28 is biased clockwise about a shaft 30 by a spring 29. Reference numeral 30 denotes a coupling lever which is coupled to the patrone press member 13 and is biased counterclockwise about a shaft 32 by a spring 31; and 33, a patrone press lock. The coupling lever 30 is stopped by a stop portion 33a of the patrone press lock 33 (see FIG. 5A). The lock 33 is biased clockwise about a shaft 35 by a spring 34. Reference numeral 36 denotes an opening/closing switch for detecting opening/closing of the lid 21.
An elongated groove 14a is formed in the patrone ratchet 14. A shaft 37 formed on the main body 1 is inserted in the elongated groove 14a. The patrone ratchet 14 is biased counterclockwise about the shaft 37 by a spring 38.
The circumferential length of the patrone from a distal end 14c of the patrone ratchet 14 and the contact 11a of the leader end detecting switch 11 is set to be slightly smaller than the length of the leader L of a film. As will be described below, therefore, while the leader L of a film is clamped by the distal end 14c of the patrone ratchet (see FIG. 1), the switch 11 is kept ON. When the film end slips off from the distal end 14c of the ratchet 14 (see FIG. 5), the switch 11 is turned off. Although the lengths of the leader portions L slightly differ from each other depending on film manufacturers, they are determined by International Standards Organization (ISO 1007). The standard of a 135-mm film patrone is 47.5 to 38 mm. Therefore, if the circumferential length of a patrone from the distal end 14c of the ratchet 14 to the contact 11a of the switch 11 is set to be longer than the length of a leader portion of a film determined by the standard, a film of any manufacturer can be equally used.
The operation of the embodiment will be described below.
FIGS. 4A and 4B show a state wherein the lid 21 is opened, in which FIG. 1A is a plan view and FIG. 1B is a view showing the lock lever 24 and the stop lever 28 when viewed from a direction indicated by an arrow A in FIG. 4A.
When the lock lever 24 is slid in the left direction in FIG. 4A by depressing the lock button 24c with a finger while the lid 21 is closed (a state shown in FIG. 5B), a pawl 24d of the lock lever 24 is detached from a stop pawl 28a of the stop lever 28, and the stop pawl 28a is moved upward by the spring 29. Although the lock lever 24 is pulled rightward by the spring 27, the pawl 24d is stopped by the stop pawl 28a, and the lock lever 24 is stopped at that position (see FIG. 4B). As a result, the lock pawls 24a and 24b of the lock lever 24 are detached from the lock portions 23a and 23b, and the lid 21 is opened. At this time, an end 14b of the patrone ratchet 14 is urged by the lock lever 24, and the patrone ratchet 14 is rotated clockwise. As a result, the distal end 14c of the patrone ratchet 14 is retracted to a position separated from the patrone 9, thereby facilitating loading of the patrone 9.
A patrone loading portion has an opening shape shown in FIG. 3B and is constituted by the patrone chamber 8 and the opening cover 25. The opening cover 25 is supported by a main body cover 1a so as to be pivoted outward from the patrone chamber 8, and is normally brought into contact with the main body cover 1a by a spring (not shown). Since the movement of the patrone 9 during loading is limited to a direction shown in FIG. 4A, the positional relationship between the leader end detecting switch 11 and the leader L of a film can be reliably restricted.
The coupling lever 30 is locked by the patrone press lock 33, and the patrone press member 13 coupled to the coupling lever 30 stands by at a position separated from the patrone 9.
When the lid 21 is closed after the patrone 9 is loaded in the patrone chamber, a distal end 28b of the stop lever 28 is urged by the lock portion 23a (see FIG. 3B) of the lid 21 to be moved downward, as shown in FIG. 5B. As a result, the lock lever 24 is disengaged from the stop lever 28, and the lock lever 24 is pulled by the spring 27 to be slid rightward in FIG. 5B. Subsequently, the lock pawls 24a and 24b of the lock lever 24 are engaged with the lock portions 23a and 23b of the lid 21, and the lid 21 is locked. At the same time, the opening/closing switch 36 is turned on, and hence it is detected that the lid 21 is closed.
As shown in FIG. 5A, when the lock lever 24 is separated from the end 14b of the patrone ratchet 14, the patrone ratchet 14 is pulled by the spring 38 to be pivoted counterclockwise about the shaft 37, and the distal end 14c is brought into contact with the film wound around the patrone 9. At this time, the patrone press member 13 stands by at a position separated from the patrone 9.
When the length of the film leader L exceeds a predetermined value, the film is rewound (in a direction indicated by an arrow B in FIG. 5A) by the rewinding shaft 20 (see FIG. 3B). When the distal end of the film is separated from the patrone ratchet 14, the leader end of a film F is detected and the end detecting switch 11 is turned off. As a result, the rewinding shaft 20 is reversed to be rotated in the direction to wind up the film. When the length of the film leader L is less than the predetermined value, the rewinding shaft 20 is not rotated in the rewinding direction but is rotated in the winding direction. Although the film is tightly wound around the spool of the patrone, when the spool is reversed, the film is loosened and extends outward to a patrone cylinder, and the patrone 9 is rotated clockwise. At this time, the distal end of the film is guided by the patrone ratchet 14 and is reliably fed to the film feed roller pair 15 (see FIG. 1).
When the patrone 9 is further rotated, a film feed portion 9c is brought into contact with the distal end 14c of the patrone ratchet 14, thus pushing the patrone ratchet 14 upward against the biasing force of the spring 38, as shown in FIG. 6A. The patrone ratchet 14 is moved downward along the elongated groove 14a so as to push the patrone press lock 33 downward against the biasing force of the spring 34. As a result, the coupling lever 30 is released from the stop portion 33a of the patrone press member 33, and the patrone press member 13 urges the patrone 9. When the patrone 9 is fixed by the patrone press member 13, feeding of the film and reading of the DX data can be stabilized. At this time, the patrone is located at the film feed position.
When the distal end of the film is fed to the film feed roller pair 15, the film is extracted by the roller pair 15 and is fed to the film exposing section 2 through the photodiode 16 and the LED 17 so as to be taken up by the film taken-up reel 6. When the photodiode 16 detects that the film is fed by three frames, automatic loading is completed.
Subsequently, the film is wound up every photographing operation. When all the photographing operations are completed, the film is rewound. During this period, each component is kept in a state shown in FIG. 6A.
During a film rewinding period, the rewinding shaft 20 is rotated in the rewinding direction, and the patrone 9 tends to pivot toward the position assumed upon loading of the patrone 9 (shown in FIG. 4A). However, since the patrone press member 13 as a reversal preventing member is brought into contact with the film feed portion 9c of the patrone 9 so as to prevent reversal of the patrone. Therefore, the film feed portion 9c and the feed direction of the film are not shifted from each other, and the film can be reliably rewound.
FIGS. 7A and 7B show a state wherein the lid 21 is opened upon completion of a film rewinding operation. When the lock button 24c is depressed and the lock lever 24 is moved leftward, the lid 21 is kept open in the same manner as described with reference to FIG. 4A. At this time, if a shaft 9a of the patrone 9 is picked up and extracted, the opening cover 25 is pushed upward by an end portion 9b of the patrone 9 (see FIG. 3A), and the patrone 9 can be extracted while its direction is kept unchanged from the state obtained upon completion of rewinding. Therefore, the direction of the patrone 9 need not be changed, and the operation is facilitated. The coupling lever 30 is pushed by the lock lever 24 and is separated from the patrone 9. When the patrone 9 is extracted, the film feed section 9c of the patrone 9 is disengaged from the distal end 14c of the patrone ratchet 14, and the patrone ratchet 14 is pulled by the spring 38 to be moved upward. With this movement, the patrone press lock 33 is pulled by the spring 34 to be moved upward, and the coupling lever 30 is stopped by the stop portion 33a. As a result, each component is set in the same state as in FIG. 4A.
FIG. 8 is a block diagram showing a control system of the embodiment. The same reference numerals in FIG. 8 denote the same parts as in the above-described drawings.
Referring to FIG. 8, reference numeral 40 denotes a film feed control circuit for driving feed motors M1 and M2 through a coupling mechanism such as a gear. The film feed roller pair 15 and the reel 6 shown in FIG. 1 are driven by the motor M2 through a coupling mechanism such as a gear. Reference numeral 42 denotes a film feed amount detector, having the photodiode 16 and the LED 17 shown in FIG. 1, for outputting a signal corresponding to a film feed amount; 43, a DX code detector having the DX contact 10 (see FIG. 1); 44, a power source circuit; and 45, a CPU for controlling an operation timing of each circuit.
An operation of this control system will be described below with reference to a flow chart in FIG. 9.
When the lid 21 is opened and the patrone 9 is inserted in the patrone chamber 8 or the lid 21 is closed without inserting the patrone 9, the CPU 45 checks whether the opening/closing switch 36 is ON or OFF (F-1). If the switch 36 is ON, i.e., the lid 21 is closed, the CPU 45 checks the patrone detecting switch 12 (F-2). At this time, if the patrone 9 is not inserted, the switch 12 is kept OFF, and the sequence is ended. If the patrone 9 is inserted, the switch 12 in ON. As a result, the flow advances to the next sequence step, and the CPU 45 checks whether the leader end detecting switch 11 is ON or OFF (F-3). If the switch 11 is ON, the motor M1 is driven to drive the rewinding shaft 20 in the rewinding direction (F-4). When the switch 11 is turned off, i.e.g, the film F is rewound with the leader L being left outside the patrone and the distal end of the film F is separated from the distal end 14c of the patrone ratchet 14, the rewinding operation is stopped (F-6). If the switch 11 is OFF in step F-3, a rewinding operation is not performed. Subsequently, the motor M1 is reversed, the rewinding shaft 20 is driven in the winding direction (F-7), and at the same time, the motor M2 is rotated to drive the film feed roller pair 15 and the reel 6 in the winding direction (F-8). A predetermined time N is set in a counter T (F-9), and it is checked whether the predetermined N has elapsed (F-10). If NO is obtained in this step, it is checked whether a film feed is detected by the film feed amount detector 42 (F-11). That is, the photodiode 16 is kept ON while the film does not shield light from the LED 17. When the film is fed, perforations of the film shield light from the LED 17, and the photodiode 16 is repeatedly turned on and off. If a film feed is not detected, the counter T is decremented (F-12), and the flow returns to step F-10. If a film feed is detected, it is determined whether the film is fed by three frames (F-13). When the film is fed by three frames, the motors M1 and M2 are stopped (F-14 and F-15), thereby completing the automatic loading operation. If the predetermined time N elapses during a film winding period without detecting a film feed (F-10), driving of the winding roller pair and the reel is stopped (F-16 and F-17), and an abnormality alarm is provided by a certain display/alarm means (F-18).
In the above-described embodiment, the patrone ratchet 14 is used to guide a film end to the exposing section 2. However, a film end may be guided by the inner surface of the patrone chamber 8 to advance into the exposing section 2 without specially forming the patrone ratchet 14. If the guide member (patrone ratchet 14) as in the embodiment is arranged, a film end can be further reliably guided to the exposing section.
In some single-focus cameras, a lens barrel can be retracted in an exposing chamber of a camera main body while they are not used. If a lens barrel is housed in a camera to flatten its front surface, the camera can be easily handled while it is not used. However, when application of the present invention to a camera of this type is considered, since a photographing lens enters an exposing chamber, if a film is loaded with a lens barrel being housed and the film has a strong curling tendency, its leader portion may enter the exposing chamber to be brought into contact with the photographing lens, thus damaging the lens.
FIG. 10 is a schematic diagram showing a camera capable of solving such an inconvenience. The same reference numerals in FIG. 10 denote the same parts as in the above drawings.
Referring to FIG. 10, reference numeral 50 denotes a lens barrel which can be extracted/housed from/in a camera main body 1. In FIG. 10, a solid line indicates a position at which the lens barrel 50 is housed, and an alternate long and dashed line C indicates a position during a photographing operation. The lens barrel 50 is driven by, e.g., a lens barrel driving motor through a gear system.
If a film is loaded while the lens barrel 50 is kept at the housing position indicated by the solid line, the distal end of the film is brought into contact with a rear lens 51, and the lens may be damaged or an automatic loading error tends to occur. For this reason, during such a period, the lens barrel is caused to advance to a position indicated by an alternate long and dashed line D in FIG. 10 so as to move the lens, thereby preventing the film end from being brought into contact with the lens. An inclined surface 52 is formed at the read end portion of the lens barrel 50, and an inclined surface 53 having the same inclination as that of the surface 52 is formed at a portion on the main body side near the lens barrel 50. When the lens barrel 50 reaches the position indicated by the alternate long and dashed line D, the two surfaces 52 and 53 are located on the same plane. Therefore, the film end is guided by the surfaces 52 and 53 to be fed to a film take-up chamber 3. Each inclined surface preferably has an an inclination of 30 degrees or more with respect to the optical axis of the lens. Referring to FIG. 10, reference numeral 54 denotes a photographing lens; and 55, a shutter driving mechanism.
FIG. 11 shows a case wherein the present invention is applied to a zooming camera. The same reference numerals in FIG. 11 denote the same parts as in FIG. 10. In a zooming camera, since the inclined surfaces 52 and 53 each having an inclination of 30 degrees or more cannot be arranged as shown in FIG. 10 at a long focal point, a rear lens 51 is covered with a plane lens 56 to be protected from damages.
As has been described above, according to the present invention, the winding shaft of a patrone is temporarily rotated in the rewinding direction to rewind a film. When the film is rewound by a predetermined length, the winding shaft is rotated in the winding direction to shorten the extracted portion of the film to a predetermined length. Thereafter, the end of the film is guided to an exposing section. With this operation, even if a film end has a strong curling tendency, the film can be reliably fed to the exposing section of a camera. In addition, since a complex eccentric mechanism need not be used as in the conventional apparatus, film loading can be reliably performed with a simple arrangement.
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An automatic patrone loading camera includes a patrone chamber, a rotating shaft, a detector, and a control section. The patrone chamber houses a patrone. A film is inserted in the patrone in the winding shaft direction while the film is wound around the outer surface of the patrone. When the patrone is housed in the patrone chamber, the rotating shaft is engaged with a winding shaft of the patrone so as to rotate the winding shaft. The detector detects an extracted state of a leader portion of the film. The control section controls a rotating direction of the rotating shaft on the basis of a detection value from the detector.
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BACKGROUND OF THE INVENTION
The present invention is directed to a method for infeeding and outfeeding light into and out of a light waveguide provided with a resilient coating with a device having at least one flexional coupler with which a pressure is exerted onto the coating of the light waveguide in order to produce a curved contour in the waveguide for outcoupling light therefrom which outfed light is evaluated in a measuring instrument.
Measuring methods wherein flexional couplers are employed are disclosed, for example, in allowed U.S. patent application Ser. No. 07/394,114, filed Aug. 15, 1989, which issued as U.S. Pat. No. 5,078,489 on Jan. 7, 1992, whose disclosure is incorporated herein by reference thereto, and which claims priority from German Application 38 28 604, and also in U.S. Pat. No. 4,652,123, whose disclosure is incorporated herein by reference thereto. As presented in detail in these two references, particularly exact results can be achieved when work is carried out with two transmitters and two receivers and a plurality of measurements are successively implemented proceeding from both sides of the unit under test.
This and all similar measuring methods are based on the measuring principle that the coupling of the receiver means or receivers and of the transmitter or transmitters occurs with at least one so-called flexional coupler, whereby the light waveguide experiences a deformation in the measuring region. The light emerging in the deformation region is acquired by the receiver and is offered to the measuring equipment for evaluation. The light is picked up by a rigidly arranged light receiver, for example a photodetector, and is offered for evaluation. At the transmitter, the deformed region of the light waveguide is situated in the radiation field of a light source. The amount of light which is coupled in or, respectively, coupled out is dependent on the spatial allocation of the light waveguide proceeding bent in the coupling region to the light receiver and is also dependent on the refractive index condition and on the geometry of the optical boundary surface in the flexional coupler insofar as no matching of refractive index, such as by immersion or elastic material, occurs. In and of itself, the measuring instrument is operational immediately after the mechanical actuation of the flexional coupler, for example after the closing of a cover, and the measurements could be immediately undertaken.
It has been shown, however, that the values obtained become all the more imprecise when the earlier measurement is undertaken after the bending of the light waveguide into the coupling position. Investigations have lead to the conclusion that a chronological variation of the infeed or, respectively, outfeed efficiency apparently occurs, namely in that a deformation, for example a flowing of the coating of the light waveguide, occurs at the coating of the light waveguide under the pressure of the element, for example an arbor, bending beam or pin, that effects the mechanical bending of the light waveguide and that this mechanical modification, however slight, modifies the position of the deformed region relative to the light source or, respectively, relative to the light receiver, in one instance, and in another instance, influences the geometry of the optical boundary surface. One could, in fact, eliminate such error influences in that one waits until the deformation of the coating has ceased because the final condition of the radiation field in the direction toward the photodetector is reached and a chronological change of the measured signals can no longer be identified, given a constant transmission signal.
SUMMARY OF THE INVENTION
The object of the present invention is to improve the method of measuring so that the desired measured results can be obtained without unnecessary dead time, but, nonetheless, be reliable.
This object is inventively achieved in that the intensity of the outfed light is measured during the deformation of the coating occurring as a consequence of the exerted pressure and that this measurement is ended before the final condition of the pressure-dependent formation has been reached and that the final measured value obtainable in the final condition is identified by extrapolation from the measured values acquired during the deformation.
In this way, it is no longer necessary to wait until the coating of the light waveguide is compressed to its final condition including all the flowing. Instead, the measuring process can be begun immediately after the light waveguide is bent into the coupling position. As a result of the extrapolation occurring based on the acquired measured values, moreover, other respective differences, which may occur, are also taken into consideration, for example, measurements for light waveguides having different coating materials. In accordance with the method of the invention, these measurements can be quickly and reliably carried out and the measured result itself is available with high precision. The invention can, therefore, be employed with particular advantages where high measuring precision can be achieved from the very offset, such as, for example, in the measuring method disclosed in the above-mentioned copending U.S. patent application Ser. No. 07/394,114.
Other advantages and features of the invention will be readily apparent from the following description of the preferred embodiments, the drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the structure of a measuring instrument for the implementation of the method of the invention;
FIG. 2 is a cross sectional view with portions in elevation for purposes of illustration taken along the lines II--II of FIG. 1 at the beginning of deformation of the light waveguide;
FIG. 3 is a cross sectional view with portions in elevation similar to FIG. 2 after the end of the deformation;
FIG. 4 is a graph illustrating the outfed power versus time; and
FIG. 5 is a graph similar to FIG. 4 showing the measuring positions of the measuring points for an exemplary embodiment of the method of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The principles of the present invention are particularly useful in a measuring device MG that contains two flexional couplers, shown in cross section, to act on two light waveguides LW1 and LW2. These two light waveguides LW1 and LW2 have an optical medium OM disposed therebetween, which optical medium may be, for example, a splice, a transmission link, a coupler or the like, whose attenuation is to be identified.
It is assumed in the present example that the transmission signal is, likewise, coupled via a flexional coupler. However, it is also possible to couple the transmission signal into the end face of the light waveguide, such as LW1, at, for example, the end of the light waveguide. The flexional coupler SE of the transmission side comprises a lower part UTS and an upper part in the form of a cover DES, between which the light waveguide LW1 is guided. This coated light waveguide LW1 is pressed firmly by an arbor or cylindrical pin DOS into a depression in the lower part UTS and the waveguide LW1 is in contact in this depression with the incoupling means PKS, for example a light emitting diode. The coupler on the transmission side works in the form of a flexional coupler. However, it is also possible to implement the coupling in of the transmission side at the end face of the light waveguide LW1. As a result of the coupling, light is coupled into the light waveguide and travels in the direction of arrow P100 with a given intensity.
After passing through the optical medium OM, a part of the transmission signal P100 is coupled out via the reception coupler EM, which, likewise, is a flexional coupler in the form of an arbor DOE that presses the light waveguide LW2 against a depression in the lower part UTE of the coupling means at the reception side. The arbor DOE is contained in the hingeable cover DEE and the light waveguide LW2 is firmly pressed against the lower part UTE when the cover DEE is lowered. An adequately firm pressing of the light waveguide LW2 occurs. An adequately high pressure PR is required in order to insure the defined position of the waveguide LW2 in the coupling region. The light, which is emerging from the light waveguide LW2, due to bending, is to be picked up by a reception means, for example a photodiode PDE that is stationarily arranged in the coupling region and is dimensioned and aligned so that it picks up an optimum quantity of the emerging light. The optimization of the light-sensitive reception means PDE is, thus, designed for the final condition, for example less light is picked up in a transition region wherein the deformation of the coating of the light waveguide has not yet been completed than with a pick-up in a "steady state" with the finished deformation.
To explain the relationships, reference is made to FIG. 2. The light waveguide LW2 is being pressed against the lower part UTE by the arbor DOE, whereby the arbor DOE just touches the surface of the coating CT of the waveguide. Since an adequately great pressure must be exerted, as indicated by the arrow PR, a flowing or, respectively, deformation of the coating CT will occur, given a somewhat longer-lasting influence of the arbor DOE. The coating CT will assume the distribution in its ultimate condition that is shown in FIG. 3 by the coating CT1, in which a part of the coating material has migrated at the top and bottom and has been pressed into the free region or gap region between the arbor DOE and the lower part UTE. The non-uniform distribution of the coating material, as illustrated by the deformed coating CT1, will, thus, occur overall. Although only the coupling at the receiver has been referenced here for the explanation, the same considerations, of course, are also valid for the coupling in the transmission side, wherein the arbor DOS, the light waveguide LW1 and the deformation of the coating thereof will occur.
Exact measurements in the final condition could, thus, only be implemented when the coating has reached the ultimate condition referenced CT1. This will occur, roughly, in the order of magnitude of 1 to 5 minutes, given current standard coatings.
In order to avoid having to wait this length of time, which is the fiber specific dead time, measurements according to the present invention are begun immediately after the closing of the covers DEE and DES of the coupling EM and SE, respectively. The chronological curve of the reception level is acquired, for example by sampling individual measuring points at short time intervals with the sample and hold circuit SUH of FIG. 1. The measured values PS at each of these intervals are then conducted to a calculating means COM, for example a microcomputer, which values PS are derived from the reception signal in this way. This calculating means COM calculates a non-linear function from the supplied measured values PS by regression and obtains a final value PSE, which is expanded therefrom by extrapolation. The value to be displayed is derived from this extrapolated value PSE, which is acquired taking the material characteristics of the fiber coating into consideration, and this value is displayed to the operator on a display means DP. A common clock generator CS controls the chronological execution of a drive LA at the transmission side and the sample and hold circuit SUH at the reception side.
What is referred to as a non-linear regression, which shall be forth in greater detail below with reference to an example, is especially suited for the non-linear extrapolation.
A curve CP of the measured level P101 upon incorporation of the flow of the deformation of the light waveguide coating is shown in FIG. 4, with the increase value being plotted against time t. The final value, i.e., after the conclusion of the flow or, respectively, of the deformation, of the quantity P101E is only achieved after a relatively long time and the illustrated curve corresponds to the course of an e-function. If one wishes to measure precisely, one would, thus, have to wait at least until the time te (dead time) has passed, for example until the curve CP has largely approximated the value P101E.
By contrast, work in the invention is completely different, for example the measuring procedure is begun immediately after the closing of the coupling means EM or, respectively, SE of the receiver and/or of the transmitter. The measurements thus occur in a region wherein the arbor DOE and/or DOS of FIG. 1 has not yet reached its ultimate position. Measurement is, thus, already carried out before the deformation process of the coating has ended and this, of course, yields the configuration shown in FIG. 3 after a number of minutes. The measuring time tm itself is relatively short at a rate significantly shorter than the dead time te of FIG. 4 and, for example, amounts to only 10 seconds.
The curve CP can be described as the following equation:
y=a(1-e.sup.-t/b) (1)
When it is assumed that the level values y1, y2. . . y5 of FIG. 5 were obtained in succession for the various temporal values t1, t2. . . t5 within the short measuring time tm, namely according to the following table:
______________________________________t1 = 1 t2 = 2 t3 = 3 t4 = 4 t5 = 5 secondsy1 = 1.0 y2 = 1.65 y3 = 2.1 y4 = 2.4 y5 = 2.6 (V)______________________________________
then the region of the curve CP obtained or acquired by the measured value y1 through y5 enables an identification of the coefficients a, b, particularly on the basis of a non-linear regression. In this example, approximately a=3 and b=2.5 occurs with a regression according to the method of least error square (the algorithm for this is described in Dr. Marquardt: "An Algorithm for at Least Square Estimation of Non-Linear Parameters", J. Soc. Indust. and Appl. Math., Vol. 11, No. 2, 1963).
The calculated function of the curve CP, thus, reads:
y=3(1-e.sup.-0.4t).
The final value ye=3 is derived therefrom for the time t→∞ as the non-linear extrapolated value, i.e., corresponding to P101E in FIGS. 4 and 5.
Instead of the above-described, non-linear regression, the coefficients a and b of the function y can also, for example, be calculated by a linear approximation of the e-function in the measuring interval. The measuring interval must thereby be selected relatively short in that, for example, only the measured value y3 through 65 are employed. By linear regression, one first obtains a straight line having the equation:
y.sub.1 =a.sub.1 +b.sub.1 ·t
wherein a 1 =1.367 and b 1 =0.25 for these values. In the middle of the interval under consideration (for t=4), this straight line has the function value y 1 =2.367 and the slope y' 1 =0.25.
The sought function will have the form:
y=a(1-e.sup.-t/b)
is then to be selected so that it has the same value and the same slope for t=4 as the straight line y 1 . This leads to two non-linear equations, which are: ##EQU1##
After solving the equation system and inserting the values of y 1 , b 1 and t, one, thus, obtains b=2.6 and a=3.03. The calculated function for CP will then read:
y=3.03(1-3.sup.-0.385t)
and the extrapolated final value is ye=3.03.
The approximation method can be implemented with less calculating outlay than the non-linear regression, but supplies less precise results.
On the basis of the extrapolation, relatively exact values are, thus, obtained overall that largely precisely describe the final condition (after the end of the flowing, as illustrated in FIG. 3), so that one need not wait until after the final condition has, in fact, been reached (after the time te) and that the short time tm already suffices for the measurement.
Although various minor modifications may be suggested by those versed in the art, it should be understood that we wish to embody within the scope of the patent granted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art.
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During an initial pressure application on a light waveguide with a coating, which waveguide is subjected to a flexional coupling, deformation of the coating will occur and the value of an outfed light from the light waveguide will change as the deformation changes. The final intensity of the outfed light is obtained during the deformation of the coating by a process of extrapolating the final value from the initial measured values occurring during the initial deformation of the coating.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention generally relates to the construction of dynamic load resistant building equipment. More particularly, the present invention relates to a device that dissipates energy during a major dynamic event. Further, the invention relates to a device that limits the loads being transmitted to the parts of the structures that are difficult to repair or replace. The invention relates to a device that may undergo plastic deformation to limit the loads levied on a structure during a dynamic event. The present invention may also be a load-limiting device that can be replaced and/or removed after plastic deformation.
[0003] 2. Description of the Prior Art
[0004] The response of buildings to major seismic events is often of sufficient magnitude to induce inelastic behavior of many components within the building. The inelastic behavior and/or characteristics displayed by the building may take the form of local yielding, cracking, buckling and fracturing of structural members. Often, the damage done to a building during a dynamic event is so severe that it jeopardizes the integrity of the entire building and/or the building must be destroyed to insure public safety.
[0005] A direct consequence of the acceptance of inelastic response of a building during major earthquakes is the possibility of significant damage being incurred during the seismic event. The cost of repairing the damage then becomes a component in the life cycle cost of the building. A well-documented comparison in the response of two difference buildings to an earthquake in Managua in 1972 highlighted the costs of repairing the damage done during a seismic event. (1)
[0006] One of two buildings observed in the comparison utilized a concrete shear wall lateral load carrying system. The concrete shear wall lateral load carrying system was able to withstand the seismic loads with modest damage while an adjacent building used a moment-resistant frame to withstand the lateral loads induced during the earthquake. This was believed to be a ductile system that provided a reliable method for avoiding catastrophic building failure. The building in question did not fail catastrophically but suffered extensive damage associated with inelastic response that proved to be too extensive to be repaired economically. In fact the building using the moment-resistant frame to withstand the lateral loads had to be abandoned and destroyed.
[0007] A structural system that relies on beneficial inelastic action during seismic response was proposed by Popov et al. (2) In that case, a modification was applied to the traditional braced frame building system. The modification of the commonly used braced frame system consisted of installing cross-braces into the building frame with marked end offsets. This had the effect of inducing increased bending stresses in the beam and, ultimately, plastic hinges at the high stress locations. The presence of these hinges may provide a method for dissipating energy in a ductile way. However, the damage associated with the formation of plastic hinges in the beams of the building is very difficult and expensive to repair.
[0008] Another method that has been used to limit structural response during a seismic event adopts a hydraulic damper at strategic locations throughout the frame. (3) This provides a method for dissipating energy from a seismic event in a controlled and engineered way. The disadvantage of this method is that it is very difficult to incorporate energy dissipation similar in magnitude to plastic hinge mechanisms without major cost and inconvenience for older, established building structures. Moreover, incorporating the hydraulic damper has many packaging ramifications associated thereto. Still further, the need for periodic routine maintenance of these hydraulic damper systems in locations throughout the building is a serious disadvantage to this type of system as the routine maintenance may be difficult to perform and costly to complete.
[0009] U.S. Pat. No. 6,651,395 discloses a device that limits relative movement of two elements of a structure by absorbing the deformation energy. The device absorbs the energy by plastic deformation using a method by which the deformable material is restrained by a stronger and stiffer guiding material. The performance of the device is dependent on the precise shape of the guiding component in the device.
SUMMARY OF THE INVENTION
[0010] The present invention provides a dampening system for bracing the frame of a structure during a dynamic event. More particularly, the present invention relates to a load-limiting device for braced frames. Moreover, the present invention relates to a load-limiting device that may be placed in a braced frame that may have plastic deformation characteristics. Further, the present invention relates to a load-limiting device that may be placed in a braced frame that may plastically deform during a dynamic event and wherein the load-limiting device may preserve a structure from extensive and/or comprehensive damage to the structure after a dynamic event. Moreover, the present invention relates to a load-limiting device that may plastically deform in response to a dynamic event and that may be positioned within a braced frame structure. The load-limiting device may be easily removed and replaced after plastic deformation with another non-plastically deformed load-limiting device.
[0011] To this end, in an embodiment of the present invention, a load-limiting device for use in a braced frame is provided. The device for use in the braced frame has a braced frame structure having at least one beam and a first column and a second column. Moreover, the present invention has a load-limiting device releasably attached to a brace wherein the brace is attached to the braced frame structure. Further, the present invention has a connection means releasably attached to the load-limiting device. Additionally, the invention has a load-limiting device providing biaxial support for the braced frame wherein said load-limiting device is being able to dissipate energy in the braced frame structure.
[0012] In an embodiment, the load-limiting device is able to plastically deform in response to a load applied thereto.
[0013] In an embodiment, the load-limiting device is able to plastically deform in response to load wherein said load-limiting device has elasto-plastic properties to allow for formation of a plastic hinge mechanism.
[0014] In an embodiment, the load-limiting device can withstand small loads without plastic deformation based on elasto-plastic properties.
[0015] In an embodiment, the load-limiting device is constructed of a plastic material.
[0016] In an embodiment, the load-limiting device is constructed of a metal based elasto-plastic material.
[0017] In an embodiment, the load-limiting device is attached to said connection means wherein said connection means couples the load-limiting device and the brace in the braced frame structure.
[0018] In an embodiment, the load-limiting device has an opening thereon for attachment of the connection means to the brace.
[0019] In an embodiment, the load-limiting device has a plurality of connection points wherein said connection points are releasably attached to said connection means.
[0020] In an embodiment of the present invention, a dynamic load, load-limiting device system for a braced frame is provided. The system has a braced frame structure having at least one beam and a first column and a second column. The system further has a brace frame structure having at least one brace. Moreover, the system has a load-limiting device releasably attached to said brace wherein said brace attaches to said at least one beam and a connection means detachably coupled to said at least one brace and said load-limiting device. Moreover, the system has the load-limiting device in connection with said brace and said braced frame structure to dissipate energy when high lateral loads are placed on the braced frame structure.
[0021] In an embodiment, the load-limiting device may undergo plastic deformation when subjected to high lateral loads.
[0022] In an embodiment, the load limiting device is releasably attached to said brace wherein said brace is attached to said at least one beam.
[0023] In an embodiment, the load limiting device is releasably attached to said brace wherein said brace is attached to said two columns.
[0024] In an embodiment, the load-limiting device when subjected to a dynamic event may yield to form hinged mechanisms to dissipate energy from the braced frame structure during a dynamic event.
[0025] In an embodiment, the load-limiting device may be removed from the braced frame structure after a dynamic event wherein the load-limiting device has undergone plastic deformation and further wherein a new un-deformed load-limiting device may be inserted into the braced frame structure to replace a plastically deformed load-limiting device.
[0026] In an embodiment of the present invention, a method for using a load-limiting device system is provided. The system comprising the steps of: providing a braced frame having at least one beam and two side columns; integrating at least one brace into the braced frame; integrating a load-limiting device into the system; and providing a connection means to connect the load-limiting device to the braced frame wherein a connection means is releasably attached to said load-limiting device and said brace.
[0027] In an embodiment, the method further comprises the step of: placing the load-limiting device into an existing braced frame with a connection means.
[0028] In an embodiment, the method further comprises the step of: providing the device with an indicator means wherein said indicator means allows for assessment of plastic deformation of the load limiting device.
[0029] In an embodiment, the method further comprises the step of: periodically checking said load-limiting device for the existence of plastic deformation after dynamic activity.
[0030] In an embodiment, the method further comprises the step of: removing a plastically deformed load-limiting device from a braced frame after a dynamic event.
[0031] In an embodiment, the method further comprises the step of: replacing a plastically deformed load-limiting device from a braced frame with an un-deformed load-limiting device after a dynamic event.
[0032] It is, therefore, an object of the present invention to provide a load-limiting device, a system and a method of using the same.
[0033] Another object of the present invention is to provide a load-limiting device and a method for using the same, for use in structural applications.
[0034] Still another object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device may be integrated into a structural frame.
[0035] Yet another object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device may be integrated into a structural frame having an X- or K-brace.
[0036] Still another object of the present invention is to provide a load-limiting device and a method for using the same wherein a frame incorporating the load-limiting device may withstand lateral seismic loads.
[0037] Yet another object of the present invention is to provide a load limiting device and a method for using the same wherein the load limiting device may withstand high dynamic loads.
[0038] Another object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device may be compressed.
[0039] Yet another object of the present invention is to provide a loading limiting device and a method for using the same wherein the load-limiting device may withstand high seismic stress.
[0040] Another object of the present invention is to provide a load limiting device and a method for using the same wherein the load-limiting device may not undergo plastic deformation during low dynamic loads.
[0041] Still another object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device may have a plurality of connection points to connect to a typical braced frame.
[0042] An object of the present invention is to provide a unique load-limiting device and a method for using the same wherein the load-limiting device may have a plurality of connection points and an opening therein.
[0043] A further object of the present invention is to provide a load-limiting device and a method for using the same wherein at low load levels the device will experience stresses within the linear elastic range for the material used in the load-limiting device wherein the load limiting device will not undergo plastic deformation.
[0044] Still another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may be comprised of metal.
[0045] Yet another object of the present invention is to provide a loading limiting device and a method for using the same wherein the device may be comprised of a high strength material.
[0046] Another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may be comprised of any material capable of undergoing plastic deformation.
[0047] Yet another object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device may have a design that avoids local stress risers that may prematurely yield or fatigue with normal loads on a structure.
[0048] Still another object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device may use materials that have elasto-plastic stress strain properties.
[0049] Another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may have elasto-plastic stress strain properties similar to low-carbon steels.
[0050] A further object of the present invention is to provide a load-limiting device and a method for using the same wherein the performance of the load-limiting device may not be impaired by strain-hardening of the material in the active part of the device.
[0051] Yet another object of the present invention is to provide a load-limiting device and a method for using the same that as deflections in the structure are increased, yielding of the device avoids a significant increase in internal loads in the building structure itself.
[0052] Another object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device may form a plastic hinge mechanism when subject to loads.
[0053] An object of the present invention is to provide a unique load-limiting device and a method for using the same wherein the device may have a plastic hinge mechanism that may be induced during plastic deformation of the load-limiting device.
[0054] Still another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may have a plastic hinge mechanism wherein the plastic hinge mechanism may deform in response to a dynamic event.
[0055] Another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may be used in buildings, vehicles, aircraft, furniture, roller-coasters and other structures.
[0056] An object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may be used for bridges, office or industrial buildings, homes, heavy lifting equipment and/or any structure that experiences severe dynamic loads and/or any structure prone to seismic events.
[0057] Yet another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may be able to dissipate energy during a dynamic and/or seismic event.
[0058] Still another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may be able to dissipate energy during a dynamic event by further yielding of the material in the plastic hinges of the load-limiting device.
[0059] Another object of the present invention is to provide a load-limiting device and a method for using the same wherein the plastic moment of a section of the device may be proportional to the plastic section modulus and the yield strength of the material used.
[0060] A further object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may be able to dissipate energy during many load reversal cycles without premature failure due to cracking and/or buckling.
[0061] Yet another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may undergo reverse yielding and allow for a plastic hinge mechanism to be compressed.
[0062] Still another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may be manufactured with a plurality of load capacities depending on the strength requirements of the load-limiting device.
[0063] Still another object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device strength may vary from story to story in the structure in which it is placed.
[0064] An object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may be able to maintain ductility during severe load-limiting cycles.
[0065] Yet another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may be checked after an earthquake of moderate to severe intensity.
[0066] Still another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may be easily removed from the structure if plastic deformation of the device is found.
[0067] Another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may be easily removed from the structure of a building after a seismic event if plastic deformation of the device is detected.
[0068] Another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may be removed from the structure after a dynamic event if plastic deformation of the device is detected and further wherein a new load-limiting device may be inserted into the place of the plastically deformed load-limiting device.
[0069] Yet another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device may be configured with a variety of variations depending on the type of structure for which the device is to be fitted.
[0070] Still another object of the present invention is to provide a load-limiting device and a method for using the same wherein the device is interchangeable with new load-limiting devices.
[0071] Yet another object of the present invention is to provide a load-limiting device and a method of using the same wherein the device may be connected to the X-brace of a building by a connection means.
[0072] Another object of the present invention is to provide a load-limiting device and a method of using the same wherein the load-limiting device may be connected to the bracing of the building by a connection means where the connection means may be a mechanical connection using high strength fasteners.
[0073] Yet another object of the present invention is to provide a load-limiting device and a method of using the same wherein the load-limiting device may be connected to the beam and/or column of a structure by a connection means wherein the connection means may be any means of connecting the load-limiting device to the braced frame structure.
[0074] A further object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device may be rectangular in shape.
[0075] Still another object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device may be square in shape.
[0076] Another object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device may be oval in shape.
[0077] An object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device may be circular in shape.
[0078] Still another object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device may be connected to the existing brace of constructed building to stabilize and dissipate energy from a dynamic event.
[0079] Yet another object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device may be applied externally to brace a building frame.
[0080] Another object of the present invention is to provide a load-limiting device and a method for using the same wherein the load-limiting device may be used on internally braced structures.
[0081] Still another object of the present invention is to provide a load-limiting device and a method of using the same wherein the device may be connected to the brace of a structure using a connection means wherein the connection means may be any mechanism to connect the device to the beam of the structure.
[0082] These and other objects of the invention will become more clear when one reads the following specification, taken together with the drawings that are attached hereto. The scope of protection sought by the inventors may be gleaned from a fair reading of the Claims that conclude this specification.
[0083] Additional features and objects of the present invention are described in, and will be apparent from, the detailed description of the presently preferred embodiments and from the drawings.
DESCRIPTION OF THE DRAWINGS
[0084] FIG. 1 is a perspective view of a load-limiting device attached to the frame of a structure in an embodiment of the invention;
[0085] FIG. 2 is a schematic representation of the prior art braced frame of a building which does not include a load-limiting device;
[0086] FIG. 3 a is a close-up schematic representation of the prior art braced frame of a structure which does not include a load-limiting device;
[0087] FIG. 3 b is a close-up schematic representation of a braced frame having a load-limiting device in an embodiment of the present invention;
[0088] FIG. 4 is a schematic illustrating a structure and the stresses involved during a dynamic event wherein the load-limiting device is illustrated in a previous state before dynamic activity and during a dynamic state;
[0089] FIG. 5 illustrates the plastic deformation undergone by the load-limiting device in an embodiment of the present invention;
[0090] FIG. 6 is an illustration of the load deflection sequence for the load-limiting device during a dynamic event in an embodiment of the present invention;
[0091] FIG. 7 is an illustrative view of a plurality of different load-limiting device geometries for various bracing configurations in an embodiment of the present invention;
[0092] FIG. 8 is an illustrative view of potential geometries for the load-limiting device in an embodiment of the present invention; and
[0093] FIG. 9 is a schematic of the external surface of a structure having external load-limiting devices in an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0094] Turning now to the drawings wherein elements are identified by numbers and like elements are identified by like numbers throughout the 10 figures, the invention is depicted in FIG. 1 and shows a load-limiting device 1 for dissipating energy during a dynamic and/or seismic event. In a preferred embodiment of the present invention, the load-limiting device 1 may have a first side 3 , a second side 5 , a third side 7 and a fourth side 9 . It should be understood that although a preferred embodiment of the present invention illustrates a four sided object, the invention is in no way limited to a load-limiting device 1 having four sides. On the contrary, the invention includes inter alia, load-limiting devices as illustrated in FIG. 8 that may be manufactured and used in a plurality of different shapes and sizes to accommodate various structural applications. In a preferred embodiment, the structural application is for a building. The load-limiting device 1 in a preferred embodiment may have a first connection point 11 , a second connection point 13 , a third connection point 15 and a fourth connection point 17 .
[0095] As illustrated in FIG. 1 , the load-limiting device may have a connection means 19 that may attach the load-limiting device 1 to a brace 21 means that may attach to the frame (not shown) of the structure. The connection means 19 may attach to an opening 23 on the load-limiting device 1 that may allow for connection means 19 to be attached through opening 23 and ultimately connected to the frame of the building by brace 21 . The connection means 19 may be any means of connecting the load-limiting device 1 to the frame of the building and/or structure. The connection means 19 may be releasably attached to the load-limiting device 1 and/or it may be an external portion that may be attached to the load-limiting device 1 . The connection means may be a high strength bolt that passes through the opening 23 of the load-limiting device 1 that allows the brace to be clamped to the load-limiting device 1 . The connection means 19 may also be a weld, adhesive bonding, clevis, shackle and/or any other means for connecting the load-limiting device 1 to the brace 21 of the structure 27 .
[0096] FIG. 2 illustrates the prior art braced frame system 25 often employed in a structures 27 that is prone to dynamic and/or seismic activity. The braced frame system 25 consists of attaching a brace 21 to the building frame beams 29 with little or no joint eccentricity. As illustrated in FIG. 3 a , the building frame may have a first beam 31 and a second beam 33 and a first column 35 and a second column 37 that may be connected to a brace 21 which extends from a first beam 31 to a second beam 33 . The braced frame system 25 tends to be a reliable method of dissipating energy during a dynamic event without being subject to member yielding. A problem with the braced frame system 25 is that during a severe dynamic event, high stresses may be imposed in the frame beams 29 and if the stresses are high enough, they can cause serious or irreparable damage to the structure. The mechanism associated with the damage may be brittle in nature and lead to catastrophic failure.
[0097] FIG. 3 a further illustrates the prior art typical bay in the braced frame systems 25 used in the construction of a structure 27 in an attempt to accommodate lateral loads when a structure 27 is subjected to a dynamic load. As FIG. 3 a illustrates, the brace 21 is attached to the first beam 31 and the second beam 33 of the structure 27 and when subjected to a dynamic load, the brace 21 may stretch to accommodate these loads. However, if the loads imposed on the brace 21 are too great, severe damage may be caused to the structure 27 and extensive repairs must be made to repair and/or reconstruct the structure 27 .
[0098] FIG. 3 b illustrates the same braced frame system 25 that may include the load-limiting device 1 contained therein. The braced frame system 25 consists of a first beam 31 connected to both a first column 35 and a second column 37 . The first column 35 and the second column 37 are connected to a second beam 33 that is parallel to the first beam 31 . A brace 21 may be connected to the frame structure within the interconnected beams 31 , 33 and columns 35 , 37 . The brace 21 may be connected to a first beam 31 and extend to the second beam 33 . In another embodiment, the brace 21 may extend from a first column 35 of the braced frame system 25 to a second column 37 of the braced frame system 25 . The load-limiting device 1 illustrated in this embodiment is rectangular in shape. However, any shape and/or size of load-limiting device 1 may be contemplated. The load-limiting device 1 may be placed at a point on the brace 21 that may be connected to the beams 31 , 33 and/or the columns 35 , 37 of the structure 27 . In a preferred embodiment, the load-limiting device 1 may be positioned centrally between a plurality of braces 21 in the structure 27 . Moreover, the load-limiting device 1 may be located centrally between the interconnected beams 31 , 33 and columns 35 , 37 . The load-limiting device 1 may be connected to the brace 21 by a connection means 19 . The load-limiting device 1 , during dynamic loading of the braced frame structure 27 may undergo plastic deformation to dissipate and/or absorb dynamic energy. Moreover, after a dynamic load has been placed on a load-limiting device 1 and the load-limiting device 1 has undergone plastic deformation, the load-limiting device 1 may be removed from the structure 27 by disengaging the connection means 19 , removing the load-limiting device 1 and replacing the used, elasto-plastically deformed load-limiting device 1 with a new load-limiting device that has not undergone plastic deformation.
[0099] FIG. 4 illustrates a schematic of the deformation process of the modified braced frame system that shows the brace forces 41 acting on the load-limiting device 1 . FIG. 4 further illustrates the inertia force 43 placed on a structure 27 and more specifically on the beam 31 , 33 and braces 21 of the structure 27 during a dynamic event. If and when a structure 27 is exposed to a dynamic event, the inertia force 43 induced by the dynamic event would act on the braces 21 , the beams 31 , 33 , the columns 35 , 37 and the load-limiting device 1 . FIG. 4 further illustrates the inertia forces 43 induced by the dynamic event causing the braces 21 and the load-limiting device 1 to move in relation to the inertia forces 43 placed on the structure 27 . The deformed geometry of FIG. 4 illustrates that plastic hinges 45 have formed at the corners of the load-limiting device 1 . In the plastically deformed configuration, the loads carried by the load-limiting device 1 and the associated braces 21 may not be increased appreciably. The shear force being carried by the braced bay may not increase even when the bay inter-story sway increases. This behavior limits the magnitude of the loads acting on other parts of the frame including the beams 31 , 33 and the columns 35 , 37 , avoiding the possibility of fracture of other less ductile components in the braced frame system 25 .
[0100] FIG. 5 illustrates the load-limiting device 1 during a severe loading event in which parts of the load-limiting device 1 have plastically deformed. The regions that have deformed plastically are generally referred to as a plastic hinge 45 , because of the change in angle from one side of the plastic hinge 45 to the other side. The plastic hinge 45 is bounded on one side by a connection portion 44 which is designed to be strong enough to preclude plastic deformation. The plastic hinge 45 is bounded on a second side by an elastic portion 48 which takes up most of the length of the bottom cord of the load-limiting device 1 . Within the elastic portion 48 , the stresses are low enough that the load-limiting device 1 material remains elastic.
[0101] As FIG. 5 further illustrates, the load-limiting device 1 may have an opening 47 thereon wherein the opening may allow for connection to a connecting means 19 that may attach the load-limiting device 1 to the braces 21 of the structure 27 . During high loads, the load-limiting device 1 may undergo plastic deformation as shown in FIG. 5 . The areas of the load-limiting device 1 that deform plastically versus elastically are a function of the geometry of the load-limiting device 1 and the orientation of the braces 21 . FIG. 5 illustrates plastic hinging 45 in the horizontal portion of the load-limiting device 1 . In another embodiment of the present invention, the plastic hinging may occur in the vertical portion of the load-limiting device 1 . Moreover, plastic hinging may occur in both the horizontal portion and the vertical portion of the load-limiting device 1 .
[0102] The load-limiting device 1 is able to dissipate energy by further yielding of the material enclosed in the plastic hinges 45 as further deformation is imposed. The amount of energy dissipated may be dependent on the geometry of the braced frame system 25 , the geometry of the load-limiting device 1 and the plastic moment capacities of the relevant load-limiting device 1 cross-sections. The plastic moment of a section may be proportional to the plastic section modulus and the yield strength of the materials used. The design of the load-limiting device 1 may account for all these variables so that an optimum load-limiting device 1 may be manufactured that would have adequate elastic strength to survive design wind loads. Moreover, the design would allow for dissipation of energy during many load cycles without premature failure due to cracking and/or buckling during severe seismic events.
[0103] FIG. 6 illustrates the load-deflection sequence for the load-limiting device 1 during a dynamic event when the load-limiting device 1 is subjected to diagonally oriented loads as illustrated in FIG. 4 . The area enclosed by the load-deflection plot during a load cycle is a direct measure of the energy dissipated by the load-limiting device 1 during one cycle of the dynamic event. The peak ordinate of the plot is proportional to the plastic moment of the device cross-section. The peak abscissa is related to the maximum shear and/or plastic deformation experienced by the load-limiting device. FIG. 6 illustrates the elastic loading 47 portion of the load-limiting device 1 in relation to the elastic unloading 49 portion and the elastic re-loading 51 portion of the load-limiting device 1 .
[0104] FIG. 7 illustrates different device geometries for various braced frame systems 25 having different configurations. The basic prior art braced frame systems 25 are typically of the X-brace 53 or K-brace 55 type. The X-brace 53 or K-brace 55 type of configuration has braces 21 that attach to the beams 31 , 33 in a plurality of different formats. Changing the shape of the load-limiting device 1 could accommodate several other bracing configurations. When a different type of brace system 25 is employed, the load-limiting device 1 geometry and shape may be changed to accommodate the differently braced system 25 . However, the load-limiting device 1 geometry and/or shape may be changed to accommodate connection features, manufacturing techniques, materials, architectural detail, and other variables in structural design and purpose. As FIG. 8 illustrates, there is very little limitation in the shape of the load-limiting device 1 . The load-limiting device may be constructed in a plurality of geometries and/or shapes provided that a plastic hinge mechanism 45 can be supported when the device is severely loaded. A suitable load-limiting device 1 may exhibit the same plastic hinging mechanism 45 when the load is reversed.
[0105] FIG. 9 illustrates a further innovative application of the load-limiting device 1 . FIG. 9 illustrates the use of a load-limiting device 1 in conjunction with externally mounted braces 21 . In some situations, the structure 25 and/or building will use a brace system mounted on the outside of the structure 25 that may cover-several stories of the structure 25 . The load-limiting device 1 may be used in this type of external bracing system in a similar fashion as the internal bracing systems. The dimension of the load-limiting device 1 may be greatly expanded to be adapted for external applications but may be used, none the less.
[0106] The load-limiting device 1 may need to be checked after a dynamic event of moderate to severe intensity. In the case of a moderate event it is possible that the load-limiting device may not have suffered any yielding and therefore can be left in place. Some damage may be expected for a major dynamic event and may be apparent by visual inspection of the structure. A “kinked” configuration of the type shown in FIG. 5 may be noticed during inspection of the load-limiting device 1 . However, it is possible that yielding may not be obvious during the post dynamic event inspection. Therefore, in an embodiment of the present invention as illustrated in FIG. 1 , an indicator means 55 may be used to indicate whether plastic deformation has begun on a load-limiting device 1 . In an embodiment, the indicator means 55 may be a brittle coat of material that may be applied to the load-limiting device 1 in order to accentuate the presence of yielding and hence make detection of plastic deformation much more simplistic. A colored brittle coat may be used to assist in detection of plastic deformation and/or yielding. In another embodiment of the present invention, the indicator means 55 may be a mechanical device (not shown) to illustrate plastic deformation. In another embodiment, an electronic sensor (not shown) may be used as an indicator means 55 to confirm plastic deformation. However, it should be understood that any indicator means may be used that may indicate the presence of plastic hinging and/or plastic deformation.
[0107] While the invention has been described with reference to a particular embodiment thereof, those skilled in the art will be able to make various modifications to the described embodiment of the invention without departing from the true spirit and scope thereof. It is intended that all combinations of elements and steps which perform substantially the same function in substantially the same way to achieve substantially the same result are within the scope of this invention.
REFERENCES
[0000]
(1) Wyllie, L. A., et. al., “Effects on Structures of the Managua Earthquake of Dec. 23, 1972”, Bulletin of the Seismological Society of America, Vol. 64, No. 4, August, 1974.
(2) Popov, Egor P., Amin, Navin R., Louie, Jason J. C., and Stephen, Roy M., “Cyclic Behavior of Large Beam-Column Assemblies,” Earthquake Spectra, Earthquake Engineering Research Institute, vol. 1, No. 2, pp. 9-23, 1985.
(3) Taylor, Douglas P., “Seismic isolator and method for strengthening structures against damage from seismic forces”, U.S. Pat. No. 5,462,141, Oct. 31, 1995.
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A load-limiting device for using in a braced frame structure is provided. The load-limiting device may be placed in a braced frame and connected to the braces of the braced frame. The load-limiting device is able to limit the lateral loads induced in the structure during a dynamic event by plastic and ductile deformation. The load-limiting device, by limiting the dynamic loads in the braced frame, may protect other less ductile areas of the structure from the loads that might lead to extensive damage, member failure and/or structural collapse. The load-limiting device is positioned within a braced frame structure and may be easily removed after it has undergone plastic deformation and replaced with an undeformed load-limiting device. The load-limiting device exhibits elastic strength to survive, without deformation, minor load scenarios. The device is suitable for retrofitting in existing structures that are susceptible to dynamic activity and that have inadequate dynamic loading capacity.
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CROSS-REFERENCE TO RELATED APPLICATION AND CLAIM OF PRIORITY
[0001] This application claims the benefit of Taiwan Patent Application No. 103127686, filed on Aug. 12, 2014, at the Taiwan Intellectual Property Office, the disclosures of which are incorporated herein in their entirety by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a preparation method for AMBROX® ((−)-3a,6,6,9a-tetramethyl-dodecahydronaphtho[2,1-b]furan), and new compounds which are extracted from Dysoxylum hongkongense and used for anti-virus, anti-inflammation or anti-cancer treatments, as well as pharmaceutical compositions and drugs thereof.
BACKGROUND OF THE INVENTION
[0003] Ambergris is a solid wax, which is formed from excretions of the sperm whale, Physeter macrocephalus L. (Physeteridae), via a bacterial and enzymatic process. It has been known that the odorous compound AMBROX® (a registered trademark name of Firmemich SA, Geneva, Switzerland), a naturally occurring triterpenoid with wide perfume applications in industry, can be obtained from ambergris. However, because it is difficult to obtain ambergris from endangered sperm whales at present the availability, ambergris and natural AMBROX® are largely
[0004] The current techniques to obtain AMBROX® are via chemical synthesis. For instance, U.S. Pat. Nos. 5,290,955 and 5,463,089, as well as WIPO Patent Publication No. WO 2012/085056 A1 disclose methods for chemically synthesizing AMBROX® (i.e. (−)-3a,6,6,9a-tetramethyl-dodecahydronaphtho[2,1-b]furan), which are incorporated herein by reference. In addition, U.S. Patent Publication No. US 2012/0301956 A1 discloses that polar hydroxylated enantiomers of ambrox can be prepared using a microbial fermentation technique using a fungi, Fusarium lini , and offer new highly prized odiferous characteristics quite different from ambrox and can be used in the preparation of perfumes, odor-masking and other odor-management applications, and the full text is incorporated herein by reference.
[0005] It is therefore the Applicant's attempt to deal with the above situation encountered in the prior art.
SUMMARY OF THE INVENTION
[0006] To search for a novel preparation method for AMBROX® that can be applied in the perfume industry, a diterpenoid of formula (I) (see below, a type of labdanes) of the present invention is extracted from a native plant, Dysoxylum hongkongense (Maliaceae), in Taiwan, and AMBROX® is synthesized from the diterpenoid of formula (I) via a series of chemical reactions. In addition, the present invention also discloses that new diterpenoids are extracted from D. hongkongense , and may be used to prepare pharmaceutical compositions for anti-virus, anti-inflammation or anti-cancer treatments, and drugs used therefore may be further manufactured from the pharmaceutical compositions.
[0007] The compounds and their chemical formulae in the present invention are illustrated as follows.
[0000]
[0008] The present invention discloses a method for preparing AMBROX® (i.e. (−)-8,12-epoxy-13,14,15,16-tetranorlabdane), including steps of (a) providing a diterpenoid represented by formula (I), wherein the diterpenoid of formula (I) is extracted from D. hongkongense ; (b) oxidatively degrading the diterpenoid of formula (I) as a diterpenoid of formula (II); (c) reducing the diterpenoid of formula (H) with sodium borohydride (NaBH 4 ) to form 3-hydroxy-sclareolide; (d) reacting the 3-hydroxy-sclareolide with methanesulfonyl chloride to form 3-mesyloxy sclareolide; (e) reacting the 3-mesyloxy sclareolide with lithium aluminium hydride (LAH) followed by dehydrocyclization using p-toluenesulfonic acid (TsOH.H 2 O) in nitromethane to form 3-mesyloxy ambrox; (f) reacting the 3-mesyloxy ambrox with lithium chloride (LiCl) to form Δ 2(3) -ambrox; and (g) treating the Δ 2(3) -ambrox with hydrogen gas to form the (−)-8,12-epoxy-13,14,15,16-tetranorlabdane.
[0009] In one embodiment of the invention, in step (b), the diterpenoid of formula (I) is executed in acetone containing potassium permanganate (KMnO 4 ) and anhydrous magnesium sulfate (MgSO 4 ). In one embodiment of the invention, step (c) is performed by adding the NaBH4 to a first solution of the diterpenoid of formula (II) in a first methanol solution. In one embodiment of the invention, step (d) is performed by adding the methansulfonyl chloride to a second solution of the 3-hydroxy-sclareolide in pyridine. In one embodiment of the invention, in step (e), the 3-mesyloxy sclareolide is dissolved in a first tetrahydrofuran (THF) solution, and LAH is dissolved in a second THF solution. In one embodiment of the invention, step (f) is performed by adding LiCl to a third solution of the 3-mesyloxy ambrox in dimethylformamide. In one embodiment of the invention, in step (g), the Δ 2(3) -ambrox is dissolved in a second methanol solution, the step (g) is performed using palladium on carbon (Pd/C), and the hydrogen gas has a pressure of 1 atm.
[0010] The present invention further discloses a method for preparing a diterpenoid of formula (II) from a diterpenoid of formula (I) which is extracted from D. hongkongense , including a step of oxidatively degrading the diterpenoid of formula (I) with KMnO 4 and MgSO 4 in acetone to form the diterpenoid of formula (II).
[0011] The present invention further discloses a method for preparing a diterpenoid represented by formula (I), including steps of: (a) extracting a D. hongkongense plant with an ethanol solution to obtain an extract; (b) partitioning the extract between ethyl acetate (EtOAc) and water to form an EtOAc layer; (c) evaporating an organic solvent from the EtOAc layer to obtain an EtOAc residue; (d) partitioning the EtOAc residue between n-hexane-methanol-water to form a methanol/water (MeOH/H 2 O) extract; and (e) chromatographing the MeOH/H 2 O extract over a silicon gel column to obtain the diterpenoid of formula (I).
[0012] The present invention further discloses a pharmaceutical composition including an effective amount of diterpenoid which is extracted from D. hongkongense , and the diterpenoid is compounds 1, 8, 9, 10, 11, 12, 13 and 14 or a combination thereof.
[0013] The present invention further discloses a use of the above pharmaceutical composition being prepared a drug used for anti-virus, anti-inflammation or anti-cancer treatments.
[0014] The present invention further discloses a diterpenoid of formula (I) being extracted from D. hongkongense.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The objectives and advantages of the present invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed descriptions and accompanying drawings.
[0016] FIG. 1 is a flow chart showing that fractions DA1 to DA14 of the present invention are obtained by extracting D. hongkongense.
[0017] FIG. 2 is a flow chart showing that ambrox of the present invention is prepared from compound 1 which is extracted from D. hongkongense.
[0018] FIG. 3 is a flow chart showing that compounds 1 and 2 of the present invention are obtained from a fraction DA4.
[0019] FIG. 4 is a flow chart showing that compounds 9 to 14 of the present invention are obtained from a fraction DA5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The present invention will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this invention are presented herein for purpose of illustration and description only; they are not intended to be exhaustive or to be limited to the precise form disclosed.
[0021] The structures of the new compounds in the present invention were established by interpretation of spectroscopic data, especially two-dimensional nuclear magnetic resonance (2D NMR). The stereochemistry of the compounds was established by chemical correlation, and the configurations thereof were definitively confirmed by X-ray crystallographic analysis.
[0022] Melting points of the compounds were recorded on a Büchi® B540 melting point apparatus. Optical rotations were recorded on a JASCO DIP-1000 polarimeter. Infrared (IR) spectra were taken on a HORIBA® FT-720 spectrophotometer. The 1 H and 13 C NMR spectra as well as 2D NMR spectra (correlation spectroscopy (COSY), heteronuclear multiple-quantum correlation (HMQC), heteronuclear multiple-bond correlation (HMBC), and nuclear overhauser enhancement spectroscopy (NOESY)) were recorded in CDCl 3 on a Bruker AVX NMR spectrometer operating at 400 MHz for 1 H and 100 MHz for 13 C using the CDCl 3 solvent peak as the internal standard (δ H 7.265, δ C 77.0 ppm). Low-resolution electron ionization mass spectroscopy (EIMS) was recorded on a VG Quattro 5022 mass spectrometer. High-resolution electrospray ionization mass spectroscopy (HRESIMS) was measured on a JEOL HX 110 mass spectrometer. LiChrospher® Si 60 (5 μm, 250-10, Merck) and LiChrospher® 100 RP-18e (5 μm, 250-10, Merck) were used for normal phase-high performance liquid chromatography (NP-HPLC) and reversed phased HPLC (RP-HPLC) (Hitachi®, L-6250; flow rate 2 mL/min, UV detection at 254 nm), respectively.
I. AMBROX® Was Obtained From the Novel Diterpenoid of Formula (I) Which Was Extracted from Dysoxylum Hongkongense
[0023] Please refer to the preparation method in FIG. 1 , a plant of D. hongkongense 10 which was planted in Ping-Tong County, Taiwan was extracted with an ethanol solution (referring to step S 1 ) to obtain a crude extract 12 , which was partitioned between ethyl acetate (EtOAc) and water (referring to step S 2 ) to form an EtOAc-soluble layer 14 . After evaporating the organic solvent, the EtOAc residue was partitioned between n-hexane methanol (MeOH)-water (referring to step S 3 ) to create an EtOAc layer 18 and an MeOH/H 2 O extract or MeOH/H 2 O layer 20 . The MeOH/H 2 O layer was passed over an Si gel flash column to create a diterpenoid of formula (I) (Dysongensin A, compound 1). The above-ground part and root of the plant of D. hongkongense can be used for the extraction, and the above-ground part includes leaves, twigs or the like.
[0024] In detail, the air-dried leaves and twigs (2.7 kg) of D. hongkongense were ground and extracted three times with ethanol at room temperature and then concentrated under reduced pressure to create a crude extract (210 g). This crude extract was partitioned between EtOAc and H 2 O (1:1) to obtain an EtOAc-soluble layer and a water layer (referring to block 16 in FIG. 1 ). After evaporating the organic solvent, the EtOAc residue (146 g) was partitioned between n-hexane-MeOH—H 2 O (4:3:1) to create an MeOH/H 2 O extract. The MeOH/H 2 O extract (86 g) was passed over an Si gel flash column (n-hexane-EtOAc, 1:0 to 0:1) to create fractions DA1 (block 22 ) to DA14 (block 28 ). Part (300 mg) of fraction DA4 (26.5 g, block 24 ) was subjected to NP-HPLC (n-hexane-EtOAc, 85:15-80:20) to create compound 1 (Dysongensin A, 98.4 mg, referring to FIG. 3 ) in fraction DA4-2, and a un-purified fraction DA4-6 was eluted with CH 2 Cl 2 -EtOAc (80:20) using NP-HPLC to create a compound 2 of formula (II) (3-ketoscareolide, 30.9 mg, referring to FIG. 3 ) in fraction DA4-6-2.
[0025] Compound 1 (Dysongensin A): off-white needles; mp 68-69° C., [α] D 25 +29.2 (c 0.26, MeOH); UV (MeOH) λ max (log ε) 232 (4.60) nm; CD (c 0.06, MeOH) [θ] 228 +24038, [θ] 255 +1537, [θ] 279 +4741; IR (neat) ν max 3455, 3086, 1702, 1638 cm −1 ; 1 H NMR (CDCl 3 ) and 13 C NMR (CDCl 3 ) spectroscopic data, see Tables 1 and 3; HRESIMS m/z 327.2307 [M+Na] + (calcd for C 20 H 32 O 2 Na, 327.2294).
[0026] The IR spectrum of compound 1 shows the presence of OH (3455 cm −1 ), carbonyl (1702 cm −1 ) and C═C double bond (3086, 1638 cm −1 ) groups. The UV spectrum of compound 1 shows an absorption band at 232 nm, which implies the presence of a conjugated system in compound 1. The 1 H NMR data of compound 1 (Table 1) exhibits signals of five methyl singlets (δ 0.92, 0.98, 1.04, 1.17 and 1.73) and four olefinic protons (δ 4.86, d, J=10.7 Hz, H-15a; 5.01, d, J=17.4 Hz, H-15b; 5.50, dd, J=7.1, 7.1 Hz; 6.27, H-12, dd, J=17.4, 10.7 Hz, H-14). An ABX spin system between H-15 and H-14 can be observed. The 13 C NMR. (Table 2) and the distortionless enhancement by the polarization transfer (DEPT) spectra of compound 1 shows 20 carbon signals, consisting of a carbonyl carbon (δ 216.7), two double bonds (δ 110.4, 132.4, 135.1 and 141.1), an oxygenated quaternary carbon (δ 73.1), two aliphatic quaternary carbon (δ 38.1, 47.0), an aliphatic methine (δ 54.6), five aliphatic methylene (δ 20.9, 24.0, 33.6, 38.4, 42.9), and five methyl carbons (δ 11.6, 14.8, 20.9, 23.6, 26.4). In the COSY spectrum of compound 1, correlations between the olefinic protons H-14/H-15, and H-12/H-11 (δ 2.16, 2.39)/H-9 (δ 1.37), as well as methylenes H-1 (δ 1.49, 1.85)/H-2 (δ 2.36, 2.47) can be observed (data not shown). In the HMBC spectrum, correlations of H-15/C-13 (δ 132.4), Me-16/C-14, C-13, C-12, H-11/C-8, C-10 and H-12/C-9 (δ 60.6), C-14 (δ 141.1), indicated the presence of a conjugated double bond moiety, which was substituted at C-9. Two methyl groups attached to C-4 were revealed by the correlations of Me-18, Me-19/C-4 (δ 47.0), C-5 (δ 54.6), and the carbonyl carbon (C-3). The Me-17 methyl group was attached to C-8 as evidenced by the HMBC correlations of Me-17/C-8 (δ 73.1), C-9 and C-7. In addition, HMBC correlations of Me-20 (δ 0.92)/C-1 (δ 38.4), C-5, C-9 (δ 60.6), C-10, and H-7/C-5, C-6 (δ 20.9) as well as H-1/C-5 may construct a bicyclic ring system with a methyl group attached at C-10. The above 2D NMR reveals that compound 1 was a labdane type diterpene. Thus, the planar structure of compound 1 can easily be identified.
[0027] The relative configuration of compound 1 was elucidated on the basis of NOESY correlations. The NOESY spectrum of compound 1 shows correlations of Me-19/H-5, H-6α, Me-18H-6β, H-20/H-2β, H-6β, H-11, Me-17, Me-17/H-6β, H-7β, H-11, H-5/H-7α, H-16/H-15β indicating that Me-17, Me-18 and Me-20 were on the β-face while Me-19, H-5 and H-9 were on the α-face of the molecule. Moreover, a strong NOESY correlation between H-12 and H-14 suggests that the double bond of C-12/C-13 was E-geometry. The CD spectrum of compound 1 shows a positive Cotton effect at 279 nm. Furthermore, compound 1 was reacted with KMnO 4 /MgSO 4 in acetone to create a crystal product identical to compound 2, which was confirmed using X-ray crystallographic analysis (referring the following descriptions). The above reaction unambiguously established the structure of compound 1.
[0028] Compound 2 (3-Ketosclareolide): [α] D 25 +10.7 (c 0.22, MeOH); CD (c 0.3, MeOH) [θ] 214 +2072, [θ] 243 +5, [θ] 277 +1056; IR (neat) ν max 1773, 1702 cm −1 ; 1 H NMR (CDCl 3 ) and 13 C NMR (CDCl 3 ) spectroscopic data, see Table 4; HRESIMS m/z 287.1631 [M+Na] + (calcd for C 16 H 24 O 3 Na, 287.1623).
[0029] In addition to being obtained from D. hongkongense , compound 2 also can be obtained from compound 1 via oxidative cyclization. Please refer to FIG. 2 , to a solution of compound 1 (200 mg, 0.656 mmol) in acetone (10 mL) was added potassium permanganate (KMnO 4 , 311 mg, 1.97 mmol) and anhydrous magnesium sulfate (MgSO 4 , 300 mg) at 0° C. After stirring for 15 minutes the reaction mixture was allowed to warm to room temperature and kept for 1 hour. The reaction mixture was filtered through celite, and the filtrate was concentrated under reduced pressure resulting a crude product, which was subjected to column chromatography eluted with hexane-ethyl acetate (3:2) to yield compound 2 of a white solid (158 mg, 91%). The spectroscopic data is identical to those in Table 4.
[0030] In one embodiment of the present invention, compound 2 can be synthesized from compound 1 which was extracted from D. hongkongense via the chemical reaction, and then compounds 4, 5, 6 and 7, as well as ambrox (compound 3) were sequentially prepared via a series of chemical reactions. Please refer to FIG. 2 , compound 1 was treated with KMnO 4 and MgSO 4 in acetone, and the reaction proceeded through oxidative degradation of the 1,3-diene side chain followed by cyclization to create compound 2 having a lactone ring C. Further reduction of the ketone at the 3-position with NaBH 4 in dry methanol compound 2 created the corresponding compound 4 having a secondary alcohol structure. Then, compound 4 was protected as a mesylate by being treated with methanesulfonyl chloride in pyridine to create compound 5 having the mesylate structure. The reduction of compound 2 to create the corresponding compound 4 and the reductive removal of the mesylate group to hydrocarbon can be performed in a one-pot manner. Accordingly, compound 5 was treated with lithium aluminium hydride (LAH) in dry tetrahydrofuran (THF) followed by dehydrocyclization of the corresponding alcohol with a catalytic amount of p-toluenesulfonic acid (p-TsOH) in nitromethane. Compound 6 was treated with lithium chloride (LiCl) in DMF to create compound 7, which has an alkene structure between C-2 and C-3. Further hydrogenation of compound 7 using 10% palladium on carbon (Pd/C) catalyst in dry methanol yielded the desired AMBROX® (compound 3).
[0031] In another embodiment of the present invention, AMBROX® can be prepared from compound 2, which is extracted from D. hongkongense , via the chemical reactions described above.
[0032] The preparation method of compounds 4, 5, 6, 7 and 3 are described below.
[0033] Compound 4 (3-Hydroxy-sclareolide): To a solution of compound 2 (100 mg, 0.378 mmol) in methanol (4 mL) was added sodium borohydride (NaBH 4 , 21 mg, 0.567 mmol) at 0° C. portion wise. After 10 minutes the reaction mixture warmed to room temperature and kept there for 30 minutes. The solvent was removed under reduced pressure and the resulting crude product was dissolved in EtOAc and washed with water. Then the organic layer was dried over MgSO 4 and the solvent was removed under vaccum. The crude product was purified by column chromatography using ethyl acetate/hexane (45-50%) to create compound 4 of a white solid (85 mg, 85%). 1 H NMR (400 MHz, CDCl 3 ), δ 3.24 (dd, J=5.2, 10.8 Hz, 1H), 2.39 (t, J=15.6 Hz, 1H), 2.22 (dd, J=6.4, 16.0 Hz, 1H), 2.05-2.08 (m, 1H), 1.87-1.92 (m, 2H), 1.61-1.66 (m, 3H), 1.40-1.44 (m, 2H), 1.31 (s, 3H), 1.16 (dt, J=4.4, 12.8 Hz, 2H), 0.98 (s, 3H), 0.90 (s, 3H), 0.78 (s, 3H); 13 C NMR (100 MHz, CDCl 3 ), δ 176.6, 86.2, 78.6, 58.9, 55.3, 38.8, 38.4, 37.7, 35.7, 28.7, 27.9, 26.8, 21.5, 20.3, 15.0, 15.1.
[0034] Compound 5 (3-Mesyloxy sclareolide): A solution of compound 4 (50 mg, 0.19 mmol) in pyridine (2 mL) was cooled to 0° C., and to that methansulfonyl chloride (21 μL, 0.281 mmol) was added. The reaction mixture was stirred at the same temperature for 2 hours, and ethyl acetate was added. The mixture was washed with 5% HCl and brine and the organic layer was dried over MgSO 4 , filtered, and concentrated in vacuo. The yellow residue was purified by column chromatography using ethyl acetate/hexane as an eluent to create compound 5 (63 mg 97%). 1 H NMR (400 MHz, CDCl 3 ), δ 4.34 (dd, J=5.2, 11.6 Hz, 1H), 3.12 (s, 3H), 2.41 (t, J=15.6 Hz, 1H), 2.22 (dd, J=6.4, 16.0 Hz, 1H), 2.03-2.07 (m, 1H), 1.97-2.01 (m, 2H), 1.87-1.94 (m, 3H), 1.69 (dt, J=3.2, 12.4 Hz, 1H), 1.43-1.51 (m, 2H), 1.32 (s, 3H), 1.10-1.26 (m, 2H), 1.03 (s, 3H), 0.94 (s, 3H), 0.87 (s, 3H); 13 C NMR (100 MHz, CDCl 3 ), δ 176.1, 89.0, 85.7, 58.6, 55.3, 38.9, 38.6, 38.2, 37.3, 35.5, 28.6, 28.0, 24.8, 21.5, 20.3, 15.9, 15.2.
[0035] Compound 6 (3-Mesyloxy ambrox): To a suspension of lithium aluminium hydride (LiAlH 4 , 44 mg, 1.16 mmol) in THF (5 mL) was added compound 5 (100 mg 0.29 mmol) dissolved in 5 mL THF at 0° C. under an N 2 atmosphere. The reaction was heated to reflux for 2 hours and then cooled to 5° C. The reaction mixture was washed with water and filtered through celite and washed with ethyl acetate. The filtrate was concentrated under reduced pressure. Nitromethane (10 mL) and TsOH.H 2 O (27 mg, 0.145 mmol) were directly added to the residue. This mixture was stirred at room temperature for 4 hours, then diluted with ethyl acetate, washed with a saturated NaHCO 3 solution and brine, dried over MgSO 4 , and filtered. The filtrate was concentrated under reduced pressure and the crude product was purified with a silica gel column using ethyl hexane-ethyl acetate (3:2) as an eluent to create compound 6 (60 mg, 63%). 1 H NMR (400 MHz, CDCl 3 ), δ 4.34 (dd, J=6.2, 10.0 Hz, 1H), 3.89-3.94 (m, 1H), 3.83 (q, J=8.0 Hz, 1H), 3.02 (s, 3H), 1.95-2.03 (m, 3H), 1.71-1.76 (m, 3H), 1.55-1.58 (m, 1H), 1.31-1.40 (m, 2H), 1.21-1.26 (m, 3H), 1.08 (s, 3H), 1.03 (s, 3H), 0.87 (s, 3H); 13 C NMR (100 MHz, CDCl 3 ), δ 90.1, 79.6, 64.9, 59.8, 56.1, 39.3, 38.8, 38.6, 37.8, 35.7, 28.4, 25.1, 22.6, 21.0, 20.4, 16.0, 15.1.
[0036] Compound 7 (Δ 2(3) -ambrox): To a solution of compound 6 (50 mg, 0.15 mmol) in DMF (7 mL) was added anhydrous LiCl (31 mg, 0.32 mmol). The mixture was stirred at 100° C. for 2 hours and then cooled to room temperature. Ethyl acetate was added, and the resulting solution was washed with water and brine, dried over MgSO 4 and filtered. The filtrate was concentrated under reduced pressure. The resulting crude product was purified over silica gel column using hexane-ethyl acetate (9:1) to create compound 7 (28 mg, 80%) as colorless oil. 1 H NMR (400 MHz, CDCl 3 ), δ 5.38-5.46 (m, 2H), 3.90-3.95 (m, 1H), 3.83 (q, J=8.4 Hz, 1H), 1.96-1.99 (m, 1H), 1.73-1.78 (m, 5H), 1.27-1.44 (m, 4H), 1.10 (s, 3H), 0.98 (s, 3H), 0.89 (s, 3H), 0.87 (s, 3H); 13 C NMR (100 MHz, CDCl 3 ), δ 138.6, 121.2, 79.8, 64.9, 58.8, 52.8, 40.5, 39.1, 35.2, 34,5, 31.9, 29.7, 22.7, 22.2, 21.5, 20.6, 15.2.
[0037] Compound 3 (AMBROX®): Palladium on carbon (Pd/C, 10%, 5 mg) was added to compound 7 (25 mg 0.11 mmol) in MeOH (3 mL) and the resulting heterogeneous mixture was treated with H 2 at 1 atm. The reaction mixture was filtered through celite and the residue was washed with methanol. The methanol was removed by a vacuum to yield the desired compound 3 (23 mg, 92%). The NMR data were identical with those of Zoretic P. A. et al. (Synthesis of d,l-Norlabdane Oxide and Related Odorants: An Intramolecular Radical Approach. J Org. Chem., 1998, 63(14): 4779-4785.). 1 H NMR (400 MHz, CDCl 3 ), δ 3.88-3.93 (m, 1H), 3.82 (q, J=8.4 Hz, 1H), 1.92-1.95 (m, 1H), 1.68-1.75 (m, 3H), 1.37-1.48 (m, 5H), 1.17-1.27 (m, 2H), 1.10 (s, 3H), 0.94-1.08 (m, 3H), 0.87 (s, 3H), 0.83 (s, 6H); 13 C NMR (100 MHz, CDCl 3 ), δ 80.0, 65.0, 60.1, 57.3, 42.5, 40.0, 39.8, 36.2, 33.6, 33.1, 22.6, 21.2, 20.7, 18.4, 15.1.
II. A Variety of Novel Diterpenoids Extracted from D. Hongkongense
[0038] A variety of novel diterpenoids, including compounds 1, 2, 8, 9, 10, 11, 12, 13 and 14, can be extracted from the plant D. hongkongense.
[0039] The extraction methods of compounds 1 and 2 are described above and are not described again in this Section II.
[0040] In FIG. 3 , fraction DA4-6 was subjected to NP-HPLC (dichloromethane-EtOAc, 80:20). and compound 8 (Dysongensin B, 6.5 mg) was obtained from fraction DA4-6-4.
[0041] In FIG. 4 , fraction DAS (6.2 g, block 26 ) was chromatographed on an Si gel column (step S 4 ), isocratically eluted with n-hexane-EtOAc (85:15), eluted with 100% MeOH and detected with thin layer chromatography (TLC) to yield fraction DA5-8 (1.58 g), which was further separated with an Si gel column (step S 5 ), isocratically eluted with n-hexane-acetone (4:1), eluted with 100% MeOH and detected with TLC to give fractions DA5-8-2 (1.07 g) and DA5-8-3 (312 mg). Fraction DA5-8-2 (1066 mg) was subjected to NP-HPLC (n-hexane-EtOAc, 65:35), the obtained fraction DA5-8-2-6 was subjected to NP-HPLC (CH 2 Cl 2 -EtOAc, 85:15) to create a new compound 11 (110 mg) from the obtained fraction DA5-8-2-6-5. Fraction DA5-8-2-8 was separated by NP-HPLC (CH 2 Cl 2 -EtOAc, 4:1), the obtained fraction DA5-8-2-8-4 was subjected to NP-HPLC (n-hexane-acetone, 85:15) to yield a new compound 9 (5.1 mg) from a given fraction DA5-8-2-8-4-2, and a new compound 10 (33.1 mg) from a given fraction DA5-8-2-8-4-3. Separation of fraction DA5-8-2-8-8 by NP-HPLC (n-hexane-acetone, 4:1) yielded a new compound 13 (7.0 mg) from a given fraction DA5-8-2-8-8-4 and a new compound 14 (9.7 mg) from a given fraction DA5-8-2-8-8-5. Fraction DA5-8-3 (312 mg) was separated by NP-HPLC (n-hexane-EtOAc, 55:45) to furnish a new compound 12 (14.2 mg) from a fraction DA5-8-3-7.
[0042] Compound 8 (Dysongensin B): off-white, amorphous powder; [α] D 25 44.3 (c 0.26, MeOH); CD (c 0.15, MeOH) [θ] 235 +395, [θ] 284 +2357; IR (neat) ν max 3455, 3082, 1702 cm −1 ; 1 H NMR (CDCl 3 ) and 13 C NMR (CDCl 3 ) spectroscopic data, see Tables 1 and 3, respectively; HRESIMS m/z 343.2252 [M+Na] + (calcd for C 20 H 32 O 3 Na, 343.2243).
[0043] The 1 H and 13 C NMR spectra of compound 8 were similar to those of compound 1, suggesting that it is a close analog of compound 1. The difference between them was that the chemical shifts of H-12 (δ 3.51), C-12 (δ 77.5) and C-13 (δ 76.6) in compound 8 were upheld shifted compared to those of compound 1 (δ H 5.50; δ c 135.1, 132.4), and the shift values of H-15 (δ 5.24, 5.43), C-15 (δ 117.4), C-8 (δ H 75.4) and C-16 (δ 27.9) were downfield shifted compared to those of the same carbon in compound 1 (δ H 4.86, 5.01; δ C 110.0, 73.7, 11.8). Thus, it is suggested that the double bond between C-12 and C-13 was missing and an ether linkage was formed between C-8 and C-13. In addition, a hydroxyl group (OH) attached at C-12 was observed in compound 8. This was supported from the COSY (H-9/H-11/H-12) and HMBC correlations of H-16 (δ 1.80)/C-12, C-13, C-14 (δ C 140.1) (not shown). The other COSY and HMBC correlations revealed that all the other structural fragments including the rings A and B were similar to those of compound 1, confirming that compound 8 belongs to a six membered cyclic ether derivative of compound 1.
[0044] NOESY correlations of Me-20 (δ 0.86)/H-11β (δ 1.57), Me-18 (δ 0.99), Me-17 (δ 1.27) and Me-17/H-14 of compound 8 indicated that Me-20, Me-17 and the vinyl group at C-13 were all β-oriented. On the other hand, NOESY cross peaks between H-9 (δ 1.33)/H-12, H-1α (δ 1.47) and H-12/H-11α (δ 1.77), Me-16 revealed that H-9, H-12 and Me-16 were α-oriented. The relative configurations at C-12 and C-13 were also determined as R. Furthermore, the positive Cotton effect at 284 nm in the CD spectrum of compound 8 also agreed with the same configuration as compound 1. Therefore, the structure of compound 8 was established.
[0045] Compound 9 (Dysongensin C): off-white prism; mp 85-86° C.; [α] D 25 18.8 (c 0.51, MeOH); CD (c 0.4, MeOH) [θ] 290 +2096; IR (neat) ν max 3480, 3088, 1702, 1641 cm −1 ; 1 H NMR (CDCl 3 ) and 13 C NMR (CDCl 3 ) spectroscopic data, see Tables 1 and 3, respectively; HRESIMS m/z 343.2243 [M+Na] + (calcd for C 20 H 32 O 3 Na, 343.2243).
[0046] The 1 H and 13 C NMR spectra of compound 9 revealed a tricyclic labdane pattern consisting of a vinyl group (δ H 5.84, dd, J=17.4, 10.9 Hz; 5.10, dd, J=10.9, 1.7 Hz, H-15a; 5.28, dd, J=17.4, 1.7 Hz, H-15b), a carbonyl carbon (δ C 216.7), five methyl protons (δ H 0.92 s, 1.02 s, 1.09 s, 1.19 s, 1.30 s) and carbons (δ C 25.9, 24.9, 20.7, 26.8, 15.3) similar to those of compound 8. However, the methine protons (δ H 3.79, 5.84) at C-12 and C-14 and carbons of C-8 (δ C 80.7), C-9 (δ C 60.2), C-12 (δ C 85.1), C-13 (δ C 73.3) and C-15 (δ C 113.6) were quite different from those of compound 8, suggesting that compound 9 might contain a pentacyclic ether in the C-ring. HMBC correlations of H-12/C-9, H-16 (δ 1.30)/C-12, C-14 (δ 140.9), H-15/C-13 and H-17/C-8, C-9, C-7 (δ 39.9) also support a tetrahydrofuran ring system with a methyl vinyl carbinol moiety attached at C-12. Assuming that H-9 of compound 9 is on the α-face same as compound 8, the NOESY correlations of H-12/H-9 revealed that H-12 is α-oriented. The configuration at C-12 and C-13 was thus elucidated as S and R respectively. An X-ray crystallographic analysis (not shown) unambiguously confirmed the configurations deduced by the NOESY experiment and also revealed that H-12 was located on the α-face. The positive Cotton effect at 290 nm in the CD spectrum of compound 9 is similar to those of compounds 1 and 8. On the basis of the above evidence, the structure of compound 9 was established.
[0047] Compound 10 (Dysongensin D): colorless, gum; [α] D 25 24 (c 0.65, MeOH); CD (c 0.5, MeOH) [θ] 234 +37, [θ] 292 +233; IR (neat) ν max 3455, 3085, 1701, 1644 cm −1 ; 1 H NMR (CDCl 3 ) and 13 C NMR (CDCl 3 ) spectroscopic data, see Tables 1 and 3, respectively; HRESIMS m/z 343.2247 [M+Na] + (calcd for C 20 H 32 O 3 Na, 343.2243).
[0048] The 1 H and 13 C NMR spectra of compound 10 contained characteristic signals of a tricyclic labdane pattern including the vinyl group (δ H 5.93, dd, J=17.3, 10.7 Hz; 5.11, dd, J=10.7, 0.8 Hz, H-15a; 5.28, dd, J=17.3, 0.8 Hz, H-15b), a carbonyl carbon (δ C 216.8), five methyl protons (δ H 0.91 s, 1.02 s, 1.09 s, 1.16 s, 1.21 s) and carbons (δ C 14.3, 20.7, 20.8, 23.6, 26.9). However, the methine proton (δ H , 3.79, J=7.9, 4.7 Hz) and carbon (δ C 85.1) at C-12 were different from those of compound 9, suggesting that the configuration of C-12 in compound 10 may be different from that of compound 9. HMBC correlations H-12C-9, C-13 and H-16 (δ 1.21)/C-12, C-14 (δ C 142.8) also support the planar structure of the side chain in compound 10 (not shown). A NOESY correlation of H-12/Me-17 and no correlation observed between H-12 and H-9 agreed with the β-orientation of H-12. Therefore the configurations of compound 10 at C-12 and C-13 were elucidated as R and R respectively.
[0049] Compound 11 (Dysongensin E): off-white, amorphous powder; [α] D 25 5.4 (c 0.85, MeOH); CD (c 0.6, MeOH) [θ] 235 +45, [θ] 290 +2144; IR (neat) ν max 3473, 3085, 1701, 1644 cm −1 ; 1 H NMR (CDCl 3 ) and 13 C NMR (CDCl 3 ) spectroscopic data, see Tables 2 and 3, respectively; HRESIMS m/z 343.2218 [M+Na] + (calcd for C 20 H 32 O 3 Na, 343.2243).
[0050] The 1 H and 13 C NMR spectra of compound 11 were superimposable with those of compound 10 except that the signals of C-14 (δ 140.9) and C-16 (δ 24.6) were slightly different from those of compound 10. The same labdane system and the side chain at C-12 of compound 11 was determined by COSY (H-9/H-11/H-12 and H-14/H-15) and HMBC (H-12/C-16, C-9, C-14). The NOESY correlation between H-12 (δ 3.88) and Me-17 (δ 1.12) and absence of correlation between H-12 and H-9 (δ 1.33) clearly determined the configuration of H-12 of compound 11 as R. The carbon chemical shifts of compound 11 revealed the S configuration at C-13.
[0051] Compound 12 (Dysongensin F): off-white, amorphous powder; [α] D 25 −2.3 (c 1.42, MeOH); IR (neat) ν max 3438, 3050, 1704, 1641 cm −1 ; 1 H NMR (CDCl 3 ) and 13 C NMR (CDCl 3 ) spectroscopic data, see Tables 2 and 3, respectively; HRESIMS m/z 345.2413 [M+Na] + (calcd for C 20 H 34 O 3 Na, 345.2400).
[0052] The carbonyl carbon in compound 11 was missing in compound 12. Instead, it was replaced by a methine proton at δ 3.20 (dd, 10.8, 5.5 Hz). Detailed comparison of the chemical shifts of H-2 (δ 1.55 m, 1.61 m), C-2 (δ 27.0), C-3 (δ 78.9) and C-4 (δ 55.9) of compound 12 with those of compound 11 revealed that compound 12 contained a hydroxyl at C-3. The COSY (H-1/H-2/H-3) and HMBC (H-1/C-3 and Me-18, Me-19/C-3) correlations also supported the planar structure of compound 12. The NOESY correlations of H-3/H-5, Me-19 determined the β-face of the C-3 hydroxyl group while correlations of H-12/Me-17, H-9/H-5 and Me-18/Me-20 agreed with the same configuration of C-5, C-9, C-10 and C-12 as compound 11. Comparison of carbon data of C-12 and C-13 of compound 12 with those of compound 11 also assigned the configuration of C-12 and C-13 as R and S respectively.
[0053] Compound 13 (Dysongensin G): off-white, amorphous powder; [α] D 25 24.0 (c 0.70, MeOH); IR (neat) ν max 3458, 3049, 1643 cm −1 ; 1 H NMR (CDCl 3 ) and 13 C NMR (CDCl 3 ) spectroscopic data, see Tables 2 and 3, respectively; HRESIMS m/z 343.2243 [M+Na] + (calcd for C 20 H 32 O 3 Na, 343.2243).
[0054] The IR absorption bands at 3458, 3049 and 1643 cm −1 of compound 13 indicated the presence of hydroxyl and double bond functionalities. The 1 H and 13 C NMR DEPT spectra of compound 13, consisting of an AMX spin system of vinyl protons (δ 5.66, dd, J=17.4. 1.4 Hz; δ 5.19, dd, J=10.9, 1.4 Hz; δ 5.37, dd, J=17.4, 1.4 Hz) and carbons (δ 137.4, CH; δ 115.9, CH 2 ), were similar to those of compound 11, suggesting an analogue. However, only three methyl protons (δ 0.77s, 0.93s, 1.16s) and carbons (δ 11.2q, 21.2q, 23.1q) instead of 5 methyls were observed in compound 13. The characteristic signals at δ 0.44 (dd, 9.2, 4.0 Hz, H-19) and δ −0.04 (dd, 5.4, 4.0 Hz, H-19) inferred the presence of a cyclopropane moiety. This finding was supported by the observation of COSY correlations of H-2 (δ 1.66 and 1.92)/H-3/H-19 and the carbonyl carbon in compound 11 was missing in compound 13. Moreover, a pair of methylene doublets at δ 3.36 (J=11.2 Hz) and δ 3.78 (J=11.2 Hz) suggest that a hydroxy was attached at C-16. This was proven by HMBC correlations of H-12/C-16, C9, C-14. Detailed analyses of COSY and HMBC spectra of compound 13 led to the elucidation of the planar structure, in which carbon signals at δ 17.8, 15.7 and δ 22.9 were assigned for the cyclopropane (C-3, C-4 and C-19) ring while carbon signals at δ 81.5, 75.4 and δ 21.2 were assigned for C-12, C-13 and C-17, respectively. The relative configuration was determined by a NOESY experiment and comparison of carbon chemical shifts of compound 13 with those of compound 11. NOESY correlations of Me-18/Me-20/Me-17/14-12 and H-3/H-19β indicate that they were all β-oriented while NOESY correlations of H-5/H-9/H-19α accounted α-orientation of H-5 and H-9. As mentioned before, the CMR data of C-12, C-13 and C-14 could suggest the R configuration of C-12 and C-13.
[0055] Compound 14 (Dysongensin H): off-white, amorphous powder; [α] D 25 35.9 (c 0.97, MeOH); IR (neat) ν max 3449, 3048, 1644 cm −1 ; 1 H NMR (CDCl 3 ) and 13 C NMR (CDCl 3 ) spectroscopic data, see Tables 2 and 3, respectively; HRESIMS m/z 343.2254 [M+Na] + (calcd for C 20 H 32 O 3 Na, 343.2243).
[0056] The 1 H and 13 C NMR spectroscopic data of compound 14 showed three methyl protons (δ 0.81s, 0.93s, 1.23s) and carbons (δ 12.0q, 23.0q, 24.7q), and the characteristic signals of a cyclopropane ring (δ 0.54; 0.45, dd, 9.4, 4.0 Hz, H-19β; δ −0.04, dd, 5.6, 4.0 Hz, H-19α) as well as a hydroxyl methylene group (δ 3.37, J=11.1 Hz; δ 3.83, J=11.1 Hz; δ 69.9, C-16), suggests that compound 14 was an analogue of compound 13. Supported by COSY, HMQC and HMBC correlations, compounds 14 and 13 could have the same planar structure. The difference could be the configuration at C-12 (δ 85.4) and C-13 (δ 73.9), whose data have been assigned from HMQC and HMBC correlations of compound 14. Moreover, analysis of a NOESY experiment of compound 14 also pointed out an identical configuration as compound 13 except without a correlation between H-12 and Me-17, but a correlation between H-12 and H-9 was observed in compound 14. This finding indicates that H-12 was on the α-face. A comparison of the chemical shifts of C-14 (δ 136.9) and C-17 (24.7) as well as C-12 and C-13 of compound 14 with those of compound 13 and published data established the S configuration of C-12 and C-13.
III. Anti-Virus, Anti-Inflammation and Anti-Cancer Effect of the Novel Diterpenoids
[0057] Anti Herpes Simplex Virus-1 (HSV-1) Assay, Cell Culture and Virus. Vero cells were cultured in minimal essential medium (MEM; GIBCO®, Grand Island, N.Y.) supplemented with 10% fetal calf serum (FCS; Hyclone™, Logan, Utah), 100 U/mL penicillin and 100 μg/mL streptomycin and incubated at 37° C. in a 5% CO 2 incubator. To prepare a stock of HSV-1 (KOS strain, VR-1493, ATCC), Vero cells were infected with HSV-1 at a multiplicity of infection points on three plaque forming units (PFU)/cell and harvested at 24 hours postinfection and centrifuged at 1500×g (Centrifuge 5810 R, Eppendorf) at 4° C. for 20 minutes. The supernatant was collected and stored at −70° C. for use.
[0058] Plaque Reduction Assay. The bioassay followed a procedure described previously (Kuo et al., Samarangenin B from Limonium sinense Suppresses Herpes Simplex Virus Type 1 Replication in Vero Cells by Regulation of Viral Macromolecular Synthesis. Antimicrob. Agents Chemother., 2002, 46(9): 2854-2864.). Vero cells (3.5×10 5 cells/dish) were incubated with 100 PFU of HSV-1 and various compounds (100 μM) or acyclovir (2.5 μM, the positive control) were added to the cells. The viruses were adsorbed for 1 hour at 37° C. and 1% methylcellulose was added to each well. After 5 days, the virus plaques formed in Vero cells were counted by crystal violet staining. The activities of various compounds and acyclovir for inhibition of plaque formation were calculated.
[0059] Anti-inflammatory Assays, Inhibitory Effect on Superoxide Anion Generation and Elastase Release by Human Neutrophils. Neutrophils were obtained by means of dextran sedimentation and Ficoll centrifugation. Superoxide generation and elastase release were carried out according to a procedure described previously (Hwang et al., Inhibition of Superoxide Anion and Elastase Release in Human Neutrophils by 3′-Isopropoxychalcone via a cAMP-dependent Pathway. Br. J. Pharmacol., 2006, 148(1): 78-87.; and Liaw et al., Frajunolides E-K, Briarane Diterpenes from Junceella fragilis. J Nat. Prod., 2008, 71(9): 1551-1556.). Superoxide anion production was assayed by monitoring the superoxide dismutase-inhibitable reduction of ferricytochrome c. Elastase release experiments were performed using MeO-Suc-Ala-Ala-Pro-Val p-nitroanilide as the elastase substrate.
[0060] Cytotoxic Assay. Human hepatocellular carcinoma Hep-G2, human colon adenocarcinoma WiDr and human laryngeal carcinoma Hep-2 were used as the targets for research, and an antitumor drug, mitomycin C, was the control. The effective dosage (ED 50 , μg/mL) of the compounds on the cancer cell cytotoxicity was determined by the well-known cytotoxicity assay (3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyltetrazolium bromide (MTT) assay) in the art.
[0061] The isolated compounds 1 and 8 to 14 were evaluated for their in vitro inhibitory activity against the HSV-1 virus. Compounds 9, 10, 13 and 14 showed moderate activity (32.7±4.0%, 25.2±6.0%, 29.3±9.0% and 29.7±6.0% inhibition, respectively) at 10 μM. The anti-inflammatory activities of compounds 1 and 8 to 14 were tested on superoxide anion generation and elastase release by human neutrophils in response to formylmethionylleucyl-phenylalanine plus dihydrocytochalasin B (FMLP/CB) at the concentration of 10 μg/mL. As a result, compounds 11 and 14 showed anti-inflammatory effects (31.29±6.67% and 25.33±4.04%) on elastase release and superoxide anion generation, respectively.
[0062] The isolated compounds 1 and 8 to 14 were evaluated for their in vitro cytotoxicity against cancer cells. Compounds 1, 8, 13 and 14 showed cytotoxic activity against Hep-G2 cells (ED 50 of 20.34±0.58, 18.05±0.58, 37.78±0.81 and 16.86±0.85 μg/mL, respectively), compounds 1, 8 and 14 showed the cytotoxic activity against WiDr cells (ED 50 of 18.67±0.56, 19.13±0.56 and 15.45±0.73 μg/mL, respectively), and compounds 8 and 12 showed the cytotoxic activity against Hep-2 cells (ED 50 of 16.07±0.17 and 17.92±0.25 μg/mL, respectively). Other compounds, compounds 9, 10 and 11, showed various cytotoxicities against Hep-G2, WiDr and Hep-2 carcinoma (not shown).
[0063] Because compounds 1, 8 and 14 belong to the diterpenoids having a similar main structure, compounds 1, 8 and 14 can be used for anti-virus, anti-inflammation or anti-cancer treatments, and can be prepared as pharmaceutical compositions and drugs.
[0064] While the invention has been described in terms of what is presently considered to be the most practical and preferred Embodiments, it is to be understood that the invention needs not be limited to the disclosed Embodiments. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.
[0000]
TABLE 1
1 H NMR Data (400 MHz) of Compounds 1, 8, 9 and 10 a
Position
1
8
9
10
1α
1.49 m
1.47 m
1.55 m
1.55 m
1β
1.85 m
1.89 ddd (13.0,
1.75 m
1.71 m
7.6, 4.4)
2α
2.36 m
2.45 ddd (16.1,
2.44 ddd (16.4,
2.43 ddd (16.4,
7.8, 4.4)
7.7, 3.6)
7.7, 3.7)
2β
2.47 ddd (16.0,
2.52 ddd (16.1,
2.55 ddd (16.4,
2.53 ddd (16.4,
10.4, 7.3)
7.8, 9.9)
7.7, 10.1)
7.7, 10.0)
3
4
5
1.47 m
1.50 m
1.47 m
1.46 m
6β
1.38 m
1.43 m
1.46 m
1.45 m
6α
1.55 m
1.61 m
1.72 m
1.69 m
7α
1.42 m
1.39 m
1.46 m
1.42 m
7β
1.85 m
1.83 m
1.97 m
1.98 m
8
9
1.37 m
1.33 dd (12.5, 1.7)
1.54 m
1.36 dd (12.0, 8.8)
10
11α
2.16 m
1.77 ddd (12.5,
1.56 m
1.70 m
4.7, 1.7)
11β
2.39 m
1.57 m
1.69 m
1.76 m
12
5.50 t (7.1)
3.51 dd (11.4, 4.7)
3.79 dd (10.0, 5.4)
3.94 dd (7.9, 4.7)
13
14
6.27 dd (17.4,
6.29 dd (17.8,
5.84 dd (17.4,
5.93 dd (17.3,
10.7)
11.3)
10.9)
10.7)
15α
4.86 d (10.7)
5.24 dd (11.3, 1.1)
5.10 dd (10.9, 1.7)
5.11 dd (10.7, 0.8)
15β
5.01 d (17.4)
5.43 dd (17.8, 1.1)
5.28 dd (17.4, 1.7)
5.28 dd (17.3, 0.8)
16
1.73 s
1.35 s
1.30 s
1.21 s
17
1.17 s
1.27 s
1.19 s
1.16 s
18
0.98 s
0.99 s
1.02 s
1.02 s
19
1.04 s
1.07 s
1.09 s
1.09 s
20
0.92 s
0.86 s
0.92 s
0.91 s
a Chemical shifts are in ppm (δ); J values in Hz are in parentheses.
[0000]
TABLE 2
1 H NMR Data (400 MHz) of Compounds 11, 12, 13 and 14 a
Position
11
12
13
14
1α
1.51 m
1.11 m
0.76 m
0.70 m
1β
1.65 m
1.42 ddd (13.1,
1.35 m
1.39 m
3.5, 3.5)
2α
2.38 ddd (16.3,
1.55 m
1.66 m
1.67 m
7.7, 3.7)
2β
2.48 ddd (16.3,
1.61 m
1.92 m
1.94 m
7.7, 10.1)
3
3.20 dd (10.8, 5.5)
0.53 m
0.54 m
4
5
1.43 m
0.87 m
0.90 m
0.87 dd (12.5, 3.6)
6β
1.41 m
1.33 m
1.46 m
1.46 m
6α
1.65 m
1.74 m
1.86 m
1.87 m
7α
1.40 m
1.35 m
1.39 m
1.40 m
7β
1.92 m
1.92 m
1.90 m
1.90 m
8
9
1.33 m
1.28 dd (12.9, 7.6)
1.22 dd (13.2, 7.4)
1.23 dd (13.8, 5.1)
10
11α
1.60 m
1.58 m
1.59 m
1.52 m
11β
1.68 m
1.64 m
1.74 m
1.79 m
12
3.88 dd (9.0, 3.6)
3.89 dd (12.9, 7.6)
4.14 dd (9.3, 3.4)
3.98 dd (10.0, 5.8)
13
14
5.81 dd (17.4,
5.84 dd (17.4,
5.66 dd (17.4, 1.4)
5.65 dd (17.4,
10.9)
10.9)
10.9)
15α
5.07 dd (10.9, 1.5)
5.10 dd (10.9, 1.3)
5.19 dd (10.9, 1.4)
5.17 dd (10.9, 1.6)
15β
5.22 dd (17.4, 1.5)
5.25 dd (17.4, 1.3)
5.37 dd (17.4, 1.4)
5.40 dd (17.4, 1.6)
16
1.21 s
1.23 s
3.36 d (11.2)
3.37 d (11.1)
3.78 d (11.2)
3.83 d (11.1)
17
1.12 s
1.11 s
1.16 s
1.23 s
18
0.97 s
0.76 s
0.93 s
0.93 s
19
1.05 s
0.96 s
0.44 dd (9.2, 4.0)
0.45 dd (9.4, 4.0)
−0.04 dd (5.4, 4.0)
−0.04 dd (5.6, 4.0)
20
0.86 s
0.78 s
0.77 s
0.81 s
a Chemical shifts are in ppm (δ); J values in Hz are in parentheses.
[0000]
TABLE 3
13 C NMR Data (100 MHz) of Compounds 1 and 8 to 14 a
Position
1
8
9
10
11
12
13
14
1
38.4
38.0
38.1
38.0
37.8
37.8
35.5
35.9
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
2
33.6
33.7
33.7
33.7
33.6
27.0
18.4
18.5
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
3
216.7
217.1
216.7
216.8
216.7
78.9
17.8
17.7
(C)
(C)
(C)
(C)
(C)
(CH)
(CH)
(CH)
4
47.0 (C)
47.2 (C)
47.3 (C)
47.3 (C)
47.1 (C)
38.7 (C)
15.7 (C)
15.8 (C)
5
54.6
54.3
54.9
55.1
54.9
55.9
52.5
52.5
(CH)
(CH)
(CH)
(CH)
(CH)
(CH)
(CH)
(CH)
6
20.9
20.8
22.4
21.6
21.5
20.2
24.3
25.0
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
7
42.9
41.4
39.9
38.7
38.5
39.3
38.9
39.9
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
8
73.1 (C)
75.4 (C)
80.7 (C)
80.9 (C)
80.8 (C)
81.3 (C)
81.9 (C)
81.8 (C)
9
60.6
56.9
60.2
59.4
59.1
59.9
57.2
57.2
(CH)
(CH)
(CH)
(CH)
(CH)
(CH)
(CH)
(CH)
10
38.1 (C)
36.4 (C)
35.9 (C)
35.9 (C)
35.7 (C)
35.9 (C)
34.9 (C)
35.0 (C)
11
24.0
25.4
24.4
23.9
24.1
24.2
24.7
24.3
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
12
135.1
77.5
85.1
81.4
81.3
81.5
81.5
85.4
(CH)
(CH)
(CH)
(CH)
(CH)
(CH)
(CH)
(CH)
13
132.4 (C)
76.6 (C)
73.3 (C)
74.4 (C)
74.3 (C)
74.5 (C)
75.4 (C)
73.9 (C)
14
141.1
140.1
140.9
142.8
140.9
141.1
137.4
136.9
(CH)
(CH)
(CH)
(CH)
(CH)
(CH)
(CH)
(CH)
15
110.4
117.4
113.6
113.0
113.6
113.6
115.9
115.7
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
(CH 2 )
16
11.6
27.9
25.9
23.6
24.6
24.9
69.4
69.9
(CH 3 )
(CH 3 )
(CH 3)
(CH 3)
(CH 3)
(CH 3)
(CH 2
(CH 2 )
17
23.6
24.9
24.9
20.7
20.8
21.3
21.2
24.7
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
18
20.9
20.8
20.7
20.8
20.6
15.1
23.1
23.0
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
19
26.4
26.6
26.8
26.9
26.8
28.1
22.9
22.9
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
20
14.8
15.6
15.3
14.3
14.1
14.8
11.2
12.0
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
(CH 3 )
a Assignments were made using HMQC and HMBC techniques.
[0000]
TABLE 4
1 H and 13 C NMR spectroscopic data of compound 2
Position
1 H a
13 C b
1
1.59 m
37.6 (CH 2 )
1.70 m
2
2.46 ddd (16.5, 7.8, 3.3)
33.3 (CH 2 )
2.55 ddd (16.5, 7.8, 10.1)
3
215.4 (C)
4
47.3 (C)
5
1.59 m
54.3 (CH)
6
1.52 m
21.4 (CH 2 )
1.81 m
7
1.69 m
37.7 (CH 2 )
2.10 ddd (12.0, 3.3, 3.3)
8
85.6 (C)
9
1.97 dd (14.8, 6.5)
58.1 (CH)
10
35.5 (C)
11
2.26 dd (16.2, 6.5)
28.6 (CH 2 )
2.44 dd (16.2, 14.8)
12
175.9 (C)
13
1.35 s
21.1 (CH 3 )
14
1.09 s
14.5 (CH 3 )
15
1.03 s
26.6 (CH 3 )
16
0.99 s
20.6 (CH 3 )
a Measured at 400 MHz, J value in Hz
b Measured at 100 MHz
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The present invention discloses eight new diterpenoids, i.e. Dysongensins A to H, extracted from the leaves and twigs of Dysoxylum hongkongense , wherein AMBROX® which is applicable in the perfume industry is prepared from Dysongensin A via a series of chemical reactions, and the cytotoxicity of Dysongensins A to H against human cancer cell lines and their antiviral and anti-inflammatory activities are determined. Therefore, in the present invention, AMBROX® prepared from Dysongensin A is a new idea for application as an odorous compound in the perfume industry, and the novel diterpenoids can be prepared as a pharmaceutical compositions and/or a drug having antiviral, anti-inflammatory and/or anti-cancer activities.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. Non-Provisional patent application Ser. No. 13/300,537, filed Nov. 18, 2011, which claims the benefit of U.S. Provisional Application Ser. No. 61/416,081 filed Nov. 22, 2010, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to novel derivatives, processes for preparing them, pharmaceutical compositions containing them and their use as pharmaceuticals, as modulators of sphingosine-1-phosphate receptors. The invention relates specifically to the use of these compounds and their pharmaceutical compositions to treat disorders associated with sphingosine-1-phosphate (S1P) receptor modulation.
BACKGROUND OF THE INVENTION
Sphingosine-1 phosphate is stored in relatively high concentrations in human platelets, which lack the enzymes responsible for its catabolism, and it is released into the blood stream upon activation of physiological stimuli, such as growth factors, cytokines, and receptor agonists and antigens. It may also have a critical role in platelet aggregation and thrombosis and could aggravate cardiovascular diseases. On the other hand the relatively high concentration of the metabolite in high-density lipoproteins (HDL) may have beneficial implications for atherogenesis. For example, there are recent suggestions that sphingosine-1-phosphate, together with other lysolipids such as sphingosylphosphorylcholine and lysosulfatide, are responsible for the beneficial clinical effects of HDL by stimulating the production of the potent antiatherogenic signaling molecule nitric oxide by the vascular endothelium. In addition, like lysophosphatidic acid, it is a marker for certain types of cancer, and there is evidence that its role in cell division or proliferation may have an influence on the development of cancers. These are currently topics that are attracting great interest amongst medical researchers, and the potential for therapeutic intervention in sphingosine-1-phosphate metabolism is under active investigation.
SUMMARY OF THE INVENTION
We have now discovered a group of novel compounds which are potent and selective sphingosine-1-phosphate modulators. As such, the compounds described herein are useful in treating a wide variety of disorders associated with modulation of sphingosine-1-phosphate receptors. The term “modulator” as used herein, includes but is not limited to: receptor agonist, antagonist, inverse agonist, inverse antagonist, partial agonist, partial antagonist.
This invention describes compounds of Formula I, which have sphingosine-1-phosphate receptor biological activity. The compounds in accordance with the present invention are thus of use in medicine, for example in the treatment of humans with diseases and conditions that are alleviated by S1P modulation. In one aspect, the invention provides a compound having Formula I or a pharmaceutically acceptable salt thereof or stereoisomeric forms thereof, or the geometrical isomers, enantiomers, diastereoisomers, tautomers, zwitterions and pharmaceutically acceptable salts thereof:
In one embodiment of the invention, there are provided compounds having the Formula I below and pharmaceutically accepted salts thereof, its enantiomers, diastereoisomers, hydrates, solvates, crystal forms and individual isomers, tautomers or a pharmaceutically acceptable salt thereof,
wherein:
R 1 is N or C—R 9 ;
R 2 is substituted or unsubstituted aromatic heterocycle, C 5-8 cycloalkenyl or C 6-10 aryl;
R 3 is O, N—R 10 , CH—R 11 , S, —CR 12 ═CR 13 —, —C≡C— or —C(O)—;
R 4 is H, C 5-8 cycloalkenyl, C 3-8 cycloalkyl or substituted or unsubstituted C 6-10 aryl;
R 5 is H, halogen, —OC 1-3 alkyl, C 1-3 alkyl or hydroxyl;
R 6 is H, halogen, —OC 1-3 alkyl, C 1-3 alkyl or hydroxyl;
a is 0, 1, 2, 3 or 4;
b is 0, 1, 2, 3 or 4;
L is CHR 7 , O, S, NR 8 or —C(O)—;
R 7 is H, C 1-3 alkyl, —OC 1-3 alkyl, halogen, hydroxyl or NR 9 R 10 ;
R 8 is H or C 1-3 alkyl;
R 9 is H, halogen or C 1-3 alkyl;
R 10 is H or C 1-3 alkyl;
R 11 is H or C 1-3 alkyl;
R 12 is H or C 1-3 alkyl;
R 13 is H or C 1-3 alkyl;
Q 1 is —CR 14 R 15 —;
R 14 is H, halogen, or C 1-3 alkyl;
R 15 is H, halogen, or C 1-3 alkyl;
m is 0, 1, 2 or 3;
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 , O, or S;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —
with the proviso that when R 3 is O, N—R 10 , S, —CR 12 ═CR 13 —, —C≡C— or —C(O)— and b is 0 or 1 then L is not O, S, NR 8 or —C(O)—.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is N or C—R 9 ;
R 2 is a five-membered aromatic substituted or unsubstituted heterocycle or C 5-8 cycloalkenyl;
R 3 is O, N—R 10 , CH—R 11 , S;
R 4 is substituted or unsubstituted C 6-10 aryl;
R 5 is H, or halogen;
R 6 is H or halogen;
R 8 is H or C 1-3 alkyl;
R 9 is H or C 1-3 alkyl;
R 10 is H or C 1-3 alkyl;
R 11 is H or C 1-3 alkyl;
a is 0, 1, 2, 3 or 4;
b is 0, 1, 2, 3 or 4;
L is CH 2 ;
m is 0;
T is —NH-Q 2 ;
“*” represents the point of attachment to the rest of the molecule.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is N or C—R 9 ;
R 2 is furan, 2-furyl and 3-furyl derivatives; thiophene, 2-thienyl and 3-thienyl derivatives; pyrrole, oxazole, thiazole, pyrrolidine, pyrroline, imidazole, pyrazole, pyrazoline, isoxazole, isothiazole, pyrazolidine, imidazoline, thiazoline, oxazoline, dihydrothiophene, dihydrofuran, tetrazole, triazole, oxadiazole, 1,2,5-oxadiazole, thiadiazole, 1,2,3-triazole, 1,2,4-triazole, pyrrolidinone, pyrrol-2(3H)-one, imidazolidin-2-one, or 1,2,4-triazol-5(4H)-one and the like 5-membered heterocyclic rings;
R 3 is O, N—R 10 , CH—R 11 , S;
R 4 is phenyl with ortho, meta and para substitution with groups such as: halogens fluoro, chloro and bromo; short chain alkyls methyl, ethyl, propyl, isopropyl and other, methoxy, trifluoromethoxy, trifluoromethyl and perfluorinated short chain alkyl groups;
R 5 is H, or halogen;
R 6 is H or halogen;
R 8 is H or C 1-3 alkyl;
R 9 is H or C 1-3 alkyl;
R 10 is H or C 1-3 alkyl;
R 11 is H or C 1-3 alkyl;
a is 0, 1, 2, 3 or 4;
b is 0, 1, 2, 3 or 4;
L is CH 2 ;
m is 0;
T is —NH-Q 2 ;
“*” represents the point of attachment to the rest of the molecule.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ;
R 2 is a five-membered aromatic substituted or unsubstituted heterocycle or C 5-8 cycloalkenyl;
R 3 is O, N—R 10 , CH—R 11 , S;
R 4 is substituted or unsubstituted C 6-10 aryl;
R 5 is H, or halogen;
R 6 is H or halogen;
R 8 is H or C 1-3 alkyl;
R 9 is H or C 1-3 alkyl;
R 10 is H or C 1-3 alkyl;
R 11 is H or C 1-3 alkyl;
a is 0, 1, 2, 3 or 4;
b is 0, 1, 2, 3 or 4;
L is CH 2 ;
m is 0;
T is —NH-Q 2 ;
“*” represents the point of attachment to the rest of the molecule.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ;
R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
R 4 is substituted or unsubstituted phenyl;
R 5 is H, Cl, Br or F;
R 6 is H, Cl, Br or F;
a is 1, 2, or 3;
b is 1, 2, or 3;
L is CHR 7 ;
R 7 is H or C 1-3 alkyl;
m is 0;
T is —NH-Q 2 ;
“*” represents the point of attachment to the rest of the molecule.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ;
R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
R 4 is substituted or unsubstituted phenyl;
R 5 is H, Cl, Br or F;
R 6 is H, Cl, Br or F;
a is 1, 2, or 3;
b is 1, 2, or 3;
L is CHR 7 ;
R 7 is H or C 1-3 alkyl;
m is 0;
T is —NH-Q 2 ;
“*” represents the point of attachment to the rest of the molecule.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ;
R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
R 4 is substituted or unsubstituted phenyl;
R 5 is H or F;
R 6 is H or F;
R 8 is H or C 1-3 alkyl;
R 9 is H or C 1-3 alkyl;
a is 1, 2, or 3;
b is 1, 2, or 3;
L is CH 2 ;
m is 0;
T is —NH-Q 2 ;
“*” represents the point of attachment to the rest of the molecule.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ;
R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
R 4 is substituted or unsubstituted phenyl;
R 5 is H or F;
R 6 is H or F;
R 9 is H;
a is 2;
b is 2;
L is CH 2 ;
m is 0;
T is —NH-Q 2 ;
Q 2 is —C 1-6 alkyl,
“*” represents the point of attachment to the rest of the molecule.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 or N;
R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
R 4 is substituted or unsubstituted C 6-10 aryl;
a is 0, 1, 2, 3 or 4;
b is 0, 1, 2, 3 or 4;
R 5 is H, or F,
R 6 is H, or F,
R 9 is H or C 1-3 alkyl;
L is CH 2 ;
Q 1 is —CR 14 R 15 —;
R 14 is H;
R 15 is H;
m is 2;
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ;
Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 or N;
R 2 is a five-membered substituted or unsubstituted heterocycle;
R 3 is O;
R 4 is substituted or unsubstituted phenyl;
R 5 is H, or F;
R 6 is H or F;
a is 1, 2, or 3;
b is 1, 2, or 3;
R 9 is H or C 1-3 alkyl;
L is CH 2 ;
Q 1 is —CR 14 R 15 —;
R 14 is H;
R 15 is H;
m is 2;
“*” represents the point of attachment to the rest of the molecule;
Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ;
R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
R 4 is substituted or unsubstituted phenyl;
R 5 is H or F;
R 6 is H or F;
R 9 is H;
a is 2;
b is 2;
L is CH 2 ;
Q 1 is —CR 14 R 15 —;
R 14 is H;
R 15 is H;
m is 2;
“*” represents the point of attachment to the rest of the molecule;
Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is N or C—R 9 ;
R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
R 4 is substituted or unsubstituted phenyl;
R 5 is H, or F;
R 6 is H, or F;
a is 1, 2, or 3;
b is 1, 2, or 3;
L is CH 2 ;
R 9 is H or C 1-3 alkyl;
m is 0;
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ;
Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9
R 2 is a five-membered aromatic substituted or unsubstituted heterocycle;
R 3 is O;
R 4 is substituted or unsubstituted phenyl;
R 5 is H, or F;
R 6 is H, or F;
R 9 is H;
a is 2;
b is 2;
L is CH 2 ;
m is 0;
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ;
Q 2 is —OPO 3 H 2 , —OH, carboxylic acid, —PO 3 H 2 , H, —C 1-6 alkyl, —P(O)MeOH or —P(O)(H)OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is N or C—R 9 ; R 2 is substituted or unsubstituted heterocycle, C 6-8 cycloalkenyl or C 6-10 aryl; R 3 is O, N—R 10 , CH—R 11 , S, —CR 12 ═CR 13 —, —C≡C— or —C(O)—; R 4 is H, C 6-8 cycloalkenyl, C 3-8 cycloalkyl or substituted or unsubstituted C 6-10 aryl; R 5 is H, halogen, —OC 1-3 alkyl, C 1-3 alkyl or hydroxyl; R 6 is H, halogen, —OC 1-3 alkyl, C 1-3 alkyl or hydroxyl; a is 0, 1, 2, 3 or 4; b is 0, 1, 2, 3 or 4; L is CHR 7 , O, S, NR 8 or —C(O)—; R 7 is H, C 1-3 alkyl, —OC 1-3 alkyl, halogen, hydroxyl or NR 9 R 10 ; R 8 is H or C 1-3 alkyl; R 9 is H, halogen or C 1-3 alkyl; R 10 is H or C 1-3 alkyl; R 11 is H or C 1-3 alkyl; R 12 is H or C 1-3 alkyl; R 13 is H or C 1-3 alkyl; Q 1 is —CR 14 R 15 —; R 14 is H, halogen, or C 1-3 alkyl; R 15 is H, halogen, or C 1-3 alkyl; m is 0, 1, 2 or 3;
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 , O, or S;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl,
with the proviso that when R 3 is O, N—R 10 , S, —CR 12 ═CR 13 —, —C≡C— or —C(O)— and b is 0 or 1 then L is not O, S, NR 8 or —C(O)—.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted C 6-10 aryl; R 5 is H or halogen; R 6 is H or halogen; a is 1 or 2; b is 1 or 2; L is CHR 7 ; R 7 is H; R 9 is H or C 1-3 alkyl; Q 1 is —CR 14 R 15 —; R 14 is H; R 15 is H; m is 2;
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —P(O)MeOH, —P(O)(H)OH, —OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted C 6-10 aryl; R 5 is H or halogen; R 6 is H or halogen; a is 1 or 2; b is 1 or 2; L is CHR 7 ; R 7 is H; R 9 is H or C 1-3 alkyl; Q 1 is —CR 14 R 15 —; R 14 is H; R 15 is H; m is 2; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
R 18 is NR 9 ;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —P(O)MeOH, —P(O)(H)OH, —OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is a five-membered substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted C 6-10 aryl; R 5 is H or halogen; R 6 is H or halogen; a is 1 or 2; b is 1 or 2; L is CHR 7 ; R 7 is H; R 9 is H or C 1-3 alkyl; Q 1 is —CR 14 R 15 —; R 14 is H; R 15 is H; m is 2;
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl, H, —P(O)MeOH, —P(O)(H)OH, —OH.
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl,
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl,
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl,
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl,
In another aspect, the invention provides a compound having Formula I wherein:
R 1 is C—R 9 ; R 2 is substituted or unsubstituted heterocycle; R 3 is O; R 4 is substituted or unsubstituted phenyl; R 5 is H or halogen; R 6 is H or halogen; a is 2; b is 2; L is CHR 7 ; R 7 is H; R 9 is H; m is 0; T is —NH-Q 2 ,
“*” represents the point of attachment to the rest of the molecule;
Q 2 is the same or independently —OPO 3 H 2 , carboxylic acid, —PO 3 H 2 , —C 1-6 alkyl,
The term “alkyl”, as used herein, refers to saturated, monovalent hydrocarbon moieties having linear or branched moieties or combinations thereof and containing 1 to 6 carbon atoms. One methylene (—CH 2 —) group, of the alkyl can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, or by a divalent C 3-6 cycloalkyl. Alkyl groups can be substituted by halogen, amino, hydroxyl, cycloalkyl, amino, non-aromatic heterocycles, carboxylic acid, phosphonic acid groups, sulphonic acid groups, phosphoric acid.
The term “short chain alkyl” as used herein, refers to saturated monovalent linear or branched moieties containing 1 to 3 carbon atoms.
The term perfluorinated short chain alkyl groups as used herein, refers to but CF 3 —CF 2 —, CF 3 , (CF 3 ) 2 —CH—, CF 3 —(CF 3 ) 2 —.
The term “alkylene”, as used herein, refers to saturated, divalent hydrocarbon moieties having linear or branched moieties or combinations thereof and containing 1 to 6 carbon atoms. One methylene (—CH 2 —) group of the alkylene can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl.
The term “cycloalkyl”, as used herein, refers to a monovalent or divalent group of 3 to 8 carbon atoms, derived from a saturated cyclic hydrocarbon. Cycloalkyl groups can be monocyclic or polycyclic. Cycloalkyl can be substituted by 1 to 3 C 1-3 alkyl groups or 1 or 2 halogens.
The term “cycloalkenyl”, as used herein, refers to a monovalent or divalent group of 5 to 8 carbon atoms, derived from a saturated cycloalkyl having one double bond. Cycloalkenyl groups can be monocyclic or polycyclic. Cycloalkenyl groups can be substituted by C 1-3 alkyl groups or halogens.
The term “halogen”, as used herein, refers to an atom of chlorine, bromine, fluorine, iodine.
The term “alkenyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one double bond. C 2-6 alkenyl can be in the E or Z configuration. Alkenyl groups can be substituted by C 1-3 alkyl.
The term “alkynyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one triple bond.
The term “heterocycle” as used herein, refers to a 3 to 10 membered ring, which is aromatic or non-aromatic, saturated or non-saturated and containing at least one heteroatom selected form O or N or S or combinations of at least two thereof, interrupting the carbocyclic ring structure. The heterocyclic ring can be interrupted by a C═O; the S heteroatom can be oxidized. Heterocycles can be monocyclic or polycyclic. Heterocyclic ring moieties can be substituted by hydroxyl, C 1-3 alkyl or halogens. Examples of aromatic heterocycles are, but not limited to: furan, 2-furyl and 3-furyl derivatives; thiophene, 2-thienyl, 3-thienyl derivatives; pyrrole, oxazole, thiazole, imidazole, pyrazole, isoxazole, isothiazole, tetrazole, triazole, oxadiazole, 1,2,5-oxadiazole, thiadiazole, 1,2,3-triazole, 1,2,4-triazole.
Examples of non-aromatic heterocycles are, but not limited to: pyrrolidine, pyrroline, pyrazoline, pyrazolidine, imidazoline, thiazoline, oxazoline, dihydrothiophene, dihydrofuran, pyrrolidinone, pyrrol-2(3H)-one, imidazolidin-2-one, or 1,2,4-triazol-5(4H)-one.
Usually, in the present case, heterocyclic groups are 5 or 6 membered rings including but not limited to: 1-substituted-1H-1,2,4-triazole, 1-substituted-azetidine-3-CO 2 H, 4-linked-indole, 6-methyl-5-linked-indazole or 6-hydro-5-linked-indazole. Some preferred heterocycles at the R 2 position include the following: furan, 2-furyl and 3-furyl derivatives; thiophene, 2-thienyl and 3-thienyl derivatives; pyrrole, oxazole, thiazole, pyrrolidine, pyrroline, imidazole, pyrazole, pyrazoline, isoxazole, isothiazole, pyrazolidine, imidazoline, thiazoline, oxazoline, dihydrothiophene, dihydrofuran, tetrazole, triazole, oxadiazole, 1,2,5-oxadiazole, thiadiazole, 1,2,3-triazole, 1,2,4-triazole, pyrrolidinone, pyrrol-2(3H)-one, imidazolidin-2-one, or 1,2,4-triazol-5(4H)-one and the like 5-membered heterocyclic rings.
The term “aryl” as used herein, refers to an organic moiety derived from an aromatic hydrocarbon consisting of a ring containing 6 to 10 carbon atoms by removal of one hydrogen. Aryl is optionally substituted by halogen atoms or by C 1-3 alkyl groups. Preferred aryl groups at the R 4 position include: phenyl with ortho, meta and para substitution with groups such as: halogens fluoro, chloro and bromo; short chain alkyls methyl, ethyl, propyl, isopropyl and other, methoxy, trifluoromethoxy, trifluoromethyl and perfluorinated short chain alkyl groups.
The group of formula “—CR 12 ═CR 13 —”, as used herein, represents an alkenyl radical.
The group of formula “—C≡C—”, as used herein, represents an alkynyl radical.
The term “hydroxyl” as used herein, represents a group of formula “—OH”.
The term “carbonyl” as used herein, represents a group of formula “—C(O)”.
The term “carboxyl” as used herein, represents a group of formula “—C(O)O—”.
The term “sulfonyl” as used herein, represents a group of formula “—SO 2 ”.
The term “sulfate” as used herein, represents a group of formula “—O—S(O) 2 —O—”.
The term “carboxylic acid” as used herein, represents a group of formula “—C(O)OH”.
The term “sulfoxide” as used herein, represents a group of formula “—S═O”.
The term “phosphonic acid” as used herein, represents a group of formula “—P(O)(OH) 2 ”.
The term “phosphoric acid” as used herein, represents a group of formula “—(O)P(O)(OH) 2 ”.
The term “boronic acid”, as used herein, represents a group of formula “—B(OH) 2 ”.
The term “sulphonic acid” as used herein, represents a group of formula “—S(O) 2 OH”.
The formula “H”, as used herein, represents a hydrogen atom.
The formula “O”, as used herein, represents an oxygen atom.
The formula “N”, as used herein, represents a nitrogen atom.
The formula “S”, as used herein, represents a sulfur atom.
Some compounds of the invention are:
(2R)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate; (2S)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate; 2-amino-3-hydroxy-2-methyl-N-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}propanamide; 2-amino-3-hydroxy-2-methyl-N-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}propanamide; (2S)-2-amino-3-({3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-3-oxopropyl dihydrogen phosphate; (2S)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate; 2-amino-N-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-3-hydroxypropanamide; 2-amino-3-hydroxy-N-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}propanamide; 2-amino-3-({3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-3-oxopropyl dihydrogen phosphate; 2-amino-3-{[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]amino}-3-oxopropyl dihydrogen phosphate; 2-amino-3-({3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-3-oxopropyl dihydrogen phosphate; 2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}amino)propyl dihydrogen phosphate; 2-amino-3-({6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}amino)-3-oxopropyl dihydrogen phosphate; 2-amino-N-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-3-hydroxypropanamide; 2-amino-N-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-3-hydroxypropanamide; 2-amino-N-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-3-hydroxypropanamide; 2-amino-3-hydroxy-N-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}propanamide; 2-amino-N-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}-3-hydroxypropanamide; 2-amino-4-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-2-(hydroxymethyl)-4-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}butyl dihydrogen phosphate; 2-amino-4-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-4-[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-4-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-2-(hydroxymethyl)-4-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}butyl dihydrogen phosphate; 2-amino-4-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}-2-(hydroxymethyl)butyl dihydrogen phosphate; 2-amino-2-(2-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}ethyl)propane-1,3-diol; 2-amino-2-(2-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}ethyl)propane-1,3-diol; 2-amino-2-(2-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}ethyl)propane-1,3-diol; 2-amino-2-{2-[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]ethyl}propane-1,3-diol; 2-amino-2-(2-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}ethyl)propane-1,3-diol; 2-amino-2-(2-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}ethyl)propane-1,3-diol; 2-amino-2-(2-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}ethyl)propane-1,3-diol; 2-amino-2-(4-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-{4-[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]-1H-imidazol-2-yl}ethyl dihydrogen phosphate; 2-amino-2-(4-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}-1H-imidazol-2-yl)ethyl dihydrogen phosphate; 2-amino-2-(4-{3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethanol; 2-amino-2-(4-{4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}-1H-imidazol-2-yl)ethanol; 2-amino-2-(4-{3-(5-fluoro-2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethanol; 2-amino-2-{4-[4-{[5-(4-fluorophenyl)pentyl]oxy}-3-(2-furyl)phenyl]-1H-imidazol-2-yl}ethanol; 2-amino-2-(4-{3-(3-furyl)-4-[(5-phenylpentyl)oxy]phenyl}-1H-imidazol-2-yl)ethanol; 2-amino-2-(4-{4-[(5-phenylpentyl)oxy]-3-(3-thienyl)phenyl}-1H-imidazol-2-yl)ethanol; 2-amino-2-(4-{6-(2-furyl)-5-[(5-phenylpentyl)oxy]pyridin-2-yl}-1H-imidazol-2-yl)ethanol.
Some compounds of Formula I and some of their intermediates have at least one stereogenic center in their structure. This stereogenic center may be present in an R or S configuration, said R and S notation is used in correspondence with the rules described in Pure Appli. Chem. (1976), 45, 11-13.
The term “pharmaceutically acceptable salts” refers to salts or complexes that retain the desired biological activity of the above identified compounds and exhibit minimal or no undesired toxicological effects. The “pharmaceutically acceptable salts” according to the invention include therapeutically active, non-toxic base or acid salt forms, which the compounds of Formula I are able to form.
The acid addition salt form of a compound of Formula I that occurs in its free form as a base can be obtained by treating the free base with an appropriate acid such as an inorganic acid, for example, a hydrohalic acid, such as hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid and the like; or an organic acid such as for example, acetic, hydroxyacetic, propanoic, lactic, pyruvic, malonic, fumaric acid, maleic acid, oxalic acid, tartaric acid, succinic acid, malic acid, ascorbic acid, benzoic acid, tannic acid, pamoic acid, citric, methylsulfonic, ethanesulfonic, benzenesulfonic, formic and the like (Handbook of Pharmaceutical Salts, P. Heinrich Stahal& Camille G. Wermuth (Eds), Verlag Helvetica Chemica Acta—Zurich, 2002, 329-345).
Compounds of Formula I and their salts can be in the form of a solvate, which is included within the scope of the present invention. Such solvates include for example hydrates, alcoholates and the like.
With respect to the present invention reference to a compound or compounds, is intended to encompass that compound in each of its possible isomeric forms and mixtures thereof unless the particular isomeric form is referred to specifically. Compounds according to the present invention may exist in different polymorphic forms. Although not explicitly indicated in the above formula, such forms are intended to be included within the scope of the present invention.
The compounds of the invention are indicated for use in treating or preventing conditions in which there is likely to be a component involving the sphingosine-1-phosphate receptors.
In another embodiment, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier.
In a further embodiment of the invention, there are provided methods for treating disorders associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a pharmaceutical composition containing a therapeutically effective amount of at least one compound of the invention.
These compounds are useful for the treatment of mammals, including humans, with a range of conditions and diseases that are alleviated by S1P modulation: not limited to the treatment of diabetic retinopathy, other retinal degenerative conditions, dry eye, angiogenesis and wounds.
Therapeutic utilities of S1P modulators are ocular diseases, such as but not limited to: wet and dry age-related macular degeneration, diabetic retinopathy, retinopathy of prematurity, retinal edema, geographic atrophy, glaucomatous optic neuropathy, chorioretinopathy, hypertensive retinopathy, ocular ischemic syndrome, prevention of inflammation-induced fibrosis in the back of the eye, various ocular inflammatory diseases including uveitis, scleritis, keratitis, and retinal vasculitis; or systemic vascular barrier related diseases such as but not limited to: various inflammatory diseases, including acute lung injury, its prevention, sepsis, tumor metastasis, atherosclerosis, pulmonary edemas, and ventilation-induced lung injury; or autoimmune diseases and immunosuppression such as but not limited to: rheumatoid arthritis, Crohn's disease, Graves' disease, inflammatory bowel disease, multiple sclerosis, Myasthenia gravis, Psoriasis, ulcerative colitis, antoimmune uveitis, renal ischemia/perfusion injury, contact hypersensitivity, atopic dermititis, and organ transplantation; or allergies and other inflammatory diseases such as but not limited to: urticaria, bronchial asthma, and other airway inflammations including pulmonary emphysema and chronic obstructive pulmonary diseases; or cardiac protection such as but not limited to: ischemia reperfusion injury and atherosclerosis; or wound healing such as but not limited to: scar-free healing of wounds from cosmetic skin surgery, ocular surgery, GI surgery, general surgery, oral injuries, various mechanical, heat and burn injuries, prevention and treatment of photoaging and skin ageing, and prevention of radiation-induced injuries; or bone formation such as but not limited to: treatment of osteoporosis and various bone fractures including hip and ankles; or anti-nociceptive activity such as but not limited to: visceral pain, pain associated with diabetic neuropathy, rheumatoid arthritis, chronic knee and joint pain, tendonitis, osteoarthritis, neuropathic pains; or central nervous system neuronal activity in Alzheimer's disease, age-related neuronal injuries; or in organ transplant such as renal, corneal, cardiac or adipose tissue transplant; inflammatory skin diseases, scleroderma, dermatomyositis, atopic dermatitis, lupus erythematosus, epidermolysis bullosa, and bullous pemphigold. Topical use of S1P (sphingosine) compounds is of use in the treatment of various acne diseases, acne vulgaris, and rosacea.
In still another embodiment of the invention, there are provided methods for treating disorders associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a therapeutically effective amount of at least one compound of the invention, or any combination thereof, or pharmaceutically acceptable salts, hydrates, solvates, crystal forms and individual isomers, enantiomers, and diastereomers thereof.
The present invention concerns the use of a compound of Formula I or a pharmaceutically acceptable salt thereof, for the manufacture of a medicament for the treatment of ocular disease, wet and dry age-related macular degeneration, diabetic retinopathy, retinopathy of prematurity, retinal edema, geographic atrophy, glaucomatous optic neuropathy, chorioretinopathy, hypertensive retinopathy, ocular ischemic syndrome, prevention of inflammation-induced fibrosis in the back of the eye, various ocular inflammatory diseases including uveitis, scleritis, keratitis, and retinal vasculitis; or systemic vascular barrier related diseases, various inflammatory diseases, including acute lung injury, its prevention, sepsis, tumor metastasis, atherosclerosis, pulmonary edemas, and ventilation-induced lung injury; or autoimmune diseases and immunosuppression, rheumatoid arthritis, Crohn's disease, Graves' disease, inflammatory bowel disease, multiple sclerosis, Myasthenia gravis, Psoriasis, ulcerative colitis, antoimmune uveitis, renal ischemia/perfusion injury, contact hypersensitivity, atopic dermititis, and organ transplantation; or allergies and other inflammatory diseases, urticaria, bronchial asthma, and other airway inflammations including pulmonary emphysema and chronic obstructive pulmonary diseases; or cardiac protection, ischemia reperfusion injury and atherosclerosis; or wound healing, scar-free healing of wounds from cosmetic skin surgery, ocular surgery, GI surgery, general surgery, oral injuries, various mechanical, heat and burn injuries, prevention and treatment of photoaging and skin ageing, and prevention of radiation-induced injuries; or bone formation, treatment of osteoporosis and various bone fractures including hip and ankles; or anti-nociceptive activity, visceral pain, pain associated with diabetic neuropathy, rheumatoid arthritis, chronic knee and joint pain, tendonitis, osteoarthritis, neuropathic pains; or central nervous system neuronal activity in Alzheimer's disease, age-related neuronal injuries; or in organ transplant such as renal, corneal, cardiac or adipose tissue transplant; inflammatory skin diseases, scleroderma, dermatomyositis, atopic dermatitis, lupus erythematosus, epidermolysis bullosa, and bullous pemphigold.
The actual amount of the compound to be administered in any given case will be determined by a physician taking into account the relevant circumstances, such as the severity of the condition, the age and weight of the patient, the patient's general physical condition, the cause of the condition, and the route of administration.
The patient will be administered the compound orally in any acceptable form, such as a tablet, liquid, capsule, powder and the like, or other routes may be desirable or necessary, particularly if the patient suffers from nausea. Such other routes may include, without exception, transdermal, parenteral, subcutaneous, intranasal, via an implant stent, intrathecal, intravitreal, topical to the eye, back to the eye, intramuscular, intravenous, and intrarectal modes of delivery. Additionally, the formulations may be designed to delay release of the active compound over a given period of time, or to carefully control the amount of drug released at a given time during the course of therapy.
In another embodiment of the invention, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier thereof. The phrase “pharmaceutically acceptable” means the carrier, diluent or excipient must be compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
Pharmaceutical compositions of the present invention can be used in the form of a solid, a solution, an emulsion, a dispersion, a patch, a micelle, a liposome, and the like, wherein the resulting composition contains one or more compounds of the present invention, as an active ingredient, in admixture with an organic or inorganic carrier or excipient suitable for enteral or parenteral applications. Invention compounds may be combined, for example, with the usual non-toxic, pharmaceutically acceptable carriers for tablets, pellets, capsules, suppositories, solutions, emulsions, suspensions, and any other form suitable for use. The carriers which can be used include glucose, lactose, gum acacia, gelatin, mannitol, starch paste, magnesium trisilicate, talc, corn starch, keratin, colloidal silica, potato starch, urea, medium chain length triglycerides, dextrans, and other carriers suitable for use in manufacturing preparations, in solid, semisolid, or liquid form. In addition auxiliary, stabilizing, thickening and coloring agents and perfumes may be used. Invention compounds are included in the pharmaceutical composition in an amount sufficient to produce the desired effect upon the process or disease condition.
Pharmaceutical compositions containing invention compounds may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Compositions intended for oral use may be prepared according to any method known in the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of a sweetening agent such as sucrose, lactose, or saccharin, flavoring agents such as peppermint, oil of wintergreen or cherry, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets containing invention compounds in admixture with non-toxic pharmaceutically acceptable excipients may also be manufactured by known methods. The excipients used may be, for example, (1) inert diluents such as calcium carbonate, lactose, calcium phosphate or sodium phosphate; (2) granulating and disintegrating agents such as corn starch, potato starch or alginic acid; (3) binding agents such as gum tragacanth, corn starch, gelatin or acacia, and (4) lubricating agents such as magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be employed.
In some cases, formulations for oral use may be in the form of hard gelatin capsules wherein the invention compounds are mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin. They may also be in the form of soft gelatin capsules wherein the invention compounds are mixed with water or an oil medium, for example, peanut oil, liquid paraffin or olive oil.
The pharmaceutical compositions may be in the form of a sterile injectable suspension. This suspension may be formulated according to known methods using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides, fatty acids (including oleic acid), naturally occurring vegetable oils like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or synthetic fatty vehicles like ethyl oleate or the like. Buffers, preservatives, antioxidants, and the like can be incorporated as required.
Invention compounds may also be administered in the form of suppositories for rectal administration of the drug. These compositions may be prepared by mixing the invention compounds with a suitable non-irritating excipient, such as cocoa butter, synthetic glyceride esters of polyethylene glycols, which are solid at ordinary temperatures, but liquefy and/or dissolve in the rectal cavity to release the drug.
Since individual subjects may present a wide variation in severity of symptoms and each drug has its unique therapeutic characteristics, the precise mode of administration and dosage employed for each subject is left to the discretion of the practitioner.
The compounds and pharmaceutical compositions described herein are useful as medicaments in mammals, including humans, for treatment of diseases and/or alleviations of conditions which are responsive to treatment by agonists or functional antagonists of sphingosine-1-phosphate receptors. Thus, in further embodiments of the invention, there are provided methods for treating a disorder associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a pharmaceutical composition containing a therapeutically effective amount of at least one invention compound. As used herein, the term “therapeutically effective amount” means the amount of the pharmaceutical composition that will elicit the biological or medical response of a subject in need thereof that is being sought by the researcher, veterinarian, medical doctor or other clinician. In some embodiments, the subject in need thereof is a mammal. In some embodiments, the mammal is human.
The present invention concerns also processes for preparing the compounds of Formula I. The compounds of formula I according to the invention can be prepared analogously to conventional methods as understood by the person skilled in the art of synthetic organic chemistry. The synthetic schemes set forth below, illustrate how compounds according to the invention can be made. Those skilled in the art will be able to routinely modify and/or adapt the following schemes to synthesize any compounds of the invention covered by Formula I.
In Scheme 1, aryl amines or aryl amine derivatives or precursors react with functionalized compounds such as halogenated or hydroxylated compounds in the presence of reagents that promote alkylation as known to synthetic chemists to give the corresponding ether intermediate. This intermediate from the last step is coupled with the boronic acid or the stannate, generally involving a metal catalyst under appropriate conditions with an R 2 group to give the corresponding intermediate. The previous intermediate from the coupling procedure may be converted to an aryl amine as required for the next step by deprotection or reduction methods. The intermediate from the previous step reacts to form an amide under conditions that may employ carboxylic acids and the like to give an intermediate of Formula I. This intermediate from the last step is reacted with appropriate reagents to promote phosphorylation and yield a derivative of Formula I as a Compound of the invention upon removal of any required protecting groups.
In Scheme II, aryl amines/amine precursors that may contain a halogen such as a bromine atom, react with functionalized compounds such as a halogenated or hydroxylated compound, in the presence of reagents that promote alkylation well known to synthetic chemists to give the corresponding ether intermediate. This intermediate from the last step is coupled with the boronic acid or the stannate involving a metal catalyst under appropriate conditions with an R 2 group (shown as a 2-furyl derivative below) to give the corresponding intermediate. The intermediate from the previous step may be converted to an aryl amine as required for the next step by deprotection or reduction methods. This aryl amine from the last step reacts to form an amide under conditions that may employ carboxylic acids and the like to give an intermediate of Formula I. This intermediate is reacted with appropriate reagents to promote phosphorylation and yield a derivative of Formula I as a Compound of the invention upon removal of any required protecting groups.
In Scheme III, elaborated aryl bromides, are obtained according to application of appropriate synthetic preparation, may react with compounds in the presence of reagents that promote alkylation. This intermediate from the last step that contains the R 3 group (representing an —O—, —S— —NH—, —CH 2 —) or other group is coupled with the boronic acid or the stannate under appropriate conditions with an R 2 group to give the corresponding intermediate. This intermediate from the previous step is reacted with appropriate reagents to promote phosphorylation and yield a derivative of Formula I as a Compound of the invention upon removal of any required protecting groups.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts lowered lymphocyte count after 24 hours (<1 number of lymphocytes 10 3 /μL blood) by Compound 4.
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention claimed. As used herein, the use of the singular includes the plural unless specifically stated otherwise.
It will be readily apparent to those skilled in the art that some of the compounds of the invention may contain one or more asymmetric centers, such that the compounds may exist in enantiomeric as well as in diastereomeric forms. Unless it is specifically noted otherwise, the scope of the present invention includes all enantiomers, diastereomers and racemic mixtures. Some of the compounds of the invention may form salts with pharmaceutically acceptable acids or bases, and such pharmaceutically acceptable salts of the compounds described herein are also within the scope of the invention.
The present invention includes all pharmaceutically acceptable isotopically enriched compounds. Any compound of the invention may contain one or more isotopic atoms enriched or different than the natural ratio such as deuterium 2 H (or D) in place of protium 1 H (or H) or use of 13 C enriched material in place of 12 C and the like. Similar substitutions can be employed for N, O and S. The use of isotopes may assist in analytical as well as therapeutic aspects of the invention. For example, use of deuterium may increase the in vivo half-life by altering the metabolism (rate) of the compounds of the invention. These compounds can be prepared in accord with the preparations described by use of isotopically enriched reagents.
The following examples are for illustrative purposes only and are not intended, nor should they be construed as limiting the invention in any manner. Those skilled in the art will appreciate that variations and modifications of the following examples can be made without exceeding the spirit or scope of the invention.
As will be evident to those skilled in the art, individual isomeric forms can be obtained by separation of mixtures thereof in conventional manner. For example, in the case of diasteroisomeric isomers, chromatographic separation may be employed.
Compound names were generated with ACD version 8, and some intermediates' and reagents' names used in the examples were generated with software such as Chem Bio Draw Ultra version 12.0 or Auto Nom 2000 from MDL ISIS Draw 2.5 SP1 or from a commercial supplier catalog such as Sigma-Aldrich.
In general, characterization of the compounds is performed using NMR spectra which were recorded on 300 and/or 600 MHz Varian and acquired at room temperature. Chemical shifts were given in ppm referenced either to internal TMS or to the solvent signal. Coupling constant J reported in Hz, hertz.
All the reagents, solvents, catalysts for which the synthesis is not described are purchased from chemical vendors such as Sigma Aldrich, Fluka, Bio-Blocks, Combi-blocks, TCI, VWR, Lancaster, Oakwood, Trans World Chemical, Alfa, Fisher, Maybridge, Frontier, Matrix, Ukrorgsynth, Toronto, Ryan Scientific, SiliCycle, Anaspec, Syn Chem, Chem-Impex, MIC-scientific, Ltd; however some known intermediates, were prepared according to published procedures. Usually the compounds of the invention were purified by column chromatography (Auto-column) on a Teledyne-ISCO CombiFlash with a silica gel column, unless noted otherwise.
The following abbreviations are used in the examples:
s, m, h, d
second, minute, hour, day
CH 3 CN
acetonitrile
PSI
pound per square inch
DCM
dichloromethane
DMF
N,N-dimethylformamide
NaOH
sodium hydroxide
MeOH
methanol
CD 3 OD
deuterated methanol
NH 3
ammonia
HCl
hydrochloric acid
Na 2 SO 4
sodium sulfate
RT or rt
room temperature
MgSO 4
magnesium sulfate
EtOAc
ethyl acetate
CDCl 3
deuterated chloroform
DMSO-d 6
deuterated dimethyl sulfoxide
Auto-column
automated flash liquid chromatography
TFA
trifluoroacetic acid
THF
tetrahydrofuran
M
molar
PdCl 2 (PPh 3 ) 2
bis(triphenylphosphine)palladium(II) chloride
AcOH
acetic acid
K 2 CO 3
potassium carbonate
NaCl
sodium chloride
CHCl 3
chloroform
HATU
(O-(7-azabenzotriazol-1-yl)-N,N,N′,N′-
tetramethyluronium hexafluorophosphate)
Those skilled in the art will be routinely able to modify and/or adapt the following procedures to synthesize any compound of the invention covered by Formula I.
Example 1
Intermediate 1
2-bromo-4-nitro-1-((5-phenylpentyl)oxy)benzene
A mixture of 2-bromo-4-nitrophenol (CAS 5847-59-6) (2.05 g, 9.4 mmol), (5-bromopentyl)benzene (CAS 14469-83-1) (2.41 g, 10.6 mmol) and K 2 CO 3 (3.5 g, 19.1 mmol) was dissolved in DMF (20 mL). The reaction mixture was heated at 100° C. for ˜18 h. The mixture was diluted with hexanes:EtOAc (1:1) (˜200 mL) and washed with H 2 O (3×). The organic solution was dried over MgSO 4 , filtered, and concentrated onto silica gel under vacuum. Auto-column (9.5 hexanes: 0.5 EtOAc) gave Intermediate 1 as a white solid 1.91 g (56%).
Example 2
Intermediate 2
2-[5-nitro-2-(5-phenyl-pentyloxy)-phenyl]-thiophene
A mixture of Intermediate 1 (1.91 g, 5.25 mmol), tributyl-thiophen-2-yl-stannane (CAS 54663-78-4) (3.4 mL, 10.7 mmol) and PdCl 2 (PPh 3 ) 2 (0.55 g, 15 mol %) in DMF (12 mL) was reacted under MWI at 160° C. for 15 m. The mixture was cooled to rt and diluted with hexanes:EtOAc (1:1, 200 mL). The mixture was washed with water (3×), dried over MgSO 4 , filtered and concentrated onto silica gel under vacuum. Auto-column (9.5 hexanes: 0.5 EtOAc) produced Intermediate 2 as an orange solid, 1.10 g (57%).
Example 3
Intermediate 3
4-(5-phenyl-pentyloxy)-3-thiophen-2-yl-phenylamine
A mixture of iron chips (0.62 g, 11.1 mmol), NH 4 Cl (0.88 g, 16.4 mmol), water (3.3 mL), and ethanol (10 mL) were heated to reflux for 15 m. This mixture was transferred into a solution of Intermediate 2 (1.0 g, 2.72 mmol) in EtOH (8 mL). The resulting mixture was heated to reflux for 5 h. The mixture was filtered, washed with EtOAc and partitioned between EtOAc and water. The organic layers were dried over MgSO 4 , filtered and concentrated onto silica gel. Auto-column (7 hexane: 3 EtOAc) gave Intermediate 3, as a tan solid 0.55 g (60%).
Example 4
Intermediate 4
(R)-tert-butyl (3-hydroxy-2-methyl-1-oxo-1-((4-((5-phenylpentyl)oxy)-3-(thiophen-2-yl)phenyl)amino)propan-2-yl)carbamate
Intermediate 3 (0.30 g, 0.89 mmol), Boc-D-serine (CAS 84311-18-2) (0.25 g, 1.11 mmol), HATU (CAS 148893-10-1) (0.51 g, 1.34 mmol), diisopropylethylamine (CAS 7087-68-5) (0.46 mL) in DMF (20 mL) was reacted at rt for ˜18 h. After an aqueous workup and extraction with (hexanes:EtOAc) the organic layers were combined and concentrated onto silica gel. Auto-column (3% MeOH in CH 2 Cl 2 ) gave Intermediate 4 0.28 g, (58%).
Example 5
Intermediate 5
2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate
Intermediate 4 (0.28 g, 5.20 mmol), tetrazole (7.0 mL, 3.15 mmol; 0.45 M in CH 3 CN), and di-tert-butyl diisopropyl-phosphoramidite (0.65 mL, 2.06 mmol) in DMF (5 mL) were stirred at RT for ˜18 h. Hydrogen peroxide 35% (0.19 mL, 2.2 mmol) excess was added at 0° C. and the mixture was warmed to RT and stirred for 1 h. The solvent was removed under vacuum and the residue was quenched with sat. Na 2 S 2 O 3 (10% aq) and extracted with EtOAc. The organic layers were dried over MgSO 4 , filtered, concentrated onto silica gel under vacuum. Auto-column (6 hexanes: 4 EtOAc) gave Intermediate 5 as a white solid 0.27 g (71%).
Example 6
Compound 1
(2R)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate
Intermediate 5 was dissolved in CH 2 Cl 2 and reacted with HCl in dioxane. The mixture was reacted for ˜18 h at rt. The solvent was removed under vacuum and the crude material was titurated several times with diethyl ether to give Compound 1 as a solid, ˜160 mg.
(300 MHz, CD 3 OD): δ 7.89 (d, J=2.4, 1H), 7.50-7.44 (m, 2H), 7.37 (d, J=5.4, 1H), 7.26-7.21 (m, 2H), 7.17-7.13 (m, 3H), 7.06-7.00 (m, 2H), 4.42 (dd, J=5.1, 11.4, 1H), 4.20 (dd, J=4.8, 11.7, 1H), 4.08 (t, J=6.3, 2H), 2.63 (t, J=7.2, 2H), 1.91-1.84 (m, 2H), 1.74-1.65 (m, 2H), 1.68 (s, 3H), 1.62-1.53 (m, 2H).
Compound 2 prepared from the corresponding starting materials in a similar manner to the procedure described for Compound 1. The results are tabulated below in Table 1.
TABLE 1
Compound 2
IUPAC Name
(2S)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-
thienyl)phenyl}amino)propyl dihydrogen phosphate
Structure
1 H NMR δ (ppm)
(600 MHz, CD 3 OD/CDCl 3 ) δ: 7.91 (d, J = 2.4, 1H), 7.51 (d, J = 3.0,
1H), 7.45 (dd, J = 2.4, 9.0, 1H), 7.33 (d, J = 4.8, 1H), 7.25 (t, J = 7.8,
2H), 7.18-7.14 (m, 3H), 7.06 (t, J = 4.8, 1H), 6.95 (d, J = 9.0, 1H),
4.27 (dd, J = 5.4, 10.8, 1H), 4.07 (t, J = 6.6, 2H), 3.96 (dd, J = 5.4,
9.6, 1H), 2.65 (t, J = 7.8, 2H), 1.93-1.89 (m, 2H), 1.74-1.68 (m, 2H),
1.61-1.57 (m, 2H), 1.50 (s, 3H).
Intermediate(s)
1, 2 and 3
starting
Boc-L-serine
material(s)
Example 7
Intermediate 7
2-(2-(benzyloxy)-5-nitrophenylfuran
Intermediate 7 was prepared from Intermediate 1 and tributyl-2-furanyl-stannane, in a similar manner to the procedure described in Example 2 for Intermediate 2.
Example 8
Intermediate 8
3-furan-2-yl-4-(5-phenyl-pentyloxy)-phenylamine
Intermediate 8 was prepared from Intermediate 7 in a similar manner to the procedure described in Example 3 for Intermediate 3.
Example 9
Intermediate 9
{(S)-1-[3-furan-2-yl-4-(5-phenyl-pentyloxy)-phenylcarbamoyl]-2-hydroxy-ethyl}-carbamic acid benzyl ester
Intermediate 8 (0.98 g, 3.05 mmol), N-carbobenzoxy-L-serine (0.82 g, 3.36 mmol), HATU (2.0 g, 5.1 mmol), and diisopropylethylamine (1.8 mL, 10.3 mmol) in DMF (30 mL) was allowed to react for ˜18 h at RT. Auto column (6 hexanes:4 EtOAc) gave a crude Intermediate 9 as a yellow solid, 1.32 g (80%).
Example 10
Intermediate 10
benzyl [2-({3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-1-{[(3-oxido-1,5-dihydro-2,4,3-benzodioxaphosphepin-3-yl)oxy]methyl}-2-oxoethyl]carbamate
Intermediate 9 (1.32 g, 2.43 mmol), tetrazole (16.2 mL, 7.29 mmol; 0.45 M in CH 3 CN), and 3-(diethylamino)-1,5-dihydro-2,4,3-benzodioxaphosphepine (CAS 82372-35-8) (0.88 mL, 3.67 mmol) in THF (25 mL) were stirred at RT for ˜24 h. Hydrogen peroxide 35% (4.7 mL, 54.6 mmol) excess was added and the mixture was stirred for 1 h. The solvent was removed under vacuum and the residue was quenched with sat. Na 2 S 2 O 3 and extracted with EtOAc. The organic layers were dried over MgSO 4 . Auto-column (5 hexanes: 5 EtOAc) gave a crude Intermediate 10 as a yellow oil ˜0.86 g.
Example 11
Compound 3
(2S)-2-amino-3-({3-(2-furyl)-4-[(5-phenylpentyl)oxy]phenyl}amino)-3-oxopropyl dihydrogen phosphate
Intermediate 10 (0.86 g, 1.19 mmol) was treated with 10% Pd on C (0.30 g) and hydrogen at 50 psi for 3 h. The mixture was filtered through celite. The filtrate was concentrated onto silica gel and purified with auto-column (gradient 0→100% MeOH in CH 2 Cl 2 ) to give Compound 3 as a solid ˜50 mg.
(300 MHz, DMSO-d 6 ) δ: 8.10 (d, J=2.7, 1H), 7.70 (s, 1H), 7.47 (dd, J=2.1, 8.7, 1H), 7.27-7.14 (m, 6H), 6.99 (d, J=8.7, 1H), 6.85 (d, J=3.0, 1H), 6.54 (dd, J=1.8, 3.6, 1H), 4.02 (t, J=6.3, 2H), 3.98-3.90 (m, 3H), 2.58 (t, J=7.5, 2H), 1.84-1.78 (m, 2H), 1.67-1.62 (m, 2H), 1.52-1.44 (m, 2H).
Compound 4 prepared from Intermediate 3 and the corresponding procedure(s) as described for preparation of Intermediate 10 and in Example 11 for Compound 3. The results are tabulated below in Table 2.
TABLE 2
Compound 4
IUPAC Name
(2S)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-
thienyl)phenyl}amino)propyl dihydrogen phosphate
Structure
1 H NMR δ (ppm)
(600 MHz, CF 3 C(O)OD) δ: 7.68 (d, J = 3.0, 1H), 7.30-7.28 (m, 1H),
7.25-7.22 (m, 3H), 7.20-7.16 (m, 3H), 7.14 (t, J = 7.2, 1H), 7.10 (d, J =
9.0, 1H), 7.06 (d, J = 3.0, 1H), 5.02-4.97 (m, 2H), 4.80-4.77 (m, 1H),
4.17 (t, J = 6.6, 2H), 2.65 (t, J = 7.2, 2H), 1.96-1.92 (m, 2H), 1.75-1.70
(m, 2H), 1.59-1.56 (m, 2H).
Intermediate
3
Biological Examples
In Vitro Assay
Compounds were tested for S1P1 activity using the GTP γ 35 S binding assay. These compounds may be assessed for their ability to activate or block activation of the human S1P1 receptor in cells stably expressing the S1P1 receptor. GTP γ 35 S binding was measured in the medium containing (mM) HEPES 25, pH 7.4, MgCl 2 10, NaCl 100, dithitothreitol 0.5, digitonin 0.003%, 0.2 nM GTP γ 35 S, and 5 μg membrane protein in a volume of 150 μl. Test compounds were included in the concentration range from 0.08 to 5,000 nM unless indicated otherwise. Membranes were incubated with 100 μM 5′-adenylylimmidodiphosphate for 30 min, and subsequently with 10 μM GDP for 10 min on ice. Drug solutions and membrane were mixed, and then reactions were initiated by adding GTP γ 35 S and continued for 30 min at 25° C. Reaction mixtures were filtered over Whatman GF/B filters under vacuum, and washed three times with 3 mL of ice-cold buffer (HEPES 25, pH7.4, MgCl 2 10 and NaCl 100). Filters were dried and mixed with scintillant, and counted for 35 S activity using a β-counter. Agonist-induced GTP γ 35 S binding was obtained by subtracting that in the absence of agonist. Binding data were analyzed using a non-linear regression method. In case of antagonist assay, the reaction mixture contained 10 nM S1P in the presence of test antagonist at concentrations ranging from 0.08 to 5000 nM.
Activity Potency:
S1P1 receptor from GTP γ 35 S: nM, (EC 50 ),
TABLE 3 S1P1 IUPAC name EC 50 (nM) (2R)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3- 96 (2-thienyl)phenyl}amino)propyl dihydrogen phosphate (2S)-2-amino-2-methyl-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3- 34 (2-thienyl)phenyl}amino)propyl dihydrogen phosphate (2S)-2-amino-3-({3-(2-furyl)-4-[(5-phenylpentyl)oxy] 8 phenyl}amino)-3-oxopropyl dihydrogen phosphate (2S)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2- 3 thienyl)phenyl}amino)propyl dihydrogen phosphate
Lymphopenia Assay in Mice
Test drugs are prepared in a solution containing 3% (w/v) 2-hydroxy propyl β-cyclodextrin (HPBCD) and 1% DMSO to a final concentration of 1 mg/ml, and subcutaneously injected to female C57BL6 mice (CHARLES RIVERS) weighing 20-25 g at the dose of 10 mg/Kg. Blood samples are obtained by puncturing the submandibular skin with a Goldenrod animal lancet at 24, 48, 72, and 96 hrs post drug application. Blood is collected into microvettes (SARSTEDT) containing EDTA tripotassium salt. Lymphocytes in blood samples are counted using a HEMAVET Multispecies Hematology System, HEMAVET HV950FS (Drew Scientific Inc.). (Hale, J. et al Bioorg. & Med. Chem. Lett. 14 (2004) 3351).
A lymphopenia assay in mice; as previously described, was employed to measure the in vivo blood lymphocyte depletion after dosing with (25)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate. This S1P1 agonist is useful for S1P-related diseases and exemplified by the lymphopenia in vivo response. Test drug, (25)-2-amino-3-oxo-3-({4-[(5-phenylpentyl)oxy]-3-(2-thienyl)phenyl}amino)propyl dihydrogen phosphate was prepared in a solution containing 3% (w/v) 2-hydroxy propyl β-cyclodextrin (HPBCD) and 1% DMSO to a final concentration of 1 mg/ml, and subcutaneously injected to female C57BL6 mice (CHARLES RIVERS) weighing 20-25 g at the dose of 10 mg/Kg. Blood samples were obtained by puncturing the submandibular skin with a Goldenrod animal lancet at different time intervals such as: 24, 48, 72, and 96 h post drug application. Blood was collected into microvettes (SARSTEDT) containing EDTA tripotassium salt. Lymphocytes in blood samples were counted using a HEMAVET Multispecies Hematology System, HEMAVET HV950FS (Drew Scientific Inc.). Results are shown in FIG. 1 that depicts lowered lymphocyte count after 24 hours (<1 number of lymphocytes 10 3 /μL blood).
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The present invention relates to novel derivatives, processes for preparing them, pharmaceutical compositions containing them and their use as pharmaceuticals as modulators of sphingosine-1-phosphate receptors.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention concerns a method for threading jet nozzles of weaving machines with a correct length of the weft thread end, and also a weaving machine which uses this method.
The invention is intended in the first place for threading the main nozzles of airjet weaving machines with a correct length of the weft thread end. More generally, however, it can be used in all weaving machines in which the weft threads are inserted into the shed via a jet nozzle by means of a fluid, for example, in weaving machines in which the fluid consists of a liquid, such as water.
2. Description of Related Art
As is known, in airjet weaving machines the weft threads are wound off from yarn packages by means of prewinders, while weft thread lengths are taken one by one from these prewinders and inserted into the shed by means of one or more main nozzles. Whenever a break in the supply of a weft thread occurs, or whenever it is necessary to work with another weft thread, rethreading of the corresponding main nozzle can be done either manually or automatically.
When a weft thread is threaded into the main nozzle manually, the weaver presents the leading end of the thread to the intake of the main nozzle, and then by pressing a pushbutton releases one turn of weft thread from the prewinder. The weft thread is then sucked up by the activated main nozzle. When threading is carried out automatically, the weft thread is presented to the main nozzle automatically, and a number of turns are released automatically, until the leading end of the weft thread reaches at least through the main nozzle.
Clearly, the free end of the weft thread which is brought in will in most cases not be situated precisely at the front end of the main nozzle, but will reach out of the main nozzle. As is known, problems result if the thread end reaching out of the main nozzle is not removed, either because the free thread end may be unintentionally woven into the cloth or because the free thread end makes inserting the next weft thread more difficult. Until now, it has been customary for the weaver to cut off the free thread end after rethreading of the main nozzle. However, since the goal is full automation of weaving machines, manual interventions should clearly be capped to a minimum.
SUMMARY OF THE INVENTION
A purpose of present invention is to provide a method for bringing a weft thread into a jet nozzle, such as a main nozzle, which does not have the above-mentioned disadvantage, i.e. a correct length of the weft thread end is provided automatically.
To this end, the includes the steps of bringing a weft thread into the jet nozzle, preferably automatically; inserting at least one weft length of this weft thread into the shed; and leaving the correct length in the main nozzle by cutting off said inserted length of weft thread at the outlet of the corresponding jet nozzle and removing it from the shed.
The method can be implemented on existing machines, provided they are fitted with a suitable control unit. The invention also concerns weaving machines which use the above-mentioned method.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to better explain the characteristics of the invention, the following preferred embodiments are described, by way of example only and without being limitative in any way, with reference to the accompanying drawings, where:
FIG. 1 is a perspective view of an airjet weaving machine;
FIG. 2 shows schematically the parts of the weaving machine required for implementation of the method according to the invention;
FIGS. 3 to 5 are schematic views in the direction of the arrow F3 in FIG. 2, for different steps of the method;
FIG. 6 is a cross-section along line VI--VI in FIG. 5;
FIGS. 7 to 9 illustrate schematically the method according to the invention, for threading two jet nozzles.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, it is known that on airjet weaving machines the weft threads 1 are unwound by means of thread preparation devices, such as prewinders 2, from yarn packages 3, after which they are led to the jet nozzles, in this case the main nozzles 4.
This process is further illustrated in the schematic configuration in FIG. 2, showing only one thread supply mechanism. Said prewinder 2 consists as is known of a fixed prewinder drum 5 and a rotatable winding tube 6, where the turns 7 wound on the prewinder drum 5 are held on by a magnetically-operated pin 8.
Also shown in FIG. 2 are an auxiliary main nozzle 9, the sley 10 with the reed 11, the sley drive 12, the shed 13, the cloth 14, a weft cutter 15, a thread clip 16, a suction nozzle 17 situated opposite the main nozzle 4, a thread detector 18 which operates in conjunction with the suction nozzle 17, a weft detector 19 mounted on the reed 11, the relay nozzles 20, a pushbutton unit 21 for manual control of the above-mentioned pin 8, and the start button 22 of the weaving machine. All these components are common technology. In this embodiment, the prewinder 2, the yarn packages 3, the auxiliary main nozzle 9, the weft cutter 15, the thread clip 16 and the suction nozzle 17 are all fixedly mounted on the frame of the weaving machine.
When the main nozzle 4 and the auxiliary main nozzle 9, if there is one, have to be threaded with weft thread 1, the weaver presents the leading end of the corresponding weft thread 1 to the intakes 23 of nozzles 9 and 4 while they are activated. He then operates the pushbutton unit 21 so that one turn is released and a section of weft thread 1 is led through the nozzles 9 and 4. Clearly, the turn released will not correspond exactly to the required length of weft thread 1, i.e. after threading there will always be a free thread end 24 reaching out of the main nozzle 4. Such a free end can cause problems when the next weft thread is inserted into the shed 13, either because the free thread end may be unintentionally woven into the cloth, or because the free thread end makes inserting the next weft thread more difficult. It is therefore customary for the weaver to cut off the thread end 24 with a pair of scissors.
The present invention provides a method by which the correct length of weft thread end is automatically obtained in the main nozzle 4. As shown in FIG. 2, for this purpose the weaving machine is equipped with a control unit 25 which controls the above-mentioned components of the weaving machine in such a way that the method described below is carried out automatically.
According to the method of the invention, a check is first carried out to ensure that the main nozzle 4 has been rethreaded. In the case that the main nozzle 4 is provided with thread automatically, the start signal from the automatic repair unit can be used as a basic datum to indicate that rethreading has been carried out. A detector 26 in the thread channel of the main nozzle 4 confirms that rethreading has been carried out. From the moment that the detector 26 gives a signal, the method according to the invention, as described below, can be carried out in order for the resulting thread end 24 to be removed.
If the main nozzle 4 is rethreaded manually, the weaver operates the pushbutton unit 21 at least once. This signal can be used as a datum to indicate that the main nozzle 4 has been threaded with weft thread 1 once more.
Another possibility is for there to be a special pushbutton which the weaver has to press once rethreading has been carried out.
The above-mentioned signals are sent to the control unit 25, so resulting in a data item from which the control unit 25 can deduce whether or not rethreading has been carried out.
When the start button 22 of the weaving machine is then pressed after the main nozzle 4 has been rethreaded, the weaving machine will not start immediately; instead, the control unit 25 first automatically carries out the method according to the invention. By means of a signalling device 27 a signal can be given to warn the weaver that the method for removing the thread end 24 is in progress.
In the first step, the shed 13 is opened. The weft cutter 15 and the thread clip 16 are brought into the open position. Then, as shown in FIG. 3, a length of weft thread 1 is inserted into the shed 13, at least until the free end 24 of this thread reaches into the suction nozzle 17. Inserting this length of weft thread can be done in the conventional way by means of the main nozzle 4 and the relay nozzles 20. Inserting the exact length can be done either by releasing a certain number of turns 7 from the prewinder drum 5, or by leaving the pin 8 of the prewinder 2 open until a weft thread 1 is detected near the suction nozzle 17, for example by means of a detector 19 mounted on the reed 11, or by means of the detector 18 mounted in the suction nozzle 17.
Here it should be noted that if as shown in the figures the cloth 14 being woven is narrower than the full weaving width of the weaving machine, the length of weft thread 1 inserted must be longer than the weft length or the width of the cloth, in order to make sure that the thread end 24 reaches into the suction nozzle 17 which is fixedly mounted on the frame of the weaving machine.
Clearly, if the width of cloth 14 being woven is the same as the full weaving width of the weaving machine, or if the suction nozzle 17 is movably mounted so that it is always positioned immediately next to the cloth 14, for example by being slide-mounted on the sley, it is sufficient for the length of weft thread 1 being inserted to be equal to the normal weft length, i.e. equal to the width of the cloth.
In the second step of the method, the length of weft thread led through the shed 13 is cut off just after the outlet 28 of the main nozzle 4. As shown in FIG. 4, this can be done by commanding the sley 10 such that the reed 11 moves a certain distance forward, so that said weft thread 1 comes up to the fell line 29. The movement of the sley 10 is stopped in time so that the weft thread 1 is not beaten up against the fell line 29. However, the movement is far enough for the weft thread to be brought into the opened cutter 15 and the clip 16. By means of the electrically-operated cutter 15, the clip 16 which operates in conjunction with said cutter is closed and the weft thread 1 is cut off just in front of the outlet 28 of the main nozzle 4.
In the third step, the length of weft thread 1 cut off is removed from the shed 13, so that finally the main nozzle 4 is left with just the right length of weft thread 1, after which the weaving process can be started.
As shown in FIGS. 5 and 6, removing the length of the weft thread 1 after it has been been cut off is preferably done by moving the sley 10 part way back until the outlets 30 of the relay nozzles 20 just reach into the shed 13, whereupon they are activated. As a result of the blowing force of the relay nozzles 20 and the pulling force of the suction nozzle 17 the length of weft thread 1 which has been cut off is easily removed from the shed 13.
Clearly, after the method according to the invention has been carried out, the weaving machine can start automatically.
The method according to the invention can be implemented on any existing weaving machine, provided it is equipped with a suitable control unit 25.
In addition, it will be appreciated by those skilled in the art that the method according to the invention can also be implemented using means specially intended for this purpose. Thus, for example, cutting the length of weft thread 1 inserted can be done by means of a cutter provided specially for this purpose rather than by means of the above-mentioned weft cutter 15. Also, special means other than nozzle 17 for removing the thread can be used in order to remove the cut-off length of weft thread 1 from the shed 13.
If two or more jet nozzles, such as main nozzles 4, have to be rethreaded at the same time, the method according to the invention is carried out simultaneously for all the corresponding weft threads. This means that two or more threads are led through the shed 13 and are then cut off simultaneously. The reason for this is that if just one thread were inserted first, then when this thread were cut off the end 24 of the other weft thread would also-be cut off, so that it would be possible for the other end 24 to be subsequently blown into the shed 13 and become entangled in the warp threads 31, causing a weaving fault.
For the sake of illustration, FIGS. 7 to 9 show the same steps of the method according to the invention as in FIGS. 3 to 5, but with two main nozzles 4 being supplied with a correct length of the weft thread end simultaneously.
Although the invention is described using an airjet weaving machine as an example, the invention clearly can also be applied to weaving machines in which the transport medium consists of a fluid other than air.
The present invention is not limited to the embodiments described by way of example and shown in the figures; on the contrary, such a method for supplying a correct length of the weft thread end into the jet nozzles of weaving machines, and weaving machines which use this method, can be made in different variants, while still remaining within the scope of this invention.
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A method of threading a weft insertion jet nozzle so that a correct length of the leading end of the weft thread extends from the jet nozzle in the direction of the shed includes the steps of bringing a weft thread into its corresponding jet nozzle, inserting at least one weft length of said weft thread into the shed, cutting off the length of weft thread which has been inserted into the shed so that the correct length of weft thread extends from the outlet of the jet nozzle, and finally removing the cut-off length of weft thread from the shed. A weaving machine adapted for carrying out the described method includes a control unit connected to the weaving machine's prewinders, jet nozzles, a suction nozzle, a cutter, and to the drive of the sley of the weaving machine.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. 100 63 861.9 filed Dec. 21, 2000, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to an apparatus in a fiber processing machine such as a cleaner, an opener, a carding machine or the like for detecting separated waste discharged by separating elements and collected in a waste collecting device. The apparatus comprises an optical measuring device which examines the dirt content of the waste.
European Patent No. 0 399 315 describes an apparatus in which the beater pins of a cleaning roll deliver the fiber tufts over cleaning bars which are adjustable for changing the cleaning intensity. Underneath the cleaning bars a light/dark sensor measures the brightness as a measure of the dirt content in the waste that was separated by the cleaning bars and collected in a funnel-like collecting device. The waste is transported away in predetermined intervals by a suction device which is arranged at the lower end of the collecting device. The brightness of the separated waste measured by the light/dark sensor is inputted in a control device as a signal and is displayed on a display device. It is a disadvantage of such a prior art arrangement that the sensor serves exclusively for detecting the proportion of dirt and thus a detection of the proportion of useful (good) fibers is not performed. It is a further drawback that the sensor is only capable of determining brightness differences so that a determination concerning the composition of the waste, particularly concerning the type of the components of the dirt content in the waste material is not possible.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved apparatus of the above-outlined type from which the discussed disadvantages are eliminated and which, in particular, makes possible a detection of the useful fiber proportion in the waste and also makes possible a determination of the waste composition.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the fiber processing machine includes a clothed roll having a surface for entraining fiber material thereon; a housing at least partially surrounding the clothed roll and conforming to the roll surface; a separating opening provided in the housing and extending along and adjacent a circumferential portion of the roll for receiving waste material thrown from the roll; a waste conduit leading from the separating opening for carrying waste material away from the roll; a camera adjoining the conduit for capturing pictures of the waste material flowing therein; and an electronic image processing device connected to the camera.
The measures according to the invention make possible an automatic detection of the useful fiber content in the waste and an evaluation of its composition. With the aid of the electronic camera and the image evaluating device connected thereto signals may be obtained which represent an exact information concerning the proportion of the useful fibers in the waste and which are used for setting the waste separating elements. Further, the electronic image evaluation permits to draw reliable conclusions concerning the waste composition (for example, neps, shell fragments, trash, and useful fibers). Such information indicates working characteristics of the machine and allows modifications thereof by appropriate adjustments of the machine components and its working elements. At the same time, a continuous, objective and thus operator-independent analysis of the waste is ensured. Further, information concerning the type of the waste may be obtained based on suitable image-capturing and evaluating technology. In particular, it is possible to determine the proportion of the useful fibers and to change such a proportion, if required. Dependent on the determined results, machine elements may be adjusted in such a manner that a previously set, desired waste composition is automatically obtained. Also, information concerning the size of the separated impurities may be determined. Information concerning the consistency and the quantity of the waste may be directly read from the display device of the machine control panel and, if required, may be transmitted to superordinated data processing or similar systems.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a schematic side elevational view of a fiber cleaning machine adapted to incorporate the invention.
FIG. 1 b is a schematic side elevational view of the invention incorporated in the fiber cleaner illustrated in FIG. 1 a.
FIG. 2 is a sectional front elevational view of the fiber cleaner shown in FIG. 1 b.
FIG. 3 is a fragmentary side elevational view of one part of the fiber cleaner shown in FIG. 1 a , illustrating a location of waste separation.
FIG. 4 is a schematic sectional top plan view of the construction shown in FIG. 1 b.
FIG. 5 is a block diagram showing an electronic control and regulating device, a camera, an evaluating device, an operating and display device and a setting device for the fiber guide wings are shown.
FIG. 6 is a schematic sectional side elevational view of a waste collecting conduit, a camera and an illuminating device.
FIG. 7 is a schematic view illustrating the arrangement of waste conduits and associated cameras on opposite lateral sides of the cleaner of FIG. 1 b.
FIG. 8 is a block diagram illustrating a central evaluating device, a plurality of cameras and an electronic control and regulating device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 a shows a fiber cleaner which may be, for example, a CVT 4 model, manufactured by Trützschler GmbH & Co. KG, Mönchengladbach, Germany. The fiber material designated with the arrow F, particularly cotton, is introduced into the cleaner as fiber tufts by a feeding device such as a conveyor belt CB. The fiber material is clamped by two feed rolls 1 , 2 and advanced to a pin roll 3 , rotating in the direction A. The pin roll 3 is followed by a sawtooth roll 4 rotating in the direction B. The pin roll 3 has a circumferential speed of approximately 10-21 m/sec whereas the sawtooth roll 4 has a circumferential speed of approximately 15-25 min/sec. The roll 4 is followed by further clothed rolls 5 and 6 which rotate in the direction C and D, respectively and which have increasing circumferential speeds as viewed in the fiber working direction E. The rolls 3 - 6 which have a diameter of approximately 150-300 mm are disposed in a closed housing.
The pin roll 3 cooperates with a separating opening 7 through which waste is discharged and whose size may be adjusted for adapting it to the degree of dirt contained in the cotton. The separating opening 7 is bordered by a mote knife 12 . As viewed in the rotary direction A of the roll 3 , a further separating opening 8 and mote knife 13 adjoin the roll periphery. Likewise, the rolls 4 , 5 and 6 cooperate with respective separating openings 9 , 10 , 11 , bordered by respective mote knives 14 , 15 and 16 . The separating openings 7 - 11 are in pneumatic communication with a respective suction hood 17 - 21 .
Also referring to FIG. 1 b , the suction hoods 17 , 18 , 19 , 20 and 21 are adjoined by respective suction conduits 22 , 23 , 24 , 25 and 26 which, in turn, are coupled to a common suction channel 27 . The rigid suction conduits 22 - 26 and the suction channel 27 are formed as a one-piece structure made of sheet metal or plastic material. The length of the suction ducts 22 - 26 is different, dependent on their distance between the respective suction hoods 17 - 21 , on the one hand, and the suction channel 27 , on the other hand. The suction channel 27 is composed of consecutive length portions 27 I through 27 VI having respective cross sections indicated at a through f which increase downstream of a suction conduit 22 - 26 , as viewed in the flow direction K in the suction channel 27 . The flow direction within the suction conduits 22 - 26 is designated with respective arrows L, M, N, O and P. The end of the suction channel 27 is adjoined by a non-illustrated suction source.
In the description which follows, the operation of the above-described apparatus will be set forth.
The fiber lap composed of fiber tufts F is advanced by the feed rolls 1 , 2 to the pin roll 3 which combs the fiber material and entrains fiber bundles thereon. As circumferential parts of the roll 3 pass by the separating opening 7 and the mote knife 12 , dependent on the circumferential speed and curvature of the roll 3 as well as the size of the separating opening 7 adapted to the first separating stage, waste (short fibers and coarse impurities) and a certain proportion of useful fibers are thrown out of the roll by centrifugal forces and, after traversing the separating opening 7 are introduced into the suction hood 17 provided in the cleaner housing. The fiber material pre-cleaned in this manner is taken off the first roll 3 by the clothing points of the roll 4 on which the fiber material is further opened. As circumferential parts of the rolls 4 , 5 and 6 pass by the respective separating openings 9 , 10 and 11 provided with the respective mote knives 14 , 15 and 16 , further impurities are thrown out of the fiber material by centrifugal forces. A suction stream G, H flowing in a duct 54 , tangentially contacts the last roll 6 and removes the fiber material therefrom.
Air guiding elements 50 , 51 , 52 and 53 border the air inlet openings of the respective suction hoods 18 - 21 with which the flow rate of the vacuum air stream may be set. In the wall of the suction channel 217 a transparent plate (window) 40 is arranged to obtain visible access to the suction channel 27 . Externally of the suction channel 27 , a camera 41 is disposed which is aligned with the window 40 and which detects the waste flowing through the suction channel 27 .
As shown in FIG. 2, the suction hood 17 is arranged between two machine frame walls (housing walls) 28 , 29 . Externally of the walls 28 and 29 at the ends 17 a , 17 b of the suction hood 17 a respective nipple 30 a , 30 b is provided whereby the suction hood 17 passes through two apertures provided in the housing walls 28 , 29 . The nipples 30 a , 30 b are surrounded by a respective annular elastic seal 32 a , 32 b made, for example, of foam material. One end region 22 a of the suction duct 22 opens into the suction channel 27 a (FIG. 1 b ), whereas the other end region 22 b of the suction conduit 22 opens into the suction channel 27 b . The ends of the suction channels 27 a , 27 b are coupled to a common removal channel 44 (FIG. 4) which is connected with a non-illustrated suction source.
As further shown in FIG. 2, on the outside of the suction channels 27 a , 27 b a respective transparent disk 40 a and 40 b is provided with which there is aligned a respective camera 41 a , 41 b arranged externally of the suction channels 27 a and 27 b for detecting the separated waste flowing therein. The waste stream inside the suction hood 17 is designated at Q and R.
The fiber cleaner illustrated in FIGS. 1 a , 1 b and 2 has devices with which the quantity and in part also the type of the separated waste (foreign particles, trash, neps, and the like) may be set or affected. The devices are motor-operated guide wings 37 a - 37 d which are situated in the region of the respective rolls 3 - 6 upstream of the mote knives as viewed in the direction of rotation of the respective roll. By adjusting the angular position of the guide wings 37 a - 37 d the quantity and, to a certain extent, the type of the separated material passing through the respective separating opening may be affected. FIG. 3 shows the guide wing 37 b controlling the separating opening 9 to affect the quantity of the separated material I. The quantity of the separated material I is proportional to the size of the opening angle of the wing 37 b . By setting the desired separated material I the cleaning effect of the machine for the useful fiber material is determined. Since, as a rule, useful fiber material is also separated, an acceptable practical compromise should be found. Stated differently, as much waste material as possible is separated while, at the same time, the proportion of the useful fibers is maintained at a minimum. To determine the separated material to thus be able to adapt it to the possible settings, the separated material I is analyzed in flight according to the invention.
Turning to FIG. 4, the separated material is gathered from the individual separating locations on each machine side and continuously transported by a vacuum stream in a conduit 44 . According to the invention, an electro-optical camera system 41 with a suitable illuminating device 42 and evaluating unit are combined with the waste collecting conduit. The illuminating device may emit colored light, for example, in the red and/or infrared range. The system is oriented in such a manner that it can detect the fiber material as well as other particles as they flow in the conduit 44 . Further, the system can distinguish between individual materials and also can supply information concerning quantity and size. Dependent on previously inputted data, the machine components (for example, the guide wings 37 a - 37 d ) which affect the separated material are automatically adjusted until the desired waste quality is reached. K 1 -K 8 , S and T designate suction streams.
As shown in FIG. 5, an electronic control and regulating device 43 (machine control), for example, a microcomputer, is connected to the camera 41 (for example, a CCD camera) with the intermediary of an image evaluating device 47 , an operating and display device 48 and two adjusting mechanisms 45 a , 45 b for setting the guide wings 37 a and 37 b . Further adjusting mechanisms for setting the other guide wings 37 c and 37 d are not shown.
FIGS. 6 and 7 show different arrangements of the detecting devices within a cleaning machine. FIG. 7 is similar to the arrangement illustrated in FIG. 2, showing back-to-back cameras 41 a and 41 b , provided with illuminating devices (light sources) 42 a - 42 d . The light sources 42 a and 42 b associated with the cameras 41 a , 41 b are used for picture-taking in transmitted light, whereas the light sources 42 c and 42 d associated with the cameras 41 a , 41 b are used for picture-taking in reflected light. The waste material flowing in ducts 27 a , 27 b is designated at I 1 and I 2 , respectively. If the fiber processing machine includes a plurality of adjustable elements for determining the waste quality, then, as a rule, such elements have different basic settings. In case a central waste detecting device is used, the elements are, for example, adjusted proportionally to their basic setting. Essentially, however, in the device according to the invention, other adjusting possibilities (for example, cleaning-roll oriented) may be present. These may be inputted (manually or by a communications network), stored and, if needed, re-used at a later time. A manual adjustment of all of these values is also feasible.
The invention, as described above, yields the following advantages:
A continuous, objective and thus operator-independent evaluation of the separated waste is obtained.
Information concerning the type of the waste may be obtained based on appropriate picture-capturing and image-evaluating technology. Thus, for example, it is feasible to determine the proportion of useful fibers separated with the waste and, if required, to change such a proportion.
As a function of the obtained results, machine elements, such as guide wings and mote knives, may be adjusted to automatically obtain a previously determined and desired waste combination.
Further, information concerning the size of the separated impurities may be obtained.
Information concerning the consistency and quantity of the waste may be directly read from the operating and display device 48 and, if required, may be transferred to superordinated data processing system or other systems.
Turning to FIG. 8, for each fiber-separating location a separate camera 41 a - 41 n may be used and in such a case the cameras may be connected to a single, central evaluating device 46 to ensure a cost-effective solution.
Further, only a single communication connection with the machine control 43 is required and numerous necessary functions and image evaluation may be jointly used by the cameras 41 a - 41 n.
A control of separating organs (such as guide wings 37 a - 37 d ) according to the invention as a function of the determined consistency or quality of the separated material may be used, apart from the described fiber cleaner, in all machines (particularly carding machines) which have such separating organs.
In case of suitable pre-given data, the system may also determine the weight of the separated material with acceptable accuracy. Thus, since the output rate is known, information concerning the ratio of useful material to waste material may be obtained. Since the type and size of the separated particles is determined, based on weight information which is obtained once empirically, corresponding data may be produced.
EXAMPLES
For all the separated particles a relationship exists between number, type, size and weight. If the latter relationships is determined and given, then based on the determinations obtained according to the invention concerning type and number, corresponding weight information may be obtained with sufficient accuracy.
By relating these values to time, information is obtained as to how much weight of material per time may be separated. If the known production rate is taken into consideration and a ratio to the separated material values is formed, a percent information concerning the separated material may be obtained (for example, 3% of the fiber material is separated as waste).
It is a further advantage of the invention that limit values for certain parameters can be determined.
A warning signal may be emitted when the separated quantity is greater than a predetermined weight value.
Further, from an analysis of automatically obtained material-specific statistics the proportion of impurities may be determined for the different materials. In this manner a customer may be optimally supported, for example, in the selection of the correct basic material for certain products.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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A fiber processing machine includes a clothed roll having a surface for entraining fiber material thereon; a housing at least partially surrounding the clothed roll and conforming to the roll surface; a separating opening provided in the housing and extending along and adjacent a circumferential portion of the roll for receiving waste material thrown from the roll; a waste conduit leading from the separating opening for carrying waste material away from the roll; a camera adjoining the conduit for capturing pictures of the waste material flowing therein; and an electronic image processing device connected to the camera.
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This application is a continuation of application Ser. No. 864,744 filed May 13, 1986, and now abandoned, which is a continuation parent application Ser. No. 651,875 filed Sept. 18, 1984 and now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to a resilient rubber coupling for use between two, relatively-movable machine parts.
A resilient rubber coupling is disclosed in U.S. Pat. No. 3,823,619 as part of a torsional-vibration damper between relatively-movable machine parts. One machine part is within the other, and a resilient rubber body couples facing peripheral surfaces in the radial direction. When one of the machine parts is angularly displaced relative to the other, the resilient body is stressed in tension in its entirety and correspondingly deformed. This can result in radial displacement of the coupled machine parts, especially when soft resilient material has been used, and this is highly undesirable.
With a view to eliminating such difficulties, a secondary guide supports two machine parts on each other in the rubber coupling disclosed in East German patent No. 72,945. The guide is metallic, however, and thus results in undamped transmission of solid-borne sound. Moreover, the manufacture of the secondary guide means is relatively complicated and, therefore, uneconomical.
SUMMARY OF THE INVENTION
The object of the invention is, therefore, to provide a resilient, e.g. rubber, coupling which is easy to produce, assures good guidance of coupled, relatively-movable machine parts relative to each other, and substantially suppresses the transmission of solid-borne sound between the coupled machine parts.
In accordance with the invention, this object is achieved with a resilient, e.g. rubber, coupling having a resilient body and at least one, integral projection which juts out from the profile of the resilient body, preferably perpendicularly to bi-directional relative motion between two machine parts coupled therewith, in use. In use, too, the projection is joined, for example with an adhesive surface, to one machine part and the resilient body is joined, for example with another adhesive surface, to the other machine part in such a way that other facing surfaces between the coupling and the two parts form relatively movable guide surfaces therebetween.
With this coupling, relative displacement of the machine parts is absorbed mainly through elastic deformation of the projection while the rest of the resilient body is substantially unaffected thereby. As a result, the resilient body substantially retains its original shape regardless of the magnitude of the relative displacement of the machine parts, and non-varying coordination of the facing guide surfaces is thus assured. Also, relative deflective movement of the machine parts in response to the relative motion thereof is substantially prevented.
The compliance of the coupling is essentially due to the deformability of the projection, that is to say, to the resilience of the rubber material used, the shape of the projection, and the orientation of the projection in relation to the direction of motion. Guidance is not a primary consideration in the design of the projection. The projection can, therefore, be given a shape completely neutral to guidance, with a view to securing particularly high resilience, for example, which is highly desirable in many cases.
The cross-sectional loading of the projection under operating conditions should be as uniform as possible. This condition is satisfied especially well with a design in which the adhered surface of the projection extends parallel to the direction of relative motion between the coupled machine parts and the projection juttingly extends at right angles thereto, or vice versa, in which the adhered surface extends at right angles to the direction of relative motion and the projection, parallel thereto. The latter alternative results in pronounced stressing of the material and diminished movability but allows to transmit great forces. Besides, even adhering the relatively-movable machine part to the surface of the projection results in a further guide moment which may be intensified by the projection extending parallel to the direction of motion.
The facing guide surfaces of the coupling may bear on each other. This provides the particularly good guidance but also makes it necessary, initially, to overcome the static friction between the guide surfaces upon relative motion of the machine parts. In some applications, this may be detrimental, and it has proved advantageous in such applications to space the guide surfaces apart. The size of the clearance is dictated by the required guiding precision in the direction of motion. In most cases, the latter will readily tolerate a clearance a few tenths of a millimeter wide.
To reduce further the frictional resistance from the guide surfaces bearing on each other, the clearance may be filled with a viscous liquid or a substance having lubricating action. It will then also damp well the relative movement of the coupled machine parts, as for a vibration damper, for example. Alternatively, if the resilient, rubber material has practically no damping action, a low-viscosity liquid may be chosen to provide mainly vibration-absorbing action, or the high-viscosity liquid may be chosen to provide mainly vibration-damping action, as required by a particular application.
A surface-active substance may also be used in clearance between the guide surfaces. In most cases, this obviates the need for all-round sealing of the clearance. Capillary forces can be relied on to hold a surface-active substance in the clearance regardless of the orientation of the coupling if the clearance is sufficiently narrow.
For the other clearance fillings, the clearance between the guide surfaces may also be sealed all around by providing projections on opposite sides of the resilient body, for example. In that case, the clearance space can also be pressurized. Varying the pressure then can vary the depth of the clearance. This possibility is of considerable importance with respect to adjusting the damping action of a vibration damper, for example. Such adjustment may be made under operating conditions, if desired, and may be based on a momentary operating status.
As a rule, the projection and the rubber coupling body are a monolithic block of homogeneous material. The differential compliance of the resilient body and its projection therefore are determined mainly by their external configurations. If desired, the latter may be modified by a chip-removing technique to adapt the relative compliances to the specific requirements of a particular application.
The dimensions for proper compliance relationship can be calculated readily. They should be chosen so that the ratio of the elasticity in shear, torsion, or bending of the resilient body to the projection, or, if there are more than one resilient body and/or projection, the sum of the elasticity thereof is less than 0.5, as determined in the direction of relative motion between the machine parts in use. The preferred range is from 0.5 to 0.25. The projections themselves may have any desired shape. However, an embodiment in which the projections are formed by striplike extensions extending perpendicular to the direction of motion is preferred. With such a shape, which can readily be produced, relatively large forces can be transmitted through the projections in the direction of motion.
The guide surfaces may be provided by interleaved guide strips which extend parallel to the direction of motion. Undesired transverse motions of the coupled machine parts can thus be effectively limited or prevented. This also enlarges the guide surface in comparison with a plane design to improve the damping characteristics when a viscous medium is used in the space between the guide surfaces, for example.
The proposed rubber coupling may have practically any desired shape, depending on the direction of the relative motions to be introduced. A plane design will render it suitable for damping rectilinear motions, while a design having rotational symmetry will render it suitable for a torsional-vibration damper, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in greater detail with reference to the accompanying drawings which illustrate, but do not limit the claimed invention, and wherein:
FIG. 1 is a sectional elevation of a first embodiment;
FIG. 2 is a sectional elevation of a second embodiment;
FIG. 3 is a sectional elevation of a third embodiment;
FIG. 4 is a sectional elevation of a fourth embodiment;
FIG. 5 is a sectional elevation of a fifth embodiment;
FIG. 6 is a sectional elevation of a sixth embodiment; and
FIG. 7 is a sectional elevation of a seventh embodiment.
DETAILED DESCRIPTION OF THE INVENTION
The rubber coupling shown in FIG. 1 in diametric section has rotational symmetry. It is formed of two, nested, cup-shaped machine parts 1 and 2 made of sheet steel.
Disposed between the two machine parts 1 and 2 is a resilient body 3 having a thinner, integral projection 4 which extends in the axial direction. The projection 4 is bonded to outer machine part 1 by vulcanization over an adhesive surface 5 at its end face. The resilient body 3 is vulcanized over its entire facing surface 7 onto the inner machine part 2. The other facing surfaces of the outer machine part 1, the resilient body 3 and the projection 4 form unconnected, spaced guide surfaces 6 for guidingly bearing movably on each other.
The torsional rigidity of the resilient body 3 is greater than that of the projection 4. The distortions of the coupling resulting from relative angular displacements between the machine parts 1 and 2 as indicated by the arrow therefore affect mainly the projection 4 while the resilient body 3 remains substantially unaffected. As a result, good radial support between the two machine parts 1 and 2 is assured even when a relatively large angular displacement occurs.
FIG. 2 illustrates the use of the rubber coupling in a longitudinal-vibration damper. It has rotational symmetry and comprises an outer machine part 1a which encloses an inner machine part 2a in the radial direction.
Disposed between the two machine parts is a resilient body 3a which is vulcanized overall onto the inside wall 7a of the outer machine part 1a. It also has two, circular, inwardly-jutting projections 4a which, by their innermost faces 5a, are fixed to the inner machine part 2a. Between facing guide surfaces 6a, there is a clearance of small width which assures good movability of the two machine parts 1 and 2 relative to each other and, at the same time, sufficiently-precise guidance.
The embodiment of FIG. 3 illustrates a rubber coupling for use as a torsional-vibration absorber for high rotative speeds. The latter consists of an outer machine part 1b and an inner machine part 2b formed, for example, by a flange of a disc. The outer and inner machine parts have interleaved annular guide strips 8 of triangular section. A layer of rubber is vulcanized along the guide strips 8 of the outer machine part 1b to form a resilient body 3b. The resilient body 3b is slightly spaced from the guide strips 8 of the inner machine part. As a result, the surfaces 6b therebetween form guides which are readily movable relative to each other, but guide on both sides in the radial direction. The clearance between the guide surfaces 6b holds a lubricant for reducing the friction of contact from the relative movement. The outer machine part 1b also encloses the totality of the axially projecting guide strips 8 of the inner machine part with a U-shaped overall profile. In proximity to the boundaries of the profile, the resilient body 3b enlarges into projections 4b bonded the inner machine part through adhesive surfaces 5b.
The rubber coupling shown in diametric section in FIG. 4 also has rotational symmetry. It is disposed between two, radially-arranged, outer and inner machine parts 1c and 2c. The outer machine part 1c is a belt pulley, and the inner machine part 2c is the associated hub.
A resilient body 3c is vulcanized as a continuous layer across an axial surface 7c of the inner machine part. The resilient body is slightly spaced radially from the adjacent inside surface of the outer machine part 1c to form guide surfaces 6c for radial coordination of relative movement between the machine parts.
The resilient body 3c has Z-arranged, opposite ends forming projections 4c. The latter are bonded to the outer machine part along radial adhesive surfaces 5c.
FIG. 5 is a diametric section of another rotationally-symmetric rubber coupling for a torsional-vibration damper. An outer machine part 1d radially encloses an inner machine part 2d. A resilient body 3d is vulcanized onto the radially-outward surface 7d of the inner machine part 2d. On its opposite ends, the resilient body 3d has corresponding projections 4d which extend outwardly in the manner of flanges of a U-shaped profile and which are vulcanized along their outermost surfaces 5d onto the outer machine part 1d. In addition to good radial guidance of the outer machine part through the guide surfaces 6d, this embodiment provides some axial guidance. This, however, does not appreciably interfere with the angular displaceability of the two machine parts. And while its manufacture is simple, the coupling can be used in practically any position.
FIG. 6 illustrates the use of a rubber coupling having two, double-ended operative sides in a vibration damper for rectilinear motion. The two machine parts 1e and 2e are provided with facing grooves accommodating between them a resilient body 3e, each with projections 4e on opposite ends of both sides in the grooves.
The projections 4e are made of the same material as the resilient body 3e and are integral therewith. They are bonded to the machine parts 1e and 2e only along end adhesive surfaces 5e which are parallel to the relative motion between the machine parts. The other facing surfaces of the resilient body 3e, the projections 4e, and the two machine parts 1e, 2e form unattached guide surfaces 6e. These are spaced apart, and the space so formed is filled with a damping liquid.
FIG. 7 is a diametric section of a rubber coupling in another torsional-vibration damper. The outer machine part 1f encloses the inner machine part 2f in the radial direction. Vulcanized onto machine part 2f along an axial surface 7f between the machine parts is a resilient body 3f. On its opposite sides, it is provided with projections 4f which extend axially outward to adhesive surfaces 5f which are vulcanized onto the outer machine part 1f. In addition to good radial guidance of the outer machine part, this embodiment provides some axial guidance through spaced guide surfaces 6f between the projections and body and part 1f. This will not appreciably interfere with the angular displaceability of the two parts. A clearance 9 between the guide surfaces 6f is filled with a damping liquid. Further, its manufacture is simple, and the coupling can be used in practically any position.
The couplings according to the invention and certain of the described preferred embodiments thereof are, therefore, particularly useful as the coupling for the inertial mass of a torsional-vibration damper.
It will be appreciated that the instant specification and claims are set forth by way of illustration and not of limitation, and that various changes and modifications may be made without departing from the spirit and scope of the present invention.
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A resilient coupling for use between two, relatively-movable machine parts has a resilient body and an integral projection jutting out from the profile of the resilient body. A surface of the resilient body is arranged for joining, for example, adhesively, to one machine part and a surface of the projection arranged for joining, for example adhesively, to the other machine part, the jut of the projection and its surface for joining to the machine part preferably being perpendicular to each other.
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BACKGROUND
Physical device security is essential when a device holding secret data is to be placed in potentially unfriendly hands. To protect the secret data, the device can be configured to sense attempted physical access (e.g., tampering) to the device and can zeroize the data upon the attempted physical access. In order to easily zeroize the data, it can be stored on a memory device (e.g., a volatile random access memory (RAM)). Sensing the attempted physical access to the device can be accomplished with a tamper sensitive material disposed to detect attempted access to the memory device. When the tamper sensitive material senses an attempted access to the memory device, the memory device can be zeroized thereby rendering the secret data unobtainable.
SUMMARY
Systems and apparatus disclosed herein provide for heat dissipation from a chip protected by an anti-tamper material. An example electronic device includes a circuit board having electronics mounted thereon, and a security shield covering one or more electronics on the circuit board and configured to sense tampering, the one or more electronics including a chip, the security shield defining an aperture. The device also includes a heat sink extending through the aperture and thermally coupling with the chip, the heat sink extending outside of the security shield
DRAWINGS
Understanding that the drawings depict only exemplary embodiments and are not therefore to be considered limiting in scope, the exemplary embodiments will be described with additional specificity and detail through the use of the accompanying drawings, in which:
FIG. 1A is a perspective view of an example of an electronic device including a plurality of electronic components protected from tampering by a tamper sensitive material.
FIG. 1B is a semi-exploded view of the electronic device of FIG. 1A .
FIG. 2 is a perspective view of an example printed circuit board and the tamper sensitive material from the electronic device of FIG. 1A .
FIG. 3 is a cross-sectional view of the electronic device of FIG. 1A .
FIG. 4 is a block diagram of example components for the electronic device of FIG. 1A .
In accordance with common practice, the various described features are not drawn to scale but are drawn to emphasize specific features relevant to the exemplary embodiments.
DETAILED DESCRIPTION
In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific illustrative embodiments. However, it is to be understood that other embodiments may be utilized and that logical, mechanical, and electrical changes may be made. Furthermore, the method presented in the drawing figures and the specification is not to be construed as limiting the order in which the individual steps may be performed. The following detailed description is, therefore, not to be taken in a limiting sense.
FIGS. 1A and 1B illustrate an example of an electronic device 100 including a plurality of electronic components protected from tampering by a tamper sensitive material. In an example, the tamper sensitive material can be integrated into a larger housing 104 for the electronic device 100 . The electronic device 100 can include a printed circuit board (PCB) 102 that is mounted to the housing 104 (e.g., a shell). The PCB 102 can include a plurality of electronic components mounted thereon and configured to implement the electronic functions of the electronic device 100 . The electronic device 100 can also include a tamper sensitive material 106 (e.g., a security shield, anti-tamper material) disposed to protect one or more of the electronic components on the PCB 102 . In an example, the tamper sensitive material 106 can be integrated into the housing 104 .
FIG. 1A is a view of the electronic device 100 showing the housing 104 in an open position. In an example, the housing 104 comprises multiple parts that are configured to be connected together and can substantially surround the PCB 102 . As shown in FIG. 1A , a first part 104 - 1 of the housing 104 can be configured to cover a first side (e.g., a bottom) of the PCB 102 and a second part 104 - 2 of the housing 104 can be configured to cover a second side (e.g., a top) of the PCB 102 . The first part 104 - 1 can be configured to connect with the second part 104 - 2 to substantially surround the PCB 102 . To secure the PCB 102 in place, the PCB 102 can be mounted to the housing 104 , for example, by mounting the PCB 102 to the first part 104 - 1 . The housing 104 can be composed of any suitable material including plastic, metal, or other materials.
In an example, the tamper sensitive material 106 can be integrated into the housing 104 , for example, into the second part 104 - 2 of the housing 104 . For example, the tamper sensitive material 106 can be integrated into the housing 104 by bonding one or more layers of the tamper sensitive material 106 to a surface of the housing 104 . The tamper sensitive material 106 can be disposed about the housing 104 such that when the housing 104 is secured around the PCB 102 , the tamper sensitive material 106 covers one or more of the electronic components on the PCB 102 . Accordingly, the tamper sensitive material 106 can be disposed to protect one or more electronic components by sensing attempted access of (e.g., tampering with) the one or more electronic components. The one or more electronic components on the PCB 102 that are protected by the tamper sensitive material 106 are referred to herein as the highly protected components 108 . In an example, the highly protected components 108 can include one or more processing devices coupled to one or more memory devices. The one or more memory devices can have data stored therein to which access can be restricted by the physical security of the electronic device 100 . The one or more memory devices can include any type of data including encryption keys, confidential information, software, or other data.
If tampering is sensed by the tamper sensitive material 106 , the data within the one or more memory devices can be zeroized. In one example, the one or more memory devices holding the data can comprise volatile memory, and zeroizing the data can include removing power from the one or more memory devices, thereby removing the data from the memory. Accordingly, the highly protected components 108 can include security electronics that are coupled to the tamper sensitive material 106 and are configured to zeroize the data in the one or more memory devices based on a state of the tamper sensitive material 106 . In an example, the tamper sensitive material 106 is a passive sensor having a plurality of states, wherein each state provides a different reading for the sensor. Accordingly, the security electronics can obtain a reading to determine the state for the tamper sensitive material 106 . The tamper sensitive material 106 can be a capacitive sensor (e.g., a touch sensitive material), an impedance sensor (e.g., formed of Kapton®), an inductive sensor, or other sensing material. In some examples, multiple layers of the tamper sensitive material 106 can be used. In some examples, the tamper sensitive material 106 can include a flexible touch sensitive circuit. Accordingly, some examples of the tamper sensitive material 106 can detect simple touching of the tamper sensitive material 106 . These touch sensitive tamper materials can be used to provide aggressive security for the highly protected components 108 .
In operation, the security electronics can obtain a first reading from the tamper sensitive material 106 prior to an attempted tampering. Then, the security electronics can operate in secure mode by continually obtaining readings from the tamper sensitive material 106 . If the reading from the tamper sensitive material 106 changes in a manner that indicates an attempted tampering, the security electronics can zeroize the data in the one or more memory devices coupled thereto.
FIG. 1B is a semi-exploded view of the electronic device 100 showing the housing in an open position and the tamper sensitive material 106 in an intermediate position to illustrate its position with respect to the circuit board 102 . As mentioned above, the tamper sensitive material 106 can be disposed to protect the highly protected components 108 . In an example, in order to protect the highly protected components 108 the tamper sensitive material 106 can be disposed to cover the highly protected components 108 and generally form an enclosure for the highly protected components 108 using the surface of the PCB 102 . That is, the highly protected components 108 can be mounted on a surface of the PCB 102 . The tamper sensitive material 108 can be disposed opposite the first surface of the PCB 102 , over the highly protected components 108 , and extend such that the tamper sensitive material 108 is adjacent to and detached from the first surface around a perimeter of the highly protected components 108 . Additionally, the PCB 102 can be constructed such that the attempted access to the highly protected components 108 through a second side (the reverse side from the first surface) of the PCB 102 can cause the data in the one or more memory devices to be zeroized and/or can render the highly protected components 108 inoperable. In an example, the PCB 102 has a layer of tamper sensitive material disposed therein which is coupled to the security electronics. Thus, attempted access through the tamper sensitive material in the PCB 102 can also cause the data in the one or more memory devices to be zeroized. In another example, the tamper sensitive material 108 can be disposed around both sides of the PCB 102 such that attempted access from both the first and second side of the PCB 102 can be detected by the tamper sensitive material 108 .
Accordingly, physical access to the highly protected components 108 can be restricted from all directions. For example, attempted access through the second side of the PCB 102 can cause the data to be zeroized and/or can render the highly protected components 108 inoperable. Attempted access through the tamper sensitive material 108 can cause the security electronics to zeroize the data. Accordingly, the data in the one or more memory devices can be protected from unauthorized physical access.
In an example, one or more sensors 110 can be mounted on the PCB 102 and can be configured to sense if the tamper sensitive material 106 is separated from the PCB 102 . In an example, the one or more sensors 110 can include a pressure sensor (e.g., a pressure sensitive switch, microswitch), wherein one or more features 112 physically associated with the tamper sensitive material 106 can be configured to contact and engage the pressure sensor when the tamper sensitive material 106 is closed over (e.g., protecting) the PCB 102 . If the tamper sensitive material 106 is separated from the PCB 102 , the pressure sensor will disengage. The disengaging of the pressure sensor can then be used to indicate that the tamper sensitive material 106 has separated from the PCB 102 and appropriate action can be taken. In another example, the one or more sensors 110 can include a light sensor (e.g., a photocell). When the tamper sensitive material 106 is closed the light sensor detects little light. If the tamper sensitive material 106 is separated from the PCB 102 , however, the light sensor can detect ambient light in the vicinity of the electronic device 100 . Thus, the light sensor can be used to indicate if the tamper sensitive material 106 is separated from the PCB 102 . In an example, both a light sensor and a pressure sensor can be used.
In an example, the one or more sensors 110 can be included in the highly protected components 108 . Accordingly, the one or more sensors 110 can be highly protected from tampering. The one or more sensors 110 can be coupled to the security electronics to enable the security electronics to zeroize the data in the one or more memory devices if the one or more sensors 110 detect that the tamper sensitive material 106 has been separated from the PCB 102 . Thus, the one or more sensors 110 can provide additional protection for the highly protected components 108 .
As shown in FIG. 1A , the tamper sensitive material 106 can be integrated into the housing 104 . In particular, the tamper sensitive material 106 can be integrated into the second part 104 - 2 of the housing 104 . With the tamper sensitive material 106 integrated into the second part 104 - 2 of the housing 104 , the tamper sensitive material 106 will physically move with the second part 104 - 2 of the housing 104 . Accordingly, the one or more features 112 for engaging the pressure sensor of the one or more sensors 110 can be formed in the second part 104 - 2 of the housing 104 . Thus, the data in the one or more memory devices can be zeroized, if the second part 104 - 2 of the housing 104 is separated from the PCB 102 . In an example, the one or more features 112 can extend through the tamper sensitive material 106 in order to contact the one or more sensors 110 . To enable the one or more features 112 to extend through the tamper sensitive material 106 , the tamper sensitive material 106 can include one or more apertures corresponding to the one or more features 112 . The one or more features 112 can extend through the one or more apertures in the tamper sensitive material 106 . In an example, the apertures in the tamper sensitive material 106 can have a size (e.g., a diameter) that is similar to or smaller than a size of a contact area for the one or more sensors 110 . Keeping the size of the apertures of the tamper sensitive material 106 small can help to reduce the likelihood that the interior of the enclosure formed by the tamper sensitive material 106 can be accessed through the apertures.
In addition to providing protection for the highly protected components 108 , the electronic device 100 can also provide tamper protection for electronic components outside the area protected by the tamper sensitive material 106 . This extended tamper protection can be provided by the security electronics detecting if the tamper sensitive material 106 has been separated from the PCB 102 . In particular, since the security electronics can detect when the second part 104 - 2 of the housing 104 and the integrated tamper sensitive material 106 are separated from the PCB 102 , the entire second part 104 - 2 can act as an extended tamper security shield. For example, the second part 104 - 2 can be formed to cover a larger area than the tamper sensitive material 106 such that the second part 104 - 2 extends to cover electronic components on the PCB 102 other than the highly protected components 108 . In an example, this larger area is at least twice as large as the area on the PCB 102 covered by the tamper sensitive material 106 . These other electronic components within the larger area and outside of the area covered by the tamper sensitive material 106 can be protected by having the security electronics take appropriate action if the second part 104 - 2 is separated from the PCB 102 . For example, the security electronics can zeroize the data in the one or more memory devices and/or can zeroize other data within the other components. In an example, the second part 104 - 2 of the housing 104 can extend to cover the entire first surface of the PCB 102 . In this way, tamper protection can be extended to the other components even through these other components are not covered by the tamper sensitive material 106 . Moreover, upon merely opening the housing 104 (e.g., separating the second part 104 - 2 from the PCB 102 ), the data in the one or more memory devices can be zeroized, thus providing increased protection for the highly protected components 108 .
In some examples, one or more of the highly protected components 108 can produce a significant amount of heat. Dissipating the heat from these components can be challenging due to the tamper sensitive material enclosing the components. Accordingly, in some examples, the tamper sensitive material 106 can be configured such that heat can be dissipated from one or more of the highly protected components 108 . For example, the tamper sensitive material 106 can define an aperture 202 above one of the highly protected components 108 . A heat sink 302 can be thermally coupled to the highly protected component 108 through the aperture. The heat sink 302 can extend outward from the aperture above the tamper sensitive material 106 to dissipate heat from the highly protected component 108 .
FIG. 2 is a top view of the PCB 102 and the tamper sensitive material 106 . As shown, the aperture 202 corresponds to a first component 204 of the highly protected components 108 . In an example, the first component 204 is a chip that generates a significant amount of heat (e.g., a processing unit). The aperture 202 can have a size that is approximately the size of an adjacent surface of the chip. In particular, the aperture 202 can be sized large enough such that sufficient contact can be made with the surface of the chip 204 to enable thermal conduction. The aperture 202 , however, can be sized small enough such that access to the interior of the enclosure formed by the tamper sensitive material 106 is difficult or impossible through the aperture 202 . Along with having a size the corresponds with the size of the aperture 202 , the tamper sensitive material 106 can be disposed such that the aperture 202 is close to the surface of the first component 204 . This can further limit the ability to access the interior of the enclosure formed by the tamper sensitive material 106 . In an example, the aperture 202 can be within a range of 0 to 5 millimeters from the surface of the first component 204 . The tamper sensitive material 106 can also include one or more apertures 206 that enable features 112 to extend through and contact sensors 110 . In an example, the one or more apertures 206 are sized corresponding to the one or more features 112 .
FIG. 3 is a cross-sectional view of the electronic device 100 . As shown, the heat sink 302 can extend through the aperture 202 to thermally couple with the first component 204 . Heat flowing into the heat sink 302 from the first component 204 can be dissipated outside of the enclosure via fins of the heat sink 302 . In an example, a thermal interface material 304 can be disposed between the heat sink 302 and the first component 204 to aid in heat transfer. The heat sink 302 can be formed of any suitable material including copper, aluminum, graphene, or other material.
FIG. 4 is a block diagram of example electronic components for the electronic device 100 . As mentioned above, the electronic device 100 can include highly protected components 108 that are protected by the tamper sensitive material 106 and less protected components 402 that are protected by the housing 104 , but not by the tamper sensitive material 106 . In an example, the highly protected components 108 can include a cryptographic processor 404 coupled to one or more memory devices 406 . As mentioned above, the one or more memory devices 406 can have data such as a cryptographic key stored therein. The cryptographic key can be provided to the cryptographic processor 404 and used to encrypt and decrypt data. In an example, the one or more memory devices 406 can include static random access memory (SRAM). The highly protected components 108 can also include a battery 408 coupled to the SRAM. The battery 408 can maintain the data within the SRAM when external power (e.g., line power) is not applied to the electronic device 100 and/or when the electronic device 100 is powered off. Accordingly, the data (e.g., the cryptographic key) within the SRAM can be maintained without needing to be repeatedly externally loaded into the electronic device 100 . Moreover, holding the data in SRAM can enable the data to be effectively zeroized. That is, the data in the SRAM can be zeroized by removing power to the SRAM. Accordingly, upon detection of tampering with the electronic device 100 , power can be removed from the SRAM thus zeroizing the data in the SRAM. Moreover, freezing of the electronic device 100 in an attempt to access the data will also result in power loss to the SRAM, thereby zeroizing the data therein. In some examples, the SRAM can include temperature sensors that automatically zeroize the data upon detecting a temperature reading out of band.
The highly protected components 108 can also include security electronics 410 coupled to control connection of the battery 408 to the one or more memory devices 406 . The security electronics 410 can be configured to cut off power to the one or more memory devices 406 upon detection of tampering with the electronic device 100 . The security electronics 410 can be coupled to the tamper sensitive material 106 in order to detect tampering. In an example, a Wheatstone bridge can be coupled to the tamper sensitive material 106 to sense a change in state in the tamper sensitive material 106 . The security electronics 410 can also be coupled to the one or more sensors 110 in order to zeroize the data in the one or more memory devices 406 if the one or more sensors 110 detect separation of the tamper sensitive material 106 from the PCB 102 . Accordingly, the highly protected components 108 can be configured to implement secret cryptographic functions which are protected from physical access. Thus, the electronic device 100 can be provided to a potentially unfriendly individual and still provide secure cryptographic functions.
In an example, the electronic device 410 can be configured to be coupled to a mass storage device 412 . The mass storage device 412 can hold encrypted data. The electronic device 410 can be configured to send data between the cryptographic processor 404 and the mass storage device 412 . Data from the mass storage device 412 can be decrypted by the cryptographic processor 404 and can be provided to the less protected components 402 . Additionally data to be stored on the mass storage device 412 can be provided by the less protected components 402 , encrypted by the cryptographic processor 404 , and stored on the mass storage device 412 . Accordingly, the data stored on the mass storage device 412 can be protected from unauthorized access.
In an example, the less protected electronics 402 can include electronic components to perform other less secretive functions of the electronic device. For example, the less protected electronics 402 can include a general purpose processor (e.g., a CPU, microprocessor) coupled to a memory device having instructions thereon for implementing the functions of the electronic device.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiments shown. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
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Systems and apparatus disclosed herein provide for heat dissipation from a chip protected by an anti-tamper material. An example electronic device includes a circuit board having electronics mounted thereon, and a security shield covering one or more electronics on the circuit board and configured to sense tampering, the one or more electronics including a chip, the security shield defining an aperture. The device also includes a heat sink extending through the aperture and thermally coupling with the chip, the heat sink extending outside of the security shield.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Priority is claimed under 35 U.S.C. § 119(e) from application Ser. No. 60/087,983 filed Jun. 3, 1998.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
This invention relates to the use of autodepositing aqueous liquid compositions that are both dispersions and solutions in water. By mere contact with these autodepositing liquid compositions, active metal surfaces can be coated with an adherent polymer film that increases in thickness the longer the time of contact, even though the aqueous liquid composition is stable for a long time against spontaneous precipitation or flocculation of any solid phase, in the absence of contact with active metal. (For the purposes of this specification, the term "active metal" is to be understood in its broadest sense as including all metals and alloys more active than hydrogen in the electromotive series, or, in other words, a metal is which is thermodynamically capable of dissolving to produce dissolved cations derived from the metal, with accompanying evolution of hydrogen gas, when contacted with an aqueous solution of a non-oxidizing acid in which the activity of hydrogen ions is 1.00 equivalent per liter.) Such liquid compositions are denoted in this specification, and commonly in the art, as "autodeposition" or "autodepositing" compositions, dispersions, emulsions, suspensions, baths, solutions, or a like term. Autodeposition is often contrasted with electrodeposition, which can produce very similar adherent films but requires that the surface to be coated be connected to a source of direct current electricity for coating to occur.
More particularly, this invention relates to autodeposition in which the adherent polymer film that forms includes as its predominant organic constituent polymers that include substantial amounts of chlorine atoms, as more specifically detailed in U.S. Pat. No. 5,352,726 of Oct. 4, 1994 to Hall, the entire disclosure of which, except to any extent that it may be contrary to any explicit statement herein, is hereby incorporated herein by reference.
The coating formed while a metal substrate is immersed in an autodeposition bath is wet and fairly weak, although sufficiently strong to maintain itself against gravity and moderate spraying forces. In this state the coating is described as "uncured". To make an autodeposition coated object suitable for normal practical use, the uncured coating is dried, usually with the aid of heat. The coating is then described as "cured".
The present invention relates more particularly to the chemical treatment of an uncured autodeposited coating for the purpose of improving various properties of the cured coating that is subsequently formed from the uncured coating. Most particularly, a major object of this invention is to increase the thermal stability of the chlorine containing polymer coatings formed. It is generally known that polymers of vinylidene chloride, residues of which are the predominant component of a coating resin used in the type of autodeposition bath toward which this invention is directed, have relatively poor thermal stability compared with most other common commercial polymers. One readily noted evidence of this thermal instability is the darkening of the polymers when exposed to heat, and the darkening is normally is well correlated with less overt losses of mechanical strength and resistance to chemical reactions that can severely limit the practical uses of polymers that undergo them. Various additives are known in the general polymer art for increasing the stability of polymers of vinylidene chloride, but all of those tried have been found to impart other unacceptable characteristics to autodeposition baths into which they have been incorporated.
Except in the claims and the operating examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material or conditions of reaction and/or use are to be understood as modified by the word "about" in describing the broadest scope of the invention. Practice within the numerical limits stated is generally preferred, however. Also, throughout the description, unless expressly stated to the contrary: percent, "parts of", and ratio values are by weight or mass; the term "polymer" includes "oligomer", "copolymer", "terpolymer" and the like; the description of a group or class of materials as suitable or preferred for a given purpose in connection with the invention implies that mixtures of any two or more of the members of the group or class are equally suitable or preferred; description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description or of generation in situ within the composition by chemical reaction(s) noted in the specification between one or more newly added constituents and one or more constituents already present in the composition when the other constituents are added, and does not necessarily preclude unspecified chemical interactions among the constituents of a mixture once mixed; specification of constituents in ionic form additionally implies the presence of sufficient counterions to produce electrical neutrality for the composition as a whole and for any substance added to the composition; any counterions thus implicitly specified preferably are selected from among other constituents explicitly specified in ionic form, to the extent possible; otherwise such counterions may be freely selected, except for avoiding counterions that act adversely to an object of the invention; the word "mole" means "gram mole", and the word itself and all of its grammatical variations may be used for any chemical species defined by all of the types and numbers of atoms present in it, irrespective of whether the species is ionic, neutral, unstable, hypothetical, or in fact a stable neutral substance with well defined molecules; and the terms "solution", "soluble", "homogeneous", and the like are to be understood as including not only true equilibrium solutions or homogeneity but also dispersions that show no visually detectable tendency toward phase separation over a period of observation of at least 100, or preferably at least 1000, hours during which the material is mechanically undisturbed and the temperature of the material is maintained within the range of 18-25° C.
BRIEF SUMMARY OF THE INVENTION
It has been found that the thermal discoloration of coatings of polymers of vinylidene chloride formed by autodeposition can be greatly reduced by contacting the wet uncured coatings formed by such an autodeposition bath with a strongly alkaline aqueous composition that contains phosphate ions and preferably also another chelating agent for iron cations. Furthermore, the impact resistance of the coatings is usually substantially increased by the same treatment.
DETAILED DESCRIPTION OF THE INVENTION
A composition according to the invention for contacting a wet autodeposited coating comprises, preferably consists essentially of, or more preferably consists of water and the following components:
(A) a component of dissolved phosphate ions; and, optionally, one or more of the following components:
(B) a component of dissolved alkalinizing agents exclusive of phosphate ions;
(C) a component of chelating agents for iron cations that are not part of either of components (A) and (B) as described immediately above; and
(D) a component of preservative molecules that are not part of any of components (A) through (C) as described immediately above.
A composition according to the invention preferably has a pH value that is at least, with increasing preference in the order given, 10.0, 10.5, 11.0, 11.2, 11.4, 11.6, 11.8, 12.0, 12.2, or 12.4 and independently, at least in part for economy, preferably is not more than, with increasing preference in the order given, 14, 13.5, 13.0, 12.8, or 12.6.
A composition according to the invention must contain dissolved phosphate anions. They may be supplied to the composition by any oxyacid of phosphorus, or water-soluble salt thereof, in which the phosphorus is in its +5 valence state, i.e., orthophosphoric acid, metaphosphoric acid, and the condensed phosphoric acids corresponding to the general formula H.sub.(n+2) P n O.sub.(3n+1), where n represents a positive integer with a value of at least 2. As is generally known in the art, these species are all believed to exist in equilibrium with one another, with the equilibrium strongly favoring orthophosphoric acid and/or its salts at low temperatures, concentrations, and pH values and favoring the more condensed acids, including metaphosphoric acid, and/or their salts at higher temperatures, concentrations, and pH values. For compositions according to this invention, tripolyphosphate salts are the preferred sources of the dissolved phosphate ions, with potassium and sodium salts, particularly the latter, being preferred primarily for economy. The concentration of phosphate ions in a working composition according to the invention, measured as the stoichiometric equivalent as tripolyphosphate ions of all sources of phosphate ions dissolved in the composition, irrespective of the actual concentrations of the various species in equilibrium with one another in the particular composition, preferably is at least, with increasing preference in the order given, 0.5, 0.8, 1.0, 1.5, 2.0, 2.5, 2.7, 2.9, 3.1, or 3.3 grams of tripolyphosphate ions (with the chemical formula P 3 O 10 5 ) per liter of total working composition, this unit of concentration being generally applied hereinafter to any dissolved component in any composition and being abbreviated as "g/l", and independently preferably is not more than, with increasing preference in the order given, 30, 20, 15, 10, 8.0, 7.0, 6.0, 5.5, 5.0, 4.5, 4.0, 3.8, or 3.6 g/l.
Because the preferred amounts of phosphate ions do not generally by themselves provide sufficient alkalinity to achieve the preferred pH values in a working composition according to the invention, such a composition preferably also includes component (B) of additional alkalinizing material as described above. This preferably is selected from the group consisting of the sufficiently water soluble alkali and alkaline earth metal hydroxides and salts of very weak acids such as silicic and boric acids. At least for economy, hydroxides, preferably those of alkali metals, are preferably used. Independently of the particular alkalinizing agent(s) used, its or their concentration(s) preferably result in pH values for the total composition already within the pH value preferences stated above. For sodium hydroxide, usually the most preferred for economy, in the presence of preferred amounts of other components as described herein, this will generally be achieved by concentrations of 0.5 to 5.0, preferably 1.0 to 3.5, or more preferably 2.0 to 3.0, g/l of sodium hydroxide.
Although the anions of component (A) are believed to have some activity as chelating agents for iron cations, the presence of optional component (C) of additional chelating agents is generally preferred. These materials are preferably selected from the group of organic molecules each of which contains at least, with increasing preference in the order given, 2, 3, or 4 moieties selected from the group consisting of carboxyl and carboxylate moieties and hydroxyl moieties that are not part of carboxyl moieties. More preferably, each selected molecule includes at least one carboxylate moiety, which of course may be furnished to the highly alkaline composition according to the invention by dissolving a corresponding acid therein. Gluconic and citric acids and their salts are particularly preferred. Irrespective of the exact chemical nature of component (C), its concentration when used in a composition according to this invention preferably is at least, with increasing preference in the order given, 0.10, 0.30, 0.50, 0.70, 0.90, 1.10, or 1.20 millimoles of chelating agent molecules per liter of total composition, a concentration unit hereinafter usually abbreviated as "millimoles/l", and independently preferably, primarily for economy, is not more than, with increasing preference in the order given, 10, 8.0, 6.0, 4.0, 3.5, 3.0, 2.5, 2.0, 1.5, or 1.3 millimoles/l.
Component (C) is capable of nourishing some microorganisms that may be present in the ambient environment where a composition for use in this invention is used or stored. If growth of microorganisms in such a composition that does not contain optional preservative component (D) is observed, a suitable material should be added to prevent the growth. Preservatives containing isothiazolin-3-one moieties are particularly suitable; more preferably a mixture of the commercial products KATHON™ 886 MW and 893 MW preservatives from Rohm and Haas Co. is utilized. KATHON™ 886 MW is reported by its supplier to contain 10-12% of 5-chloro-2-methyl-isothiazolin-3-one and 3-5% of 2-methyl-isothiazolin-3-one as its preservative active ingredients along with 14-18% of magnesium nitrate and 8-10% of magnesium chloride, all in water solution with water as the balance, and to be particularly effective against bacteria. KATHON™ 893 MW is reported by its supplier to contain 45-48% of 2-n-octyl-4-isothiazolin-3-one and 52-55% of propylene glycol. Accordingly, a composition according to the invention in which a preservative is desired preferably contains, independently for each material noted, at least, with increasing preference in the order given: 0.50, 0.75, 0.90, 1.00, 1.10, 1.20, 1.30, or 1.37 parts per million by weight of the total composition, hereinafter usually abbreviated as "ppm", of 5-chloro-2-methyl-isothiazolin-3-one; 0.10, 0.20, 0.25, 0.30, 0.35, 0.40, 0.45, or 0.48 ppm of 2-methy-isothiazolin-3-one; and 0.75, 1.00, 1.50, 2.00, 2.25, 2.45, 2.60, 2.75, or 2.90 ppm of 2-n-octyl-isothiazolin-3-one. Also, independently of other preferences and independently for each material noted, a composition according to the invention preferably contains not more than, with increasing preference in the order given: 10, 8, 6, 4.0, 3.0, 2.5, 2.0 or 1.5 ppm of 5-chloro-2-methyl-isothiazolin-3-one; 5, 3, 2.0, 1.5, 1.0, 0.8, 0.6, or 0.54 ppm of 2-methyl-isothiazolin-3-one; and 25, 15, 10, 8, 6, 5.0, 4.0, 3.7, 3.4, 3.2, or 3.0 ppm of 2-n-octyl-isothiazolin-3-one, all of the preferences stated in this sentence being primarily for economy.
A process according to the invention comprises at a minimum an operation of contacting a wet autodeposited coating containing polymers of vinyl chloride and/or vinylidene chloride as its predominant organic constituent with a composition according to the invention as described above, the contact being maintained for a sufficient time to cause the cured coating that eventually results from the thus contacted wet coating to manifest greater resistance against discoloration when heated in the nature ambient atmosphere than does an Otherwise identical coating made by a process in which the composition according to this invention is substituted by deionized or similarly purified water. The contact may be established by any method such as spraying, immersion, curtain coating, or the like, but in view of the ease of mechanically damaging the wet autodeposited coating, immersion is usually preferred because it is less likely to cause mechanical damage than any other method of establishing contact. During the immersion, a relative velocity of no more than a few centimeters per second between the substrate and the liquid in which it is immersed is preferably maintained, in order to mix the volume of the liquid in immediate proximity to the wet autodeposited coating with the bulk of the liquid in which the coating is immersed. When contact is by immersion, the time of contact preferably is at least, with increasing preference in the order given, 10, 20, 30, 40, 50, or 55 seconds and independently, primarily for economy, preferably is not more than, with increasing preference in the order given, 600, 400, 300, 200, 100, 80, 70, or 60 seconds. Also, independently of the contact method and time, the temperature of a composition according to the invention during its contact with a wet autodeposited coating preferably is at least, with increasing preference in the order given, 18, 20, or 22° C. and independently preferably is not more than, with increasing preference in the order given, 30, 28, or 26° C.
A wet autodeposited coating to be treated in a process according to the invention preferably should be dried as little as is reasonably possible before being contacted with a composition according to the invention. Therefore, if the wet coating is, as is usual, exposed to the ambient atmosphere for at least a few seconds during its transfer from one location where the wet autodeposited coating is formed to another location where the coating thus formed is contacted with a composition according to the invention, the relative humidity of the ambient atmosphere preferably is at least, with increasing preference in the order given, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80%.
A wet autodeposited coating that is to be treated in a process according to the invention may be and preferably is rinsed with water before being contacted with a composition according to this invention. Such a rinse, as for the contact with a composition according to the invention, may be carried out by any suitable method but is preferably by immersion and may satisfactorily utilize ordinary tap water. When contact between the rinse liquid and the wet autodeposited coating during this rinse is by immersion, the time of contact preferably is at least, with increasing preference in the order given, 10, 20, 30, 40, 50, or 55 seconds and independently, primarily for economy, preferably is not more than, with increasing preference in the order given, 600, 400, 300, 200, 100, 80, 70, or 60 seconds, and the temperature of the rinse liquid preferably is at least, with increasing preference in the order given, 18, 20, or 22° C. and independently preferably is not more than, with increasing preference in the order given, 30, 28, or 26° C.
After contact of a wet autodeposited coating with a composition according to this invention, the still wet coating as thus modified preferably is transferred as soon as reasonably possible into a higher temperature environment to begin curing. The curing temperature preferably is at least, with increasing preference in the order given, 40, 60, 70, 80, 90, or 97° C. and independently preferably is not more than, with increasing preference in the order given, 150, 140, 130, 120, 115, 110, 107, 105, 103, or 101° C., and the time of exposure to a curing temperature preferably is at least, with increasing preference in the order given, 1, 3, 5, 7, 8.0, 9.0, or 9.7 minutes and independently preferably is not more than, with increasing preference in the order given, 100, 50, 40, 30, 25, 23, 21, 19, 17, 15, 13, or 11 minutes.
For any part of a process according to the invention that includes other operations not specified above, adequate guidance as to preferred and satisfactory materials and conditions of use may be obtained from the prior autodeposition art.
The practice and benefits of the invention may be further appreciated by consideration of the following working and comparison examples.
Cold rolled steel test panels were subjected to the following process sequence in the order shown:
1. Clean by immersion for 2.0 minutes in a solution in water containing 7.4 g/l of AUTO-PHORETIC® Cleaner 1727, a commercially available product of the Henkel Surface Technologies Div. of Henkel Corp., Madison Heights, Mich., which is maintained during the immersion at a temperature of 71±2° C.
2. Remove from contact with the cleaning solution described in operation 1 and immerse for 1.0 minute in tap water maintained at a temperature within the range from 18-23° C.
3. Remove from contact with the tap water described in operation 2 and immerse for 1.0 minute in deionized water maintained at a temperature within the range from 18-23° C.
4. Remove from contact with the deionized water described in operation 3 and, while the surface is still wet, immerse for 1.0 minute in an autodepositing composition, with the ingredients shown in the table in column 20 of U.S. Pat. No. 5,352,726, except that the black pigment dispersion was omitted, the autodepositing composition being maintained at a temperature within the range from 18-23° C. during its contact with the substrate.
5. Remove the substrate, now bearing a wet autodeposited coating, from contact with the autodepositing composition described in operation 4 and immerse for 1.0 minute in tap water rinse liquid maintained at a temperature within the range from 18-23° C.
6. Remove the substrate, now bearing a rinsed wet autodeposited coating, from contact with the tap water rinse liquid described in operation 5 and immerse for 1.0 minute in a rinse liquid with a composition as specified further below, maintained at a temperature within the range from 18-23° C.
7. Remove the substrate, now bearing a treated rinsed autodeposited coating, from contact with the rinse liquid described in operation 6, and cure for 10.0 minutes in a forced air electric oven maintained at 100±2° C.
Compositions of the rinse liquids used in step 6 from the above process sequence are shown in Table 1 below.
The cured autodeposited coatings prepared in this manner were tested for thermal stability by exposure for 8.0 hours to air at 120±2° C. The results of these tests are shown in Table 2 below.
TABLE 1______________________________________COMPOSITIONS OF RINSE LIQUIDS USEDIdentifyingName or Grams per Liter in Rinse Liquid of:Number Na.sub.5 P.sub.3 O.sub.10 Gluconic Acid NaOH NH.sub.4 HCO.sub.3______________________________________Control -- -- -- 0.91 5.0 -- -- --2 5.0 0.25 -- --3 5.0 0.25 2.5 --______________________________________ Note for Table 1 The balance not specified above for each rinse liquid was water. A hyphen entry indicates no addition of the material at the top of the column in which it occurs.
TABLE 2______________________________________RESULTS OF THE THERMAL STABILITY TESTSIdentifyingName orNumber Test Results______________________________________Control Coating was dark black, and panel failed a 0.30 kilogram- meter impact test.1 Coating was brownish black, and panel barely passed a direct 0.30 kilogram-meter impact test.2 Coating was less darkened than with rinse liquid 1, and panel passed a direct 0.30 kilogram-meter impact test but failed a reverse 0.30 kilogram-meter impact test.3 Coating was less darkened than with rinse liquid 2, and panel passed both direct and reverse impact tests at 0.30, 1.2, and 1.5 kilogram-meter; at the latter value only, there was slight crazing in the reverse test______________________________________ only.
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The susceptibility to heat degradation of an autodeposited coating in which the principal organic constituents are copolymers of vinylidene chloride in which vinylidene chloride residues constitute at least half the weight of the total binder phase in the autodeposited coating is improved if the wet autodeposited coatings are rinsed, before being later dried and cured, with a water-based liquid rinse that comprises dissolved phosphate ions in a concentration that corresponds stoichiometrically to at least 0.5 g/l of tripolyphosphate ions. The water-based liquid rinse preferably has a strongly alkaline pH and also comprises dissolved organic molecules that are effective chelating agents for dissolved iron cations by reason of having in each molecule at least two carboxyl, carboxylate, and/or other hydroxy moieties.
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RELATED APPLICATIONS
The present invention was first described in Disclosure Document No. 580,695 filed on Jun. 23, 2005. Other than stated herein, there are no previously filed, nor currently any co-pending non-provisional applications, anywhere in the world.
FIELD OF THE INVENTION
The present invention is an apparatus that aids in the transportation of old roofing material from the roof to a refuse dumpster comprising a hopper with a false bottom telescopically mounted onto a wheeled base.
BACKGROUND OF THE INVENTION
Anyone involved in the roofing business will tell you what a strenuous business it is. A typical day involves carrying heavy loads, enduring high temperatures and scorching sun and climbing steep roofs, all the while working at dangerous elevations above ground. Anything that reduces work or allows for a better job is welcome. Those roofing jobs which require the removal of the old roof, or a “tear-off” as it is commonly called, requires a much higher level of physical work. The old shingles must be dislodged, ripped up, and then pushed off of the roof. The physical activity required to transport these materials from the roof to the dumpster or refuse vehicle is staggering. Additionally, as these materials fall from the roof to the ground, damage to landscaping or even the house itself can occur. Finally, additional aids such as tarps or wheel barrows are required to pickup the material from the ground.
Several attempts have been made in the past to provide an apparatus for assisting in the transportation of roofing waste materials. U.S. Pat. No. 6,817,677 in the name of Beiler discloses a self-propelled trailer comprising a box-like bin with a tailgate with provisions to raise the bin to the height of the eaves of roofs via hydraulic pistons. The Beiler device requires transportation via motor vehicles to the job site and the hydraulic pistons require maintenance. The present invention, contrastingly, may be transported manually to and from a job site and a dumpster and simply telescopes up and down.
U.S. Pat. No. 6,113,340 issued in the name of Zalal provides an apparatus for an automatic debris removal system comprising a tilting dumpster riding on a carriage device of a pre-existing construction hoist, a detachable chute device, and an automatic dumping mechanism for the dumpster. The Zalal invention requires the use of a pre-existing construction hoist which may not be present on a particular jobsite.
U.S. Pat. No. 4,854,804 issued in the name of Mayle describes a an apparatus for lifting and carrying heavy loads comprising a steerable trolley-like device with a winch for moving a load onto an optional pan and a pair of lifting arms to move said load between the ground and roof. The Mayle device lacks the inherent benefit of removing the load through a false bottom, a feature in the present invention.
U.S. Pat. No. 5,570,524 issued in the name of Groat discloses a snow removal system for roofs and vehicles consisting of differing embodiments centered around a bermed tarp acting as a chute. Groat discloses a device that utilizes material not suited for removal of roofing debris and does not provide means to transport collected refuse to a sanitation dumpster.
U.S. Pat. No. 6,543,126 issued in the name of Hamlin describes a machine for loading and removing a flat roof comprising a flat conveyor belt on a pair of drive wheels and a chisel-like front member. A drive mechanism operates the conveyor belt to unload the old roofing material upward and outward, which needs to be scored so that it breaks as it ascends the conveyor and drops into a cart. The Hamlin invention utilizes a driven conveyor system to transport material and does not benefit from a simple and manually operated hopper dump system. The Hamlin invention is also highly specialized for removing flat roofing material prior to reparations or replacement.
U.S. Pat. No. 6,056,027 issued in the name of Patterson describes an apparatus and method for accurately measuring and dispensing dry material into a portable container. The Patterson apparatus is concerned with the accurate measuring of material and is therefore not within the scope of the present invention.
U.S. Pat. No. 4,923,358 issued in the name of Van Mill discloses a portable cart with an angular discharge auger, particularly for handling granular material. The auger tube is fixed to the hopper sump for drawing material from said sump and can be pivoted away during transport. The present invention handles material of a larger and bulkier nature than that of the device in the Van Mill patent and therefore does not benefit from the use of an auger. Additionally, the Van Mill device has no provisions for vertically manipulating the hopper structure to a job site.
U.S. Pat. No. 5,454,625 issued in the name of Christensen et al. discloses a portable ice cart with both elevation and tilt adjustment for an ice hopper. The Christensen et al. device utilizes a scissor-like linkage operated by a foot pedal actuating hydraulic cylinder for raising the ice hopper. The present invention utilizes a simple telescopic means for raising and lowering the hopper portion as opposed to the hydraulic system in the Christensen et al. apparatus.
None of the prior art particularly describes an apparatus that allows roofers to easily remove discarded roofing materials in a timely fashion without damage to landscaping and without excessive physical labor. Accordingly, there exists a need for a means by which the transportation of discarded roofing materials from the roof to the refuse container can be accomplished in an easier manner than current methods allow.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the prior art, it has been observed that there is a need for a device to collect and remove roofing materials or other objects from elevated heights for subsequent removal to a sanitation device.
It has further been observed that there is a need for an apparatus that may be elevated in a simple and effective manner from a lower ground position to an upper position adjacent to, or abutting against, a roof or other elevated job site.
The object of the invention is to provide an apparatus that collects and retains removed roofing materials from a job site into a hopper structure.
It is a further object of the invention to elevate the hopper structure via telescopic support legs to a roof or other elevated job site to minimize the effort in collecting and retaining removed roofing materials.
It is a further object of the invention to transport the collected and retained removed roofing materials to a refuse container on a wheeled support frame.
It is yet a further object of the present invention to provide a wheeled support frame with the proper clearance around a conventional roll-off dumpster or other common commercial refuse container, while the hopper structure is in its elevated state.
Still yet another object of the invention is to provide a handle to hingedly release a false bottom in order to release the contents of the hopper structure into a conventional refuse container.
To achieve the above and other objectives, the present invention provides a method for the collection, retention, and removal of roofing materials loaded within an elevated and transportable dump hopper, and the transportation of said roofing materials within the elevated dump hopper to a conventional refuse container, such as a roll-off dumpster, via a wheeled support frame that provides the needed clearance for the subsequent release of the false bottom of the hopper structure to remove the contents of the hopper structure directly into the refuse container.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is a perspective view of the roof shingle removal device 10 , according to a preferred embodiment of the present invention; and,
FIG. 2 is a side elevation view of the roof shingle removal device 10 , according to a preferred embodiment of the present invention; and,
FIG. 3 a is a top view of the hopper structure 11 with a bottom opening door 16 , according to a preferred embodiment of the present invention; and,
FIG. 3 b is a perspective view of the hopper extension device 32 , according to a preferred embodiment of the present invention.
FIG. 4 is a bottom view of the roof shingle removal device 10 , according to a preferred embodiment of the present invention; and,
FIG. 5 is a top view of the roof shingle removal device 10 , according to a preferred embodiment of the present invention; and,
FIG. 6 is a front elevation view of the roof shingle removal device 10 , according to a preferred embodiment of the present invention.
DESCRIPTIVE KEY
10 roof shingle dump cart
11 hopper structure
12 lid
13 release lever
14 hook
15 knob
16 false bottom
17 catch
20 adjustable leg
21 handle
22 adjustment hole
23 support structure
24 caster wheel suspension
25 caster wheel
27 lid handle
28 coupling
29 hinge
30 top/bottom hopper lip
31 side hopper lip
32 hopper extension device
33 extension supporter/adjuster
34 hopper bottom
35 hopper sump side walls
36 hopper sump
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 3 b . However the invention is not limited to the described embodiment, and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention. Any such work around will also fall under the scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
The present invention describes an apparatus and method for assisting in the transportation of old roofing material. The roof shingle dump cart with hopper (herein described as the “apparatus”) 10 consists of a hopper system, an adjustable leg assembly, and a caster wheel assembly.
Referring now to FIGS. 1-3 , the apparatus 10 takes the form of an elevated hopper system. The hopper assembly consists of a hopper 11 preferably comprised of a resilient material, such as steel in an extrusion, stamping, and bending process; a false bottom 16 hingedly connected to the bottom of the hopper 11 ; a lid 12 with a lid handle 27 hingedly connected to the top of the hopper 11 ; and a hopper extension device 32 . FIG. 3 a depicts the angular interior of the hopper 11 allowing the gravitational effect to progress the discarded contents towards the hopper bottom 34 and the false bottom 16 , which has a catch 17 on it to hook onto a release lever 13 . The hopper 11 generally is a reverse pyramidal structure with two (2) long inwardly sloping sides 31 and two (2) short inwardly sloping sides 30 . Each sloping side 30 , 31 slopes downward to the hopper sump 36 defined as a centrally dissected hopper bottom 34 . The centrally dissected area comprises two (2) opposing vertically downward sloping dumper sump side walls 35 to a hingedly attached false bottom 16 . At least one (1) release lever 13 , which retains the false bottom 16 in a closed position with a hook 14 engaging the catch 17 , disengages the false bottom 16 , providing an aperture for the discarded contents to flow through. The release lever(s) 13 also have a knob 15 on the opposite end of the hook 14 for one to grasp and are attached to the exterior of the dumper sump side walls 35 . The length of the hopper 11 can be extended by the use of the hopper extension device 32 to accommodate the conventional width of roofs. The hopper extension device 32 is attached to the hopper 11 via two adjustable lid supports 33 removably attachable to the lid 12 . FIGS. 3 a and 3 b depict the use of the supports and adjusters.
The hopper 11 has four (4) opposing upwardly adjustable legs 20 that contain a plurality of aligned adjustment holes 22 drilled therethrough. The adjustable legs 20 may be fabricated out of the same material as the hopper assembly. The adjustable leg assembly consists of adjustable legs 20 , adjustment holes 22 , and a handle 21 . The adjustable legs 20 comprise two (2) nested hollow legs, either tubular or rectangular, which are joined together by a coupling 28 and containing aligned adjustment holes 22 drilled therethrough, capable of extending the adjustable legs 20 to the desired height for accommodating differing roof heights and differing refuse containers. A locking pin or similar device can secure the vertical adjustment of the legs 20 . The adjustable legs 20 can be elevated by the use of the handles 21 attached to each adjustable leg 20 by mechanical fasteners. A piece of flat iron connects the handles 21 permitting a single person manipulate the telescoping legs 20 . The adjustable leg assembly is attached to the outer surface of the side walls of the hopper 11 via conventional material fastening means.
The wheel assembly preferably comprises caster wheels 25 , a wheel suspension 24 , and a support structure 23 . The caster wheels 25 and the wheel suspension 24 are secured to the support structure 23 and configured in such a way which allows the caster wheels 25 to swivel in a 360° arc and to also employ locking means. The support structure 23 is configured in a curvature method over the wheel suspension 24 to provide extra stability and to allow the apparatus 10 to straddle the back of a pick up truck and/or refuse container. The size of the caster wheels 25 allows better mobility over uneven grades of terrain and prevents landscape from being trampled. The adjustable leg assembly is attached to the upper surface of the support structure 23 via mechanical fasteners or welding methods.
The preferred embodiment of the present invention is designed to be used by the common consumer with little or no special skills and minimal experience and training necessary. Likewise, experienced roofers, maintenance workers, and do-it-yourselfers can find this invention to greatly aid them in roofing, particularly in eliminating damage to property, eliminating possible injury to workers, and in assisting in clean-up to protect and maintain the environment. When the device is first procured, it should be made of a resilient material, such as steel with a suitable anti-corrosion finish, such as paint.
The method of utilizing the device may be achieved by performing the following steps: adjusting the legs 20 to the proper height; opening the hinged lid 12 with the lid handle 27 ; adjusting the lid supports 33 as necessary by sliding them upwards so the lid 12 reaches the edge of the roof; and attaching the hopper extension device 32 to the lid supports 33 . Once the old shingles have been removed, and placed within the hopper 11 , the disposable contents are ready to be vacated. The apparatus 10 can then be rolled over to a roll-off dumpster to dispose of the contents through the false bottom 16 .
More specifically, the apparatus 10 rolls over to the job site by utilizing the swiveling caster wheels 25 . The caster wheels 25 are large enough to allow easy rolling over rough surfaces and grades while preventing grass or landscaping from being tattered. The apparatus 10 can then be elevated by adjusting the height of the adjustable legs 20 . The height is situated by the adjustment holes 22 to a convenient height at the roof eave level. At this height, the apparatus 10 can be above shrubbery, flowers, and other landscaping. The elongated span between the adjustable legs 20 not only provides stability but permits the straddling of the refuse containers. The stability is augmented even further with the curvature of the support structure 23 . The apparatus 10 then needs to be strapped down or anchored and have the caster wheels 25 locked to prevent motion during the process of removing shingles. The lid 12 of the apparatus 10 must be opened by lifting the end that is not hinged to the hopper structure 11 or via the lid handle 27 . The lid supports 33 slide upwards so that the lid 12 reaches the edge of roof.
The hopper structure 11 attached to the adjustable legs 20 is now elevated at a convenient height at the desired location. The elevated hopper structure 11 encompasses an aperture for old roofing material from the roof of the dwelling. The angular interior of the hopper structure 11 compels the discarded materials to flow to the bottom by gravitational effect. A hopper extension device 32 extends the aperture of the hopper structure 11 to accommodate the conventional width of roofs for further reach. The hopper extension device 32 is attached to the hopper structure 11 via two adjustable lid supports 33 attached to the lid 12 .
Once the hopper structure 11 is filled with the old roofing materials, the apparatus 10 is unstrapped and the caster wheels 25 are unlocked, to transport the discarded contents to a roll-off dumpster or refuse container. The elevated apparatus 10 is now at a convenient height to straddle the roll-off dumpster or refuse container, with the false bottom 6 positioned above the interior of the dumpster. The discarded contents can then be vacated by using the release lever(s) 13 . The release lever(s) 13 disengage the false bottom 16 , by removing the hook portion 14 of the lever(s) 13 retaining the catch 17 of the false bottom 16 providing an aperture for the discarded contents to flow through. The false bottom 16 is hinged on one side of the hopper structure 11 to prevent discarded contents from exiting until the release lever 13 is pulled.
The elevation of the apparatus 10 also provides for easy transportation within the bed of a pickup truck.
Yet another embodiment of the present invention 10 is the use of the dump cart with hopper as a dumping mechanism for other materials such as old gutters, leaves and other grime found in gutters, or other similar discarded materials obtained from an elevation.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention and method of use to the precise forms disclosed. 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 and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions or substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.
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An adjustable hopper for aiding in the transportation of old roofing material, such as shingles, to a refuse dumpster is herein disclosed. The hopper is inwardly tapered towards a false bottom and has a manually actuating release lever for vacating the contents through said false bottom. The hopper assembly is mounted on four height-adjustable leg assemblies manipulated by a handle. The hopper and leg assemblies are mounted on a support frame with heavy-duty caster wheel assemblies at each of four corners. The support frame is constructed so as to enable the entire hopper assembly to be positioned about a conventional refuse dumpster with a minimal amount of clearance.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation in part of International Patent Application PCT/EP02/03785 filed Apr. 5, 2002 and claiming priority to co-pending German Patent Application No. 101 18 355.0-42 filed Apr. 12, 2001 both of which are entitled “Verfahren und Vorrichtung zur Mehrphotonenanregung einer Probe”.
FIELD OF THE INVENTION
[0002] The present invention generally relates to a method for multi photon excitation of a sample, comprising the steps of splitting a laser beam into at least two coherent partial beams each having a beam axis and a same intensity distribution about its beam axis, directing the partial beams in different directions, and projecting the partial beams from different directions onto a common measuring plane running transversely to the beam axes, an interference pattern being formed by the coherent partial beams in the area of the measuring plane.
[0003] Further, the invention relates to a device for multi photon excitation comprising a laser providing a laser beam, a beam splitter splitting the laser beam into at least two coherent partial beams each having a beam axis and a same intensity distribution about its beam axis, beam directing means directing the partial beams in different directions, and projecting means projecting the partial beams from different directions onto a common measurement plane running transversely to the beam axes, an interference pattern being formed by the coherent partial beams in the area of the measuring plane.
PRIOR ART
[0004] Multi photon excitation of a sample in a measuring point is, for example, accomplished in scanning microscopes in which a particularly high spatial resolution is to be obtained. In case of a two photon excitation of a sample, the intensity distribution of the fluorescence light emitted by the sample is proportional to the third power of the intensity distribution of the excitation light. Thus the effective spatial resolution can be increased with a limited minimum full width of half maximum of the intensity distribution of the excitation light in each measuring point by means of analyzing the fluorescence light from a multi photon excitation.
[0005] It is a disadvantage of multi photon excitation of a sample that the intensity of the fluorescence light, because of its dependency on a power of the intensity of the excitation light described above, is often only very small with smaller intensity of the excitation lights avoiding damages to the sample, and thus requires longer measuring times. In a method and a device of that types described at the beginning which are known from DE 196 53 413 A1, it is accounted for this disadvantage by exciting the sample in a plurality of measuring points located side by side in the measuring plane at the same time. This is accomplished in that an incoming laser beam is directed onto a micro lens array and is thus focused in a multitude of focus points of the single micro lenses arranged side by side. These focus points are then projected by a projection system into measuring points in the measuring plane. In this context, DE 196 53 413 A1 also discloses embodiments of the method and the device in which the single micro lenses of the micro lens array have different positions along the beam axis and/or different focal lengths. Thus, the measuring points are arranged at different depth within the sample to scan the sample also in depth direction. These arrangements, in which the measuring points do not exactly fall within one geometric plane shall be included, when a “plurality of measuring points which are arranged side by side within one measuring plane running transversely to the respective beam axis” is mentioned here.
[0006] The embodiments of DE 196 53 413 A1 which correspond to the method and the device of the types described at the beginning split the laser beam into two partial beams of a same intensity distribution about their respective beam axes, after the laser beam has been directed onto the micro lens array and was thus distributed over a plurality of focus points arranged side by side. These partial beams are then focused into the measuring points within the measuring plane out of two diametrically opposing directions, i.e. towards the front and towards the back of the sample, by means of two lens systems. Because of the coherence of the partial beams a interference pattern results in each of the measuring points, the areas of maximum and minimum intensity showing a sequence in the direction of the beam axes. Particularly, a main maximum in which an essential excitation of the sample occurs is formed in the measuring plane directly about the geometric measuring point. The side maximums located in front and behind the measuring plane are only of minor importance, simply because of the intensity distribution of each partial beam about the measuring point, so that they do not relevantly contribute to a multi photon excitation of the sample. In this way, the depth resolution is enhanced in multi photon excitation of the sample. The overall construction required for this enhancement is, however, comparatively complicated as the division of the laser beam into two partial beams of the same intensity distribution extends up to the sample. I.e., there is one optical system for each partial beam, and these two optical systems have to be fine adjusted with regard to each other. Additionally, a sample slide and holder have to permit that the two partial beams enter the sample from two opposite directions.
[0007] To the end of making an as good as possible use of the light power of the laser beam provided by a laser, the single micro lenses of the micro lens array according to DE 196 53 413 A1 are as close to each other as possible so that no portions of the laser beam are blocked.
[0008] A plurality of measuring points located side by side in the measuring plane, the sample being exited with about the same intensity via a multi photon process in each of which, is not always without problems with the known methods and the known devices. There are samples having a strongly differing local sensitivities with regard to the exiting light. Thus, with an uniform intensity distribution over the different measuring points, a sample may already be damaged by the excitation light in some of the measuring points, while in other measuring points there is not yet a suitable intensity of fluorescence light.
[0009] DE 198 51 240 C1 discloses a fluorescence microscope with multi photon excitation in which a spatial limitation to the multi photon excitation is achieved in that different parts of the incident light are directed into a common focal point under incident directions intersecting each other at a larger angle. This results into an intersection volume clearly smaller than the single volumes which are illuminated by one of the parts of the incident light only and which are each elongated in the light incident direction. The actual multi photon excitation is limited to that intersection volume. An interference of the single parts of the incident light is not considered in DE 198 51 240 C1. Indeed, they have different wave lengths. The angle, at which the light incident directions intersect is in the area of about 90°. As an additional and separate measure in certain embodiments of the known fluorescence microscope, it is intended that the light incident directions are diametrically opposing each other in the focal points so that the parts of incident light interfere and form an interference pattern along the opposing light incident directions. This corresponds to that part of the disclosure of DE 196 53 413 A1 discussed above which is regarded as the most relevant prior art.
BACKGROUND OF THE INVENTION
[0010] The invention is based on the task to provide a method and a device of the types described at the beginning which make use of a given intensity of a laser beam for multi photon excitation of a sample in an optimized way.
SUMMARY OF THE INVENTION
[0011] The present invention provides A method for multi photon excitation of a sample, comprising the steps of splitting a laser beam into at least two coherent partial beams each having a beam axis and a same intensity distribution about its beam axis; directing the partial beams from different directions towards a common measuring plane running transversely to the beam axes at an inclination angle <1 between the beam axes of the partial beams; and projecting the partial beams onto the measuring plane by means of a common lens system, an interference pattern formed by the coherent partial beams within the measuring plane providing areas of maximum light intensity adjacent to areas of minimum light intensity.
[0012] The value of the inclination angle which has to be smaller than 1 is its circular measure by radians. I.e. the limit of 1 corresponds to 360°/2 π which is about 57°.
[0013] In the new method, the partial beams are not caused to interfere in the area of the measuring plane out of diametrically opposed directions. Instead, the partial beams the number of which may also be higher than 2 originate from essentially the same direction, only the small inclination angle of less than 1 being between them. This results into an interference pattern in which the areas of maximum and minimum intensity do not show a sequence in the direction of the depth of the sample but in the measuring plane, and particularly in the direction of the inclination angle. The distance of the areas of maximum intensity within this interference pattern depends on the inclination angle and also on the optical data of the lens system. Thus, this distance can be adjusted as desired. Independently of this distance, the method according to the invention always has the advantage that the utilization of a given intensity of the laser beam is improved because an inhomogeneous intensity distribution is provided in the measuring plane by means of the interference pattern. The resulting better utilization of the provided light power of the excitation light is based on the non-linearity of the fluorescence light yield in a multi photon excitation. Considering, for example, a two photon excitation, an interference pattern which distributes an average relative intensity of 1 over areas of a relative intensities of 2 and 0 results in a relative excitation of 2 2 =4 in the areas of the relative intensity of 2. As the portions of the areas of both relative intensities are the same, this corresponds to an average excitation of 2. In case of the original intensity, an average excitation of 1 2 =1 is achieved only. Although the intensity distribution of the excitation light on which this example is based is just theoretic, the example nevertheless shows the potential of the present invention. In other words, the interference pattern in the measurement plane improves the relative yield of fluorescence light in a multi photon excitation per se. This effect is even more prominent in case of a three photon excitation or in a process in which even more photons are involved. The above stated points apply independently of whether the intensity distribution of the excitation light caused by the interference pattern in the measurement plane is resolved or not in observing the fluorescence light from the sample.
[0014] A lateral offset of the partial beams in the measurement plane caused by the inclination angle should always be <50% of the full width at half-maximum (FWHM) of the intensity distribution of each partial beam in the measuring plane. A lateral offset of the partial beams in the measuring plane which is 25% of this FWHM at maximum is even more preferred.
[0015] Focusing the partial beams in at least one common measuring point within the measuring plane is not necessary for utilizing the general advantages of the new method with regard to the fluorescent light yield but it is nevertheless useful for utilizing the possibility of realizing a high spatial resolution in multiple photon excitation of the sample.
[0016] Because of the comparatively small inclination angle between the axes of the partial beams it is very useful to split the laser beam into the partial beams prior to any further beam formation, i.e. particularly prior to dividing the partial beams onto a plurality of focal points arranged side by side by means of a micro lens array, for example, to then project these focus points into the measuring points.
[0017] Besides the general advantage of the intensity distribution of the interference pattern in the measuring plane described above, particular advantages can be achieved in that the distance of the areas of maximum intensity in the interference pattern is at least half as wide as the distance of the measuring points. Thus, on the one hand, the single measuring point can fully utilize the increased relative yield of fluorescence light. On the other hand, it is possible to excite areas of different sensitivity of a sample with excitation light of different intensity by means of the intensity distribution of the interference pattern.
[0018] If it is not useful or necessary with a particular sample to excite different areas of a sample with different intensities of excitation light, the phase of at least one of the partial beams can be modulated by varying its path length so that the areas of maximum intensity of the interference pattern are moved forth and back in the measuring plane. It is not necessarily the sense of this measure to scan the sample with the interference pattern but to uniformly distribute the exciting light intensity. Because of the non-linearity of the multi photon excitation there is nevertheless an improved utilization of the provided light intensity, i.e. input light power, of the laser beam as it has been described above in the context of fine interference patterns. The invention also provides a device for multi photon excitation comprising a laser providing a laser beam, a beam splitter splitting a laser beam into at least two coherent partial beams each having a beam axis and a same intensity distribution about its beam axis, beam directing means directing the partial beams from different directions towards a common measuring plane running transversely to the beam axes at an inclination angle <1 between the beam axes of the partial beams, and a common lens system projecting the partial beams onto the measuring plane, an interference pattern formed by the coherent partial beams within the measuring plane providing areas of maximum light intensity adjacent to areas of minimum light intensity.
[0019] The beam directing means may include a roof mirror joining the partial beams which are directed towards the roof mirror from opposite directions at its roof ridge. For implementing the invention, it is however only important, that two partial beams with about a same intensity distribution are provided, and that these can be oriented at a small inclination angle with regard to each other. This can also be achieved by other optical means well known to those skilled in the art.
[0020] Thus, for example, the beam splitter and the beam directing means can both be formed by one optical element. For example, the optical element may have an active surface made of micro mirrors which in groups are inclined against each other. Such optical elements are available from Texas Instruments, USA. The micro mirrors may, for example, be divided up and controlled in two groups arranged like the fields of a chessboard: each the “black” and the “white” fields or micro mirrors have a same orientation and together form one of the partial beams of the laser beam.
[0021] The optical element may, however, also have an active transmission area which is comprised of groups of different or differently operated micro delay plates. Optical elements having electronically operated liquid crystal delay segments are, for example, available from DisplayTech USA. An arrangement of two groups of the micro delay plates for forming the two partial beams may here also be like a chessboard. Although optical elements with liquid crystal delay segments up to now only have a comparatively small transmission, it will be seen that they will be a future first choice in the realization of the present invention as soon as they have enhanced transmission values.
[0022] The lens system may comprise a micro lens array made of a plurality of micro lenses arranged side by side in one plane for distributing the partial beams over a plurality of focal points. In general, it is also possible to make use of other possibilities like a multiple aperture to this end. However, all apertures have the drawback that the incident beam of light or the incident partial beams are partially blocked so that valuable light power is lost.
[0023] In using a micro lens array an upper limit for the inclination angle should be smaller than Lambda (M*NA*f), Lambda being the wavelength of the laser beam and the partial beams, M being the magnification upon focusing the partial beams into each measuring point, NA being the numeric aperture of the lens systems, and f being the focal length of each micro lens of the micro lens array. Typical values of lambda are between 0,004 and 0,0015 mm. Typical values of M are between 0,05 and 0,01. Typical values of NA are between 0,2 and 1,6; and typical values of f are between 1 and 20 mm. This results into an inclination angle which can be smaller than 0,25*10 −3 and which is typically ≦1,0*10 −3 .
[0024] The beam directing means may comprise at least one deviation element which modulates the phase of at least one of the partial beams by varying its paths length. This deviation element can, for example, be a mirror supported by an piezo element the position of which is periodically moved by actuating the piezo element over a distance which is longer than the wavelength of the partial beam. If the period of this process is shorter than the time resolution in registering the fluorescence light emitted because of the multiple photon excitation, the intensity distribution of the interference pattern in the measuring plane is averaged but the general advantage of the non uniform intensity distribution of the interference pattern in multiple photon excitation is nevertheless retained.
[0025] The present invention does not relate to a new way of registering or observing fluorescence light emitted by a sample. However, it is clear, that those skilled in the art will provide corresponding known method steps and corresponding known equipment for detecting the fluorescence light. These include, for example, an electronic camera such as a CCD- or CMOS-camera, or one or more photo multipliers. In a preferred embodiment such a photo multiplier is assigned to each of the micro lenses of the micro lens array, the arrangement of the micro lenses being fixed with regard to the photo multipliers, and the sample being scanned, for example, by means of an Galvano mirror or by moving the sample itself.
[0026] Other features and advantages of the present invention will become apparent to one with skill in the art upon examination of the following drawings and the detailed description. It is intended that all such additional features and advantages be included herein within the scope of the present invention, as defined by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The invention can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. In the drawings, like reference numerals designate corresponding parts throughout the several views.
[0028] [0028]FIG. 1 shows the construction of the new device.
[0029] [0029]FIG. 2 shows a detail of the device according to FIG. 1.
[0030] [0030]FIG. 3 shows intensity distributions of excitation light over a cross section through the measuring plane in the device according to FIG. 1 as a result of theoretic considerations.
[0031] [0031]FIG. 4 shows actually measured intensity distributions corresponding to FIG. 3.
[0032] [0032]FIG. 5 shows one of the intensity distributions according to FIG. 4 in the measuring plane.
[0033] [0033]FIG. 6 shows the second intensity distribution according to FIG. 4 in the measuring plane; and
[0034] [0034]FIG. 7 shows the third intensity distribution according to FIG. 4 in the measuring plane.
DETAILED DESCRIPTION
[0035] Referring now in greater detail to the drawings, the device 1 shown in FIG. 1 consists of two partial arrangements 2 and 3 , the areas of which are each enclosed by a line in the present drawing. This does, however, not mean that the partial arrangements 2 and 3 have to be placed in different housings, or that there has to be another spatial or physical separation. The subdivision of the device 1 into the partial arrangements 2 and 3 only relates to their function.
[0036] The partial arrangements 2 of the device 1 includes a laser 4 , a beam splitter 5 , deviation mirrors 6 , 7 and 8 , and a roof mirror 9 . The laser 4 emits a coherent laser beam 10 . The beam splitter 5 splits the laser beam 10 into two partial beams 11 and 12 which are coherent with regard to each other and which each have a same intensity distribution about their beam axes. The partial beams 11 und 12 are deviated by means of the deviation mirrors 6 to 8 , and they are directed towards the roof ridge 13 of the roof mirror 9 from different directions. By the roof mirror 9 they are each deviated in such a way that they again run along a common optical axis 15 besides of an inclination angle 14 between their beam axes. In detail, the deviation mirrors 6 are provided for deviating the partial beam 11 , and the deviation mirrors 7 and 8 are provided for deviating the partial beam 12 . The path lengths of both partial beams between the beam splitter 5 and the roof mirror 9 are of equal length. Accordingly, the partial beams are suitable for interference behind the roof mirror 9 . Interference patterns resulting here can be varied by means of operating an piezo element 16 which is supporting the deviation mirror 8 in the optical path of the partial beam 12 , because a variation of the path length of the partial beams 12 corresponds to a phase shift as compared to the partial beam 11 . The angle 14 between the partial beams 11 and 12 behind the roof mirror 9 is 8,4*10 −4 here.
[0037] In the partial arrangement 3 of the device 1 , the incident partial beams 11 and 12 are formed as follows by means of a lens system 21 , which consists of a telescope 17 , a micro lens array 18 , a plurality of lenses 22 and an oil objective 23 . First, the partial beams 11 and 12 are each expanded by the telescope 17 . Then the expanded partial beams 11 and 12 reach the micro lens array 18 , which is formed by a micro lens disk 20 rotating about an axis 19 . The micro lens array 18 focuses each of the partial beams 11 and 12 into a plurality of focus points which are then projected into different measuring points in a measuring plane within a sample 24 via the lenses 22 and the oil objective 23 . The intensity distributions of the partial beams 11 and 12 overlap in each measuring point in such a way that their offset with regard to each other is only about 20% of the FWHM of their respective intensity distributions. The inclination angle 14 between the partial beams 11 and 12 results in a formation of an interference pattern extending over the single measuring points in the measuring plane, the type of interference, i.e. destructive or constructive, being dependent on the relative phase and thus on the operation of the piezo element 16 which support the deviation mirror 8 . This will be further explained in context of FIG. 3. There where the partial beams 11 and 12 are superimposed in a constructive way and provide a resulting excitation intensity, the sample 24 is excided in a multi photon excitation, which may be assumed as being a two photon excitation, for emission of fluorescence light. This fluorescence light can be directly viewed via an ocular 25 , or it can be registered with an electronic camera 26 . To this end, two further beams 27 and 28 are provided in the beam path of the device 1 . The mirror 27 is preferably a chromatic beam splitter which deviates the partial beams 11 and 12 towards the sample 24 but which allows for transmission of the fluorescence light from the sample towards the ocular 25 and the camera 26 , respectively, thus using the different wave length of the partial beams 11 and 12 , on the one hand, and of the fluorescence light, of the other light. Even in addition to the mirror 27 being a chromatic beam splitter, a filter which is not depicted here may be arranged in the beam path running towards the camera 26 or the ocular 25 , to absorb laser light reflected by the sample 24 for enhancing the signal to background ratio or for protecting the eyes. The mirror 28 can be a semi transmitting mirror. Preferably, however, it is a full reflecting mirror which can be pushed or tilted into the beam path to either observe the sample with the electronic camera 26 or to view it through the ocular 25 each time making use of the full intensity of the fluorescence light.
[0038] [0038]FIG. 3 shows the excitation of the sample for emission of fluorescence light plotted over the position in the sample, i.e. over a cross section through the measuring plane along which the single measuring points are arranged. The cross section through the measuring plane depicted in FIG. 3 is scanned by the micro lens array 18 rotating about the axis 19 . In FIG. 3, a curve 29 shows the intensity distribution of the two photon excitation, which would result without dividing up the laser beam 10 into the partial beams 11 and 12 . It is a Gaussian intensity distribution. In contrast, the curve 30 shows a constructive superposition in the middle of the overlapping of the partial beams 11 and 12 . This results in three areas 31 of maximum intensity arranged side by side between which the excitation of fluorescence light goes down to zero. The curve 32 shows a case of destructive interference in the middle of both intensity distributions. Correspondingly, the fluorescence excitation in the areas 31 of the curve 30 goes down to zero. Instead, areas 33 of maximum intensity are formed in between. If an average is calculated for the curves 30 and 32 and all other possible relative phases of the partial beams 11 and 12 , this results in the curve 34 for the fluorescence excitation of the sample 24 . The curve 34 corresponds, for example, to measuring the fluorescence with a smaller time resolution than a periodic vibration of the piezoelement 16 which supports the deviation mirror 8 . As a result of the non-linearity of the multi photon excitation on which the fluorescence is based, the curve 34 is clearly above the curve 29 ; i.e. because of the interference of both partial beams 11 and 12 in the area of the sample 24 , the yield of fluorescence light from a multi photon excitation of the sample is enhanced. In case of a two photon excitation, the yield of fluorescence light should be practically up to 50% higher than in case of a direct use of the laser beam, only because of the interference of the two partial beams. In case of a three photon excitation, the improvement is up to 150%.
[0039] The theoretic values depicted in FIG. 3 are confirmed by the measurement values in FIG. 4 which are there represented by the curves 30 , 33 and 34 . The curve 29 is not depicted in FIG. 4, but it constantly runs below the curve 34 and also has a Gaussian shape.
[0040] [0040]FIGS. 5, 6 and 7 show intensity distributions of the excited fluorescence of a homogenous sample arranged in the measurement plane, which correspond to the curves 30 , 33 and 34 . Whereas FIG. 7 does only report an increase in yield of fluorescence light by means of smearing out the interference patterns of the partial beams 11 and 12 , FIGS. 5 and 6 show that the interference pattern also allows for purposefully excite certain areas of a sample stronger than others to, for example, account for different sensitivities of the sample. The interference pattern produced by the partial beams 11 and 12 in the measuring plane is not necessarily comparatively coarse like that one shown in FIGS. 5 and 6. It may also have a higher number of smaller areas of maximum intensity arranged side by side. The general advantages of the new method for multi photon excitation of a sample and of an corresponding device are nevertheless retained. It may even become easier to average the interference patterns over different relative phases. Averaging is a quasi-automatic result, if the interference pattern is finer than the intensity distribution of the partial beams in each measuring point.
[0041] Many variations and modifications may be made to the preferred embodiments of the invention without departing substantially from the spirit and principles of the invention. All such modifications and variations are intended to be included herein within the scope of the present invention, as defined by the following claims.
LIST OF REFERENCE NUMERALS 1 Device 11 partial beam 2 partial arrangement 12 partial beam 3 partial arrangement 13 roof ridge 4 laser 14 inclination angle 5 beam splitter 15 optical axis 6 deviation mirror 16 piezo element 7 deviation mirror 17 telescope 8 deviation mirror 18 micro lens array 9 roof mirror 19 axis 10 laser beam 20 micro lens wheel 21 lens system 31 area 22 Lens 32 curve 23 Objective 33 area 24 Sample 34 curve 25 Ocular 26 Camera 27 Mirror 28 Mirror 29 Curve 30 Curve
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In a method for multi photon excitation of a sample a laser beam is split into at least two coherent partial beams each having a beam axis and a same intensity distribution about its beam axis. The partial beams are directed from different directions towards a common measuring plane running transversely to the beam axes at an inclination angle <1 between the beam axes of the partial beams; and the partial beams are projected onto the measuring plane by means of a common lens system. Thus, an interference pattern formed by the coherent partial beams within the measuring plane provides areas of maximum light intensity adjacent to areas of minimum light intensity.
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FIELD OF INVENTION
[0001] The present invention relates generally to the field of forming joints for plastic tubing. More specifically, the present invention relates to permanent, leak-proof joints in polyolefin tubes made with integral male and female ends and a method of forming such tubes and joints.
BACKGROUND OF INVENTION
[0002] Pipes typically known as ‘Quick Connect’ pipes and joints systems made using these pipes have been used in sprinkler irrigation since last so many years. These joints are easily assembled and disassembled in field conditions and used in systems for conveyance of pressured fluids. Pipes used in such systems are typically the extruded type. The male and female ends are manufactured separately by injection moulding. The moulded ends are welded to a pipe's plain ends to make a pipe length suitable for joining with other pipes. Each pipe thus has a male and a female end.
[0003] The male and female ends can be welded to the pipe in a number of ways such as butt fusion welding, socket fusion welding etc. The female sockets are further machined to form grooves for placing rubber rings that help form a seal. Waste material produced during the grooving process is normally recycled. The pipes fitted with male and female ends thus produced are easily connected with and disconnected from each other. In the case of systems carrying fluids under pressure, a clamp is used to hold securely the joints thus formed to withstand pressure, and sealing rings are used to make the joints leak-proof.
[0004] Piping systems with easily assembled and disassembled coupling arrangements used for conveyance of pressured fluids are available. An ideal pipe system that is deployed in transportable sprinkler irrigation systems which are operated under pressured fluids should be designed so that the following requirements are met:
It withstands the applied pressure. It is easy to install and dismantle in field. The joints are leak-proof The pipe ends, which are generally prone to damage, are unbreakable. The pressure drop should be minimum. The system must be cost effective.
[0011] Many of the existing piping systems used for sprinkler irrigation fulfill the first three requirements from the above list of requirements, however, most of these systems suffer from drawbacks such as:
The welds of male and female ends can fail if proper welding procedures are not followed. The welded joints, due to their roughness and irregular surface, cause restriction to flow of water, which results in pressure drop across the joint. The joints are created using injection moulding technique thus requiring heavy investment in injection moulding machine and equipment, in a business that otherwise would be operating on a extrusion technique. A separate huge inventory of moulded articles needs to be maintained to fulfill requirements on time, leading to huge space requirement. Substantial amount of welding equipment is required to manufacture welded joints in large quantities. The welded joints also require to be machined to the required groove in moulded female end which also generates waste. Another drawback is that the existing systems typically require skilled manpower to produce good quality welded joints. Weld quality can vary dependent upon the operator skill
[0020] In order to overcome the restriction-to-flow drawback, there have been attempts to make the inner edge of the pipe at the plane of the joint as smooth as possible by a debeading operation. This helps in reducing the flow restriction, which ultimately reduces pressure drop over the length of the joint. However, this method is not effective in sprinkler piping system as the pipes used are generally thin walled and debeading operation poses a serious risk to the integrity of the weld joint, possibly resulting in weld failure. The debeading operation is also time consuming and thus increases the cost of the irrigation system.
[0021] There have been attempts to eliminate the post-forming operation of machining grooving in a moulded female end. In one such attempt, a collapsible mould was used to form groove directly, however, shrinkage could not be controlled effectively, as a result of which the grooves formed were not of good quality. Uneven shrinkage properties of polyolefin during moulding lead to change in article wall thickness. The uneven shrinkage ultimately results in problems relating to sealing of joints and assembling the pipe system.
[0022] In the U.S. Pat. No. 5,554,332, Schnallinger discloses a process of manufacturing shaped elements from synthetic thermoplastics, in which plastic material (synthetic thermoplastics) is heated to a temperature above its softening point and shaped to form the shaped element. The shaped element is subsequently cooled to a temperature below its softening temperature.
[0023] However, Schnallinger did not teach how to create a thermoplastic pipe that has an integrally formed male spigot and a female socket at once. Nor did he teach how to make a leakproof joint from a thermoplastic pipes with such male and female ends.
[0024] There is therefore a need to provide a system of joints which will fulfill all the requirements as specified above for long life working of piping system used in sprinkler irrigation at lowest cost, and which will not suffer from any of the drawbacks mentioned above.
OBJECTIVES AND ADVANTAGES
[0025] Accordingly, the objectives & advantages of the present invention are as described below.
[0026] An objective of the invention is to provide a system of joints suitable for use in irrigations system and made from pipes that are provided with integral male & female ends so as to:
Eliminate the need for injection moulding of male & female ends. Eliminate the need for welding activities. Eliminate the risk of welded joint failure. Minimize the pressure drop across the pipe joints. Eliminate the coupler grooving activities. Eliminate the material wastages during female end groove machining. Ensure that the system will withstand the pressure applied in the system and is leak proof Ensure that the system is easy to install & dismantle in field Ensure that the system does not suffer from shrinkage effects Ensure that the system is cost effective.
[0037] Another object of the present application is to provide a process by which the pipes with integrally formed male and female ends proposed in this invention are manufactured.
BRIEF DESCRIPTION OF FIGURES
[0038] FIG. 1 —Existing male and female sockets and welded pipe assembly
[0039] FIG. 2 —Pipe with integrally formed male and female ends
[0040] FIG. 3 —A section through the joint of the present invention)
[0041] FIG. 4 —longitudinal sections of the male spigot and the female sockets
[0042] FIG. 4 A—cross section of the seal ring
[0043] FIGS. 5 A and 5 B—The effect of entry length of the male socket
[0044] FIG. 6 —Variations in the female socket configuration
[0045] FIG. 7 —Flow chart of the process of the invention
[0046] FIG. 8 —Schematic of the process of the invention
[0047] FIG. 9 shows a belling machine
SUMMARY OF THE INVENTION
[0048] The invention describes easily attachable and detachable joints for use in pipe systems carrying pressured fluids. The pipes used for the purpose are made using thermoplastics, preferably polyolefin and provided with integrally formed male and female ends. Any material from the entire polyolefin group is acceptable for use. The invention also discloses a method of forming such tubes along with their male spigot and the female sockets.
[0049] The process of manufacturing the integral male & female ends of extruded pipes disclosed herein is characterized in that the ends of extruded pipe are heated and expanded in a controlled manner to form either a male a spigot or a female socket, each pipe having a male spigot at one end and the female socket at the other. The male spigot thus formed in the heated state has an external diameter which is 0.5 to 5% in excess of the desired final pipe diameter (this is independent of the material), and the female socket thus formed has an internal diameter which is 0.5 to 5% in excess of the desired final pipe diameter, and which is independent of the material. The resulting male spigot or the female socket is cooled and subsequently compacted in a pressing tool to have a diameter such that when released from the pressing tool, the socket will undergo an elastic expansion to have the desired final diameter.
[0050] Joints using the pipes provided with integral male and female ends are constructed using a push-fit principle. A sealing ring is inserted in the sealing groove made in the female socket thereby helping make the joint leak proof. Plastic or metal clamps are provided to sustain the longitudinal forces imposed on the joint exerted by the pressured fluid. The male spigot is provided with an integrally formed collar that serves as the holding surface to clamp resisting longitudinal forces. The joint is simple in its construction, easy to assemble in field & cost effective.
LIST OF PARTS
[0051]
[0000]
Part
Name
No.
1.
Integrally formed male end or
male spigot of pipe
lA
Conventional male spigot
2.
Integrally formed female end or
female socket of pipe
2A
Conventional female socket
2B
Weld
3.
Sealing ring groove
4.
Collar at male end
4A
Internal upper surface of collar
4B
Internal gap of the collar
4C
Internal lower surface of the
collar
5
Sealing ring
5B
Collar gap
6
Holding Clamp
7
Male Entry length
8
Female Entry length
9
Depth of Engagement
9A
Width of the sealing ring
groove
9B
Height of the sealing ring
groove
10
Metal ring on female
socket
DETAILED DESCRIPTION OF THE INVENTION
[0052] The invention describes a novel leakproof joint for use in pipe systems which carry fluids under pressure. The invention also discloses a method of forming male spigots and female sockets integrally on extruded polyolefin pipes.
[0053] As shown in FIG. 1 , the existing available pipe systems with joints are made with pipes that have welded-on male spigots ( 1 A) and female sockets ( 2 A). Male spigots ( 1 A) and female sockets ( 2 A) are formed by means such as intrusion moulding separately and joined onto the pipe ends using welds ( 2 B).
[0054] The most preferred embodiment of the invention is now described.
[0055] In the preferred embodiment of the invention, a joint made from pipes having integrally formed male spigots and female sockets on either ends is described (see FIG. 2 ). FIG. 4 shows the longitudinal sections taken through the male and female ends and also through the pipe joint, and FIG. 3 shows a cross-sectional view of the assembled pipe joint.
[0056] A leakproof joint is formed by inserting the integrally formed male ( 1 ) spigot of one pipe into the integrally formed female ( 2 ) socket of another pipe and holding the joint thus formed together with the help of means such as a holding clamp ( 6 ).
[0057] The joint of the preferred embodiment further comprises an arrangement for sealing, which together with the holding clamp enables the formed joint to withstand fluid pressure in the field situation. The sealing arrangement comprises a sealing ring ( 5 ) placed inside the sealing ring groove ( 3 ) to prevent fluid leakage whereas the holding clamp ( 6 ) provides secure locking against axial movement due to fluid pressure. As shown in FIG. 4A , the sealing ring preferably has a serrated internal surface.
[0058] While Schnallinger has described the process of forming an integrally formed female socket at one end of a pipe, no one has since thought of making a pipe that has a female socket thus formed at its one end and a male spigot at the other. No one has since further thought of using such pipes to form joints that can be used in pipe systems that carry pressured fluids used in open field conditions. Pipes with integrally formed female sockets have been in use in pipe systems that carry fluids with pressure but these pipes need to be buried in the ground or some anchoring has to be done to keep it integral. This makes their use expensive and cumbersome. In such instances, the plain end of the pipe is uses as a male end and joints are formed by simply inserting the male end into the female socket with or without sealing. Such joints are unsuitable for use in systems carrying fluids under pressure in open field condition. For making joints suitable for use in systems carrying pressured fluids, special male spigots are formed separately and welded onto the pipe ends as described earlier.
[0059] Therefore, one key novel feature of the invention is the integrally formed male spigot with a collar & female sockets at either ends of the same pipe. The formation of the collar is hugely important at it allows use of a clamp necessary to form a leakproof joint suitable for use in pressured pipe systems, which can be used in open field condition.
[0060] In the present invention, instead of using injection moulded pieces which are produced separately from the pipes and then welded to the pipe ends, and as is the current practice in the related industry, the inventors have advantageously made a pipe where integral male spigot ( 1 ) with a collar & female sockets ( 2 ) are formed at the end of the pipes after the pipe extrusion process. The integral female ( 2 ) socket has a sealing ring groove ( 3 ) on its inside surface and the integral male ( 1 ) socket has corresponding collar ( 4 ) on its external surface. The inventors have found that the collar ( 4 ) advantageously secures the pipe against the axial movement and acts as stopper for male ( 1 ) spigot's entry length ( 7 ) into the female ( 2 ) socket. It is important that the collar is formed such that the two faces (the internal upper surface ( 4 A), and the internal lower surface ( 4 C)) of the collar are as near to each other as possible whereby the internal gap ( 4 B) of the collar is minimized. This improves greatly the strength of the collar against the clamp forces. Collars which are formed without attention to this aspect are not strong enough and become damaged by the stresses induced by the clamp.
[0061] FIG. 3 shows longitudinal section of pipe taken through a typical male ( 1 ) end. The male ( 1 ) end shows the formed collar ( 4 ) and male entry length ( 7 ). The male entry length ( 7 ) sits inside the female ( 2 ) end compressing the sealing ring ( 5 ) and making the joint leak-proof.
[0062] FIG. 3 also shows a longitudinal section of pipe taken through a typical female ( 2 ) end. This shows the sealing ring groove ( 3 ), female entry length ( 8 ), which is the length of the pipe beyond the sealing ring groove, depth of engagement ( 9 ) of male and female ends, and a metal ring ( 10 ) on female end ( 2 ). The depth of engagement is of importance as the integrity of the joint and its leakproofness depends on its adequacy. It is defined as the length of overlap between the portion of the male spigot beyond its collar and the female socket. The provision of female entry length ( 8 ) beyond the sealing ring groove helps in ensuring a proper alignment during assembly. The metal ring ( 10 ) on female socket ( 2 ) helps to withstand the pressure in the system & to avoid the deformation of groove diameter which ultimately ensures that the joint remains leakproof.
Construction of the Assembled Joint:
[0063] To construct the joint as disclosed in the preferred embodiment and as shown in FIG. 2 , a sealing ring ( 5 ) is placed inside the sealing ring groove ( 3 ) which is provided inside of the integral female ( 2 ) socket of pipe. Next, the integrally formed male spigot ( 1 ) is inserted or push-fitted into the integrally formed female ( 2 ) socket of another pipe, preferably till the collar ( 4 ) touches the top of the female entry ( 8 ) length. Next, the holding clamp ( 6 ) is put in place which ensures that the pipe remains held in place under the axial forces. The resultant joint is leak-proof without any possibility of breakage.
[0064] As discussed earlier, the integrity of the joint and also its leakproofness depends in part on the magnitude of the depth of engagement. It is important to provide sufficient depth of engagement so that when operating under the fluid pressure, the joint doesn't open up by the male spigot slipping out of the female socket. The greater the depth of engagement, the more difficult it is for the male spigot to come out of the female socket. It is important to ensure that the entry length of the male end is sufficient so that the end of male end is outside the sealing ring area, preferably resting on the chamfer of the female socket. This is indicated in FIGS. 5A and 5B , where it can be seen that the collar gap ( 5 B) between the external lower surface of the collar and the top of the female entry length is minimized, preferably these two parts touching.
[0065] There are several variations possible of the female socket, as shown in FIG. 6 , which shows the width ( 9 A) and height ( 9 B) of the sealing ring groove. These dimensions may vary to suit the size of the sealing rings available. Variations are also possible where the female sockets are produced with or without a female entry length ( 8 ), and the sealing ring groove of variable longitudinal and cross-sectional depths.
[0066] In another embodiment of the present invention a method to manufacture the pipes with integrally formed male spigot end and integrally formed female socket ends is disclosed. This is explained with the help of a flow chart ( FIG. 7 ), and a schematic diagram ( FIG. 8 ). The process comprises the steps of:
supplying raw material extruding the pipe of predetermined diameter using a standard forming process using a novel belling machine to form a female end socket at one end using a novel mandrel to form a male spigot with a collar at the other end of the pipe
[0071] The process of forming the pipes with male and female ends and making joints using them is now described. The pipes that are formed using a standard process of forming are picked up by a belling machine, preferably directly from the conveyer belt of the extrusion line. The pipe distance is set so that the socket is not shortened. A transport system moves the pipes, preferably a number of them at a time, to the heating station, where the pipe end lengths are heated so that the belling operation can be performed.
[0072] Once the pipe ends are softened adequately, they are placed in a socket and spigot forming station where male spigots and female sockets are formed in any sequence, that is, male spigots first and female sockets later or vice versa. The size of spigots and sockets in the heated state is somewhat larger than their final size in the cooled down state. The spigots and sockets formed are cooled down in an anti-shrinkage station, where they are cooled down under the application of pressure, whereby the final sockets are of desired size.
[0073] The male spigot is formed by the forming process under the action of blowing and pressurizing using a specially designed mandrel. A person skilled in the art will know the difficulties in integrally forming the male spigot with a collar during a process of pipe extrusion. When the belling operation on the male spigot forms the collar, the mandrel applies longitudinal pressure on it to ensure that the width of the collar is minimized such that the two internal surfaces of the collar come as close to each other as possible. This is achieved by application of longitudinal pressure applied from the male end, preferably across entire thickness of the pipe, after the collar has been formed. The difficulties arise in providing grip to the pipe end, inserting an implement to form the collar in the pipe, and the shrinkage issues. The conventional wisdom has therefore been to form the male socket separately and attach it by means such as welding to the pipe end. As discussed earlier, this has several drawbacks.
[0074] One of the other key features of the present invention is the anti-shrinkage measure that is provided during the process of the invention. The steps of forming sockets are carried out using a purpose built plant which has special forming stations for the male and female ends.
[0075] The shrinkage phenomenon is due to the latent memory in the molecular structure of the polyolefin by which the intermolecular space reduces once the material cools down. This ‘memory effect’ is effectively eliminated with the use the anti shrinkage technology in which the male and female sockets are constructed to a larger than final size and cold-pressed into the final size. The inventors have observed that this method eliminates any shrinkage that would result from the pipes that are cooled down. The major disadvantage of shrinkage is that the dimensional changes are uncontrolled and non-uniform. The anti shrinkage technology allows a controlled reduction from the larger to smaller size of a formed part such that the final size and shape of the final part is to the desired specification and the male and female sockets thus formed are uniform and dimensionally stable in the field conditions.
Testing:
[0076] Testing was performed in accordance with IS: 14151 PART—2.
[0077] Three tests were performed on joints made in accordance with the preferred embodiment: a holding attachment (clamp) test, a leakage test, and a hydraulic proof test.
The Holding Attachment (Clamp) Test:
[0078] The holding attachment test was designed to observe integrity of the holding attachment while under field conditions. IS: 14151 PART—2 stipulates that in the case where any external attachment is provided for holding the coupler parts to from a quick leak proof joint of a pipe system carrying fluid under pressure, the holding attachment must be strong enough to withstand the pressure two times the working pressure of the pipes. Accordingly a clamp was fitted on a joint made from 75 mm OD polyolefin pipes using the present invention to carry water under 6.4 kg/cm2 pressure. The joint was observed for one hour for visible distortion of pipes and the holding clamp. No deformation of either the pipes or the holding was observed.
Leakage Test:
[0079] Joints were assembled along with the clamps put in place. In accordance with IS: 14151 PART—2, the joint was placed in a test system that carried water as fluid under a pressure which was raised from 0 kg/cm2 to its maximum value of 6.4 kg/cm2 over a period of 5 minutes. The joint was observed at the maximum pressure for one hour during which period no leakage was observed. Although the test standards stipulates that for pressure activated joints of the type the present invention discloses, there shall be no leakage at or beyond the pressure of 0.05 Mpa, the inventors have tested the joint for a much higher value.
Hydraulic Proof Test:
[0080] Joints were assembled along with the clamps put in place. In accordance with IS: 14151 PART—2, the joint was placed in a test system that carried water as fluid under a pressure which was raised from 0 kg/cm2 to its maximum value of 6.4 kg/cm2 over a period of 5 minutes. The joint was observed at the maximum pressure for one hour during which period no distortion of individual parts of the joint or deformation of the joint as a whole were observed. The joint did not show any visible signs of swelling, weeping or deformation and did not burst during the prescribed test duration.
[0081] The test results have been incorporated in Table 1.
[0000]
TABLE 1
Test
Test
No. of
Test
pressure
duration
samples
No.
description
kg/cm 2
Hrs.
tested
remark
1
Leakage
0.5
1
5
No leak-
test
age found
2
Hydraulic
6.4
1
5
No leak-
proof test
age found
3
Holding
6.4
1
5
No
attach-
deforma-
ment
tion found
4
Leakage
6.4
1
5
No Leak-
test
age found
[0082] In summary, the inventors have found that the novel quick connects integral pipe joint described in the present invention has the advantages such as:
[0083] It eliminates the injection moulding of male & female ends.
It eliminates the welding activities. It eliminates the risk of welded joint failure. It minimizes the pressure drop as there are no rough surfaces or protrusions that could restrict the flow. It eliminates the coupler grooving activities. It eliminates the generation of wastages during female end grooving. It withstands the pressure applied in the system and is leak proof. It is easy to install & dismantle in field It is cost effective. Provides the metal ring on female socket so when pressure applied in the system, groove dia. Joints are not deformed and are leak proof.
[0094] In view of the details given in foregoing description of the present invention, it will be apparent to a person skilled in the art that the present invention basically comprises the following items:
[0000] 1. A pipe made with integrally formed male spigot at one end of said pipe, wherein said male spigot has an integrally formed collar.
2. A pipe as described in item 1 wherein said pipe further comprises an integrally formed female socket at the other end of said pipe, wherein said female socket preferably has an integrally formed sealing ring groove.
3. A joint made using two separate pipes, each of the pipes being as described in item 2, wherein said joint further comprises a holding clamp, a sealing ring, and a female socket ring, wherein
said joint is formed by inserting said male spigot of one of the two pipe into said female socket of the other pipe, the sealing ring groove of which houses said sealing ring, such that the necessary depth of engagement is achieved, followed by applying a clamp to secure said male spigot and said female socket in an engaged position.
4. A joint as described in item 3, wherein the male entry length is such that the end of the male spigot is well outside the sealing ring area, said male spigot end preferably resting on the chamfer of the female socket.
5. A novel joint as described in item 3 wherein said collar is positioned such that it preferably touches the top of the female entry length thereby acting as stopper for said male spigot's entry length into said female socket.
6. A novel joint as described in item 3 wherein the internal gap of said collar is small, preferably 0 mm.
7. A novel joint as described in item 3 wherein said pipes are made from thermoplastic resins, preferably polyolefin, preferably using extrusion forming process.
8. A process of making a pipe, one end of which has an integrally formed male spigot with a collar and the other end an integrally formed female socket, comprising the steps of:
a. extrusion forming said pipes, preferably formed using a standard process of extrusion forming b. heating the formed pipes at a heating station c. forming in a socket and spigot forming station, in any order, a female socket at one end of the pipe preferably using a belling machine, and forming a male spigot with a collar at the other end using appropriate means, preferably a mandrel, such that the size of the socket and spigot formed in the hot pipe is somewhat larger, preferably 0.5%, than their respective final sizes, d. ensuring that the width of the collar is adjusted to a minimum, e. cooling along with application of suitable pressure, the integrally formed male spigot and female sockets in an anti shrinkage station.
9. A process of making a novel joint using two pipes made using the process as described in item 8, wherein the steps of making said joints comprise:
a. inserting a sealing ring into the sealing ring groove of said female socket of one of the two pipes b. inserting said male spigot of one of the two pipe into said female socket containing said sealing ring groove, c. ensuring that a necessary depth of engagement is achieved between the male spigot and female sockets referred to in step b, d. applying a holding clamp to secure said male spigot and said female socket in an engaged position, thereby forming a secure joint.
[0104] Although the invention has been described with reference to certain preferred embodiments, the invention is not meant to be limited to those preferred embodiments. Alterations to the preferred embodiments described are possible without departing from the spirit of the invention. However, the process and composition described above are intended to be illustrative only, and the novel characteristics of the invention may be incorporated in other forms without departing from the scope of the invention.
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The invention describes easily attachable and detachable joints for use in pipe systems carrying pressured fluids. The pipes used for the purpose are made using thermoplastics, preferably polyolefin and provided with integrally formed male spigot end ( 1 ) and a female socket end ( 2 ). The invention also discloses a method of forming tubes along with their male spigot ( 1 ) and the female sockets ( 2 ). Joints made using the pipes provided with integral male ( 1 ) and female ends ( 2 ) are constructed using a push-fit principle. A sealing ring ( 10 ) is inserted in the sealing groove ( 3 ) of the female socket ( 2 ), making the joint leak proof. Plastic or metal clamps ( 6 ) are provided to sustain the longitudinal forces imposed on the joint exerted by the pressured fluid. The male spigot ( 1 ) is provided with an integrally formed collar ( 4 ) that serves as the holding surface to clamp resisting longitudinal forces. The joint is simple in its construction, easy to assemble in field, robust and cost effective.
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BACKGROUND OF THE INVENTION
The present invention relates to an information service system which provides information service to particular persons and more particularly to an information service system which selects and provides information which is especially important to participants in (users of) an object system.
In recent years, attempts have been made in transportation systems, plants and the like to transform intellectual activities of experts for system driving or controlling into algorithmic forms One of such attempts involves use of a fuzzy control method wherein the subjective ambiguity of people is quantitatively classified into fuzzy sets to determine control instructions. As examples of fuzzy theory controls, a scheme which relies on experts' estimation of system controls has been employed in controlling a cement kiln or in controlling the dose of chemicals to be provided in a water cleaning bed. The outline and applications of fuzzy controls are described in detail in IEEE Spectrum, Vol. 21, No. 8, pp. 26 to 32, Aug. 1984.
The present inventors have proposed a predictive fuzzy control scheme which determines a control instruction based on estimation of control objects sought by experts while using models of the object system, and this scheme is practically applied to automatic train operation and automatic crane operation (U.S. application Ser. No. 488,455, filed on Apr. 25, 1983, entitled "Method and device for stopping vehicle at predetermined position", now abandoned, from which we have filed a continuation U.S. application Ser. No. 127,549 filed on Dec. 2, 1987, both applications being assigned to the same assignee as the present application).
In line with developments of a highly sophisticated information system using new media, it has become important to provide a technology by which information really important to a user of (a participant in) the system is selected among a great amount of information and the selected information is supplied to the user, while aiming at supplying information which is comparable to that a skilled person would supply.
The above-described fuzzy control system aims at optimum control of an object system and gives a display of inferred results, an explanation of causes, and so on to a system participant. However, it does not positively provide information really desired by a system participant.
With conventional information services for an elevator operation system, a train operation system and so on, only a fixed message is supplied to a system participant when the object system reaches a predetermined condition However, such conventional information services are uniform or standardized so that meaningless or inferior information may sometimes be given to the system participant, who accordingly feels uneasy and restless.
SUMMARY OF THE INVENTION
The role played by experts in a control system will be considered In a control system, particularly in a system operating in close connection with a human, there is provided not only a driver or operator of the object system, but also a conductor, guide and other personnel who explain the driving or controlling condition to passengers, all of whom work together to allow the passengers to use the system with mental comfort and ease. Namely, in a train operation system, by way of example, the conductor gives passengers control information including an advance notice of rolling at a switch point, of braking action, and so on, as well as external information including information regarding train transfer, and so on. Thus, the conductor provides information services to passengers at proper times and places. In a control system, such as in plants without expert operators, taking as an example the case where a skilled person drives or controls the system while accompanied by a beginner, the skilled person not only drives the system, but also teaches the beginner how to judge the present system condition and why the next action is to be selected. This invention proposes an information service system which not only transforms intellectual control activities of such a skilled person into a form usable by computers, but also integrates and builds into the system intellectual activities regarding information services related to the control activities.
It is therefore a first object of the present invention to provide an information service system which is capable of supplying optimum information to a participant in accordance with the object system condition and control condition.
It is a second object of the present invention to provide an information service system wherein intellectual activities of experts regarding information services are integrated in the form of a fuzzy knowledge base to provide most suitable information services to a system participant.
The above first and second objects can be achieved by the provision of an information service system which supplies predetermined information to a participant in an object system in accordance with predetermined control rules, which system includes an information service rule storage unit for transforming intellectual activities regarding information services to the participant in an algorithmic form and storing the algorithmic form data as an information knowledge base; an information storage unit for storing as an information base the internal information regarding the object system and external information, such as news, weather predictions and the like; an information service control unit for fetching the condition of the object system, calculating the condition in accordance with the information knowledge base, selecting most suitable information for the participant from the information storage unit in accordance with the calculated result, and outputting the most suitable information; and an information display for notifying the system participant of the information corresponding to the most suitable information from the information service control unit.
According to a preferred embodiment of the information service system, the satisfaction degree of an estimation standard which a human has felt subjectively is obtained based on measured values of present and past conditions Based on a service rule determined by a human through past information service experiences while taking the estimation standard into consideration, a most suitable information service for a particular situation as would be sought by a human is given.
These and other objects and many of the attendant advantages of this invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the overall configuration of an embodiment of the information service system according to the present invention;
FIG. 2 shows details of the object system controller 10 shown in FIG. 1;
FIG. 3 shows details of the information service controller 20 shown in FIG. 1;
FIG. 4 shows the outline of an elevator group supervisory system;
FIG. 5 is a flow chart illustrating the procedure performed by an information service controller 20 shown in FIG. 1;
FIG. 6 shows the content of an information service rule table stored in an information service rule storage; and
FIG. 7 shows an example of a membership function of an information service proposition.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will be described in detail with reference to the accompanying 20 drawings.
FIG. 1 shows an embodiment of the information service system according to the present invention.
The system is broadly classified into three units including an object system controller, an information service controller and a knowledge editor. According to the information service system, the object system is automatically driven while considering proper service information for passengers and crews by using each rule made up in dependence upon the knowledge of a skilled person and the like.
The object system 1 may be one of various control systems, such as an elevator-group supervisory system, train operation system, process control system and the like. In this embodiment, an elevator-group supervisory system is used by way of example.
The object system 1 is coupled to an object system controller 110 and information service controller 20 to both of which it supplies a system-condition signal 1a indicating the condition of the object system 1. The object system 1 and object-system controller 10 constitute a closed loop. The object-system controller 10 supplies a control instruction signal 10a corresponding to the system condition to the object system 1 for control of the latter.
A knowledge editing portion 70 edits a fuzzy knowledge base by introducing empirical rules regarding the system control and information service into the fuzzy knowledge base. The edited respective knowledge base is supplied to a control rule storage 11 and information service rule storage 30 to be stored therein. The control rule storage 11 is coupled to the object system controller 10 which controls the object system 1 in accordance with control rules of the storage 11.
The information service controller 20 is coupled to a voice synthesizer 60, display 50, object system controller 10, information service rule storage 30, object system 1 and external information data base 80. The information service controller 20 receives a control condition signal 10b and system condition signal 1a to arithmetically process them in dependence upon rule information supplied from the information service rule storage 30, and notifies a system participant 90 of optimum information from the external information data base 80 by means of the display 50 and/or voice synthesizer 60.
FIG. 2 shows details of the object system controller 10. The object system controller 10 transforms empirical rules derived from persons' individual or fragmentary control knowledge into fuzzy control rules, by making fuzzy sets representative of their subjective grasp or comprehension of object system conditions, models of dynamic characteristics, and fuzzy estimation of control purposes, to allow control of the object system 1 by using the fuzzy control rules. Stored in the control rule storage 11 are qualitative characteristics, in the form of software, of past experiences of experts for the control of the object system. The object system controller 10 determines for a very important situation a control plan to satisfy a primary control purpose on the basis of the control rules. Generally, a control instruction is determined in accordance with the determined control plan, and a response to past control instructions is checked from time to time to infer the present characteristic of the object system 1. The object system controller 10 hierarchically organizes the control rules as in the following:
(a) Control object estimation means 101 receives the object system condition signal 1a and control instruction u(t) 10a and checks the present response of the object system 1 by comparing it with past experienced responses If the structure or constitution of the object system 1 or system parameters 101a have changed, such change is recognized by the control object estimation means 101.
(b) Control plan determination means 102 discriminates and determines an optimum control plan 102a by predicting the result of carrying out a presently executable control plan, based on past experiences, from the present system condition la and system parameters 101a.
(c) Control execution means 103 determines and executes a control instruction 10a in a conditioned response to the present condition, in dependence upon the determined control plan 102a.
FIG. 3 shows details of the information service controller 20.
Similar to the object system controller 10, the information service controller 20 transforms empirical rules derived from persons' individual information-service knowledges into fuzzy information-service rules, to allow supply of an information service to a participant 90 to the object system 1, by using the fuzzy information service rules. The information service controller 20 selects an information service item to be provided for the present system condition 1a, determines the particular content and expression of the selected information service item, and supplies the information by means of the display or the voice synthesizer while considering timings when the determined information and fixed external information are outputted. The information service controller 20 hierarchically organizes the service rules as in the following:
(a) Item selection means 201 is started and actuated at the occurrence of an event or a control condition change, or at predetermined time intervals to check the present object system condition 1a and control condition 10b, and selects an information service item 201a to be presently supplied.
(b) Content determination means 202 determines and provides a specific information content 202a, expression and the like of the selected item in dependence upon the present condition of the object system 1, predicted future estimation values and the like.
(c) Information service execution means 203 supplies the service information and external information (news, weather prediction or the like) stored in the external information data base 80 to a system participant 90 by means of the display 50, voice synthesizer 60 or the like while considering the output timing thereof.
The knowledge editor 70 introduces and edits empirical rules regarding the control and information service in the form of the fuzzy knowledge base. The fuzzy knowledge base is organized into the following four hierarchies:
(a) Fuzzy meaning base: the meaning of propositions each composed of a subject and a predictive value are defined by fuzzy sets.
(b) Fuzzy control rule: experts' empirical rules of control are formulated using the propositions defined by the fuzzy meaning base.
(c) Fuzzy information service rule: empirical rules for information service are formulated in a similar manner to that of the control rule.
(d) Object model base: a dynamic model of the object system necessary for estimation or evaluation of each rule is defined.
The following description is directed to an embodiment of an elevator group supervisory system according to the present invention.
Buildings in cities have become large scaled and complicated and are nowadays provided with highly sophisticated information and intelligence. The complicated and enormous flow of persons within a building can be regulated safely, comfortably and efficiently with an elevator system, the main system of which is an elevator group supervisory system which uses four to eight elevators and assigns a proper elevator to a call request at each hall.
The outline of such an elevator group supervisory system is shown in FIG. 4. A group supervision controller 10' receives a hall call signal 1a' from a hall passenger 13, an elevator call signal and an elevator condition signal 1a" from an elevator-cage passenger 14 to thereby perform elevator assignment control by using as estimation indices a predicted wait time by a hall passenger 13, the congestion degree of cage passengers 14 and the like.
For hall passengers 13 and cage passengers 14 the status information and the like which are given by an elevator operator are effective in improving mental ease and comfort of the passengers. In view of this, such information service rules are prepared to serve in cooperative association with fuzzy control rules of elevator group supervision, to thereby provide a voice information service and/or a character display.
FIG. 5 is a flow chart showing the procedure performed by the information service controller 20 constructed of a microcomputer and the like. FIG. 6 shows the contents of an information service rule number table 31 and information service rule table 32 provided in the information 25 service rule storage 30. The information service rules shown in FIG. 6 are the following four check rules:
Rule No. 1: if the wait time is immediately after a call request and the predicted wait time is proper, then identify an assigned elevator.
Rule No. 2: If the wait time is short and the predicted wait time is short, then identify a coming elevator.
Rule No. 3: If the wait time is long and the predicted wait time is short, then announce "sorry for waiting" and identify a coming elevator
Rule No. 4: If the wait time is immediately after a call request and the predicted wait time is long, then announce "now congested" and identify an assigned elevator
These rules are used for hall passengers who have pushed a call button. In FIG. 6, the "wait time" in the column of the first estimation or value proposition refers to a lapse time from a call request time to the present time. The "immediately after call request" indicates the system condition for a lapse time from a call request time to the present time an above if check has been just made, namely, the wait time or lapse time is very short. The "predicted wait time" in the column of the second estimation (value) proposition means a predicted time from the present time to the time when an elevator comes to the floor now concerned, and is predicted by the controller 10'. Each of the estimation indices in the If portion of the rule table 32 is called an estimation (value) proposition which is defined by fuzzy sets. FIG. 7 shows as an example of a membership function the content of one of the estimation (value) propositions, "long wait time", stored in the service rule storage 30. This value proposition is defined by a fuzzy set of a membership function ν A(t) which expresses the membership degree to which a person feels that a wait time t is long by a value from 0.0 to 1.0. Other estimation (value) propositions are defined similarly and stored in the table.
The operation of the embodiment will be described in conjunction with the process flow chart shown in FIG. 5. The process program in the information service controller 20 is initiated at the occurrence of a hall passenger call or an elevator cage passenger call, and hereafter at predetermined time intervals (e.g., every one second). First, the system condition, such as a wait time at a concerned hall, is inputted (step 100). Next, a control condition, such as a predicted wait time until an elevator comes to the hall, is inputted (step 110). Then the information service rule number i to be estimated is set at 1 (step 120), and the number j of the estimation proposition is set at 1 (step 130). Next, the satisfaction degree Ri of the presently estimated rule number i is set at 1.0 (step 140). It is then checked to determine if the j-th estimation proposition of the rule number i is present or not. If not present, the estimation of the rule number i is terminated to jump to step 200. Alternatively, if present, an estimation proposition satisfaction degree Eij is obtained using the membership function as shown in FIG. 7. For example, in case of a long wait time, a value of from 0.0 to 1.0 is obtained (step 160) in accordance with:
Eij=νA(t) (1)
where t is the wait time Next, a minimum value among the values of satisfaction degrees Ri and Eij of the preceding rule numbers i and rule propositions j is selected to use it as a new satisfaction degree Ri of the rule number i, thus Ri=min (Ri, Eij) (step 170). Next, the estimation proposition number j is checked to determine if it is a maximum value (in this embodiment, the maximum value being equal to 2). If not, 1 is added to j to jump to step 150 (step 190). If the proposition number j reaches the maximum value (i.e., j=2) at step 180, the rule number i is checked (step 200). If the number i is smaller than a maximum information service rule number (in this embodiment, it being equal to 4), 1 is added to i to jump to step 130 (step 210). If the rule number i reaches the maximum information service rule number (i.e., i=4) at step 200, a rule k is selected which gives a maximum satisfaction degree among the rule satisfaction degrees Ri, where i=1 to 4 (step 220). Next, the information service content indicated by the k-th information service rule is outputted to the display 50 and/or the voice synthesizer 60. The voice from the voice synthesizer 60 is arranged to be outputted only when the information service content changes, to thereby avoid repetitive voice outputting of the same information.
According to the present invention, it is possible to provide proper information based on rules of information services performed by human operators while estimating the object system condition and control condition, thus enabling provision of comfortable automatic information services.
In the above embodiment, the operation of the information service system has been described with respect to information services provided to hall passengers in elevator systems, However, such information services are also possible for elevator cage passengers, elevator supervisory members and the like. The invention is further applicable to the following uses.
(1) Train operation system: Information is supplied to passengers in trains and other passengers on platforms while estimating the train operation condition in accordance with information service rules In case of automatic operation, information on the control condition is also considered in supplying information service. It is also possible to supply information on operation or failure conditions of apparatuses to the train driver and the like.
(2) Process control system: For control of a dose of chemicals in a water cleaning bed, of operation of a cement kiln, of a blast furnace, and the like, information service to the operator and supervisory members can be realized based on information service rules while estimating the automatic or manual operation condition.
(3) Cash dispenser and the like: The invention is effectively applied to the cash dispenser and the like to be operated by an unskilled person. The person given information service in accordance with information service rules can operate the machine with mental comfort.
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An information service system which supplies a predetermined information to a participant to an object system in accordance with predetermined control rules. The information service system includes an information service rule storage unit for transforming intellectual activities regarding information services to the participant into an algorithmic form, and storing the algorithmic form data as an information knowledge base; an information storage unit for storing as an information data base the integral information regarding the object system and the external information such as news, weather predictions and the like; an information service control unit for receiving a condition signal from the object system, calculating on the condition signal in accordance with the information knowledge base, selecting a most suitable information for the participant from the information storage unit in accordance with the calculated result, and outputting the most suitable information; and an information display unit for notifying the system participant of information corresponding to the most suitable information from the information service control unit.
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BACKGROUND OF THE INVENTION
Wheelbarrows are used for the manual transport of small loads. Conventional wheelbarrows have rigid buckets which are fixed in place in a frame which rests on an anterior wheel and two posterior legs. The frame consists of two long handles which are attached directly or indirectly to an axle upon which the wheel rotates. A worker lifts the back end of the handles, thus raising the legs and, balancing the wheelbarrow on the single wheel, wheels the load to its destination.
The rigid bucket causes the wheelbarrow to take up space when the wheelbarrow is stored. In a cramped garage or tool shed this is a problem which has been addressed with the introduction of folding wheelbarrows. Most of the folding wheelbarrows introduced to date construct the bucket out of rigid folding panels.
U.S. Pat. No. 5,222,757 issued to Magyar, for a FOLD-UP WHEELBARROW introduced a bucket made of a plurality of sheet-like panels. The panels are made of materials such as nylon, reinforced plastic, and canvas. One end of each of the elongated members, or handles, is connected directly to the axle of the wheel and each handle pivots at that end to approximate the other handle for storage. A number of manoeuvres are required to fold the frame.
SUMMARY OF THE INVENTION
It is an object of this invention to introduce a folding wheelbarrow which is durable and also easy to store. The legs fold up against the frame and the wheel is suspended below the frame. This construction allows the topside of the frame to rest flush against a wall for storage. Another feature of the invention is the use of an anterior resting brace which serves as a platform upon which to rest the wheelbarrow as it stands on end for storage and serves also as a support upon which to pivot the wheelbarrow when dumping a load. The folding of the legs is the only requirement for storage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of a wheelbarrow according to the invention.
FIG. 2 is a top plan view of the frame of FIG. 1.
FIG. 3 is a top plan view of the frame of another embodiment of the invention.
FIG. 4 is a top plan view of another embodiment of a wheelbarrow according to the invention.
FIG. 5 is a side elevation view of the frame of the invention.
DESCRIPTION OF THE INVENTION
Referring to FIG. 3, the frame of the wheelbarrow is comprised of a first elongate member 10, said elongate member having a first end and a second end; a second elongate member 20, said elongate member having a first end and a second end, wherein said first and second elongate members lie in the same plane and the distance between said first ends of said elongate members is less than the distance between said second ends of said elongate members; an anterior resting brace 40 having a first end and a second end, one end of said anterior resting brace being connected to the first end of said first elongate member, and the other end of said anterior resting brace being connected to the first end of said second elongate member; at most one anterior bucket support brace 80 having a first end and a second end, one said end of said anterior bucket support brace being connected to said first elongate member, and the other end of said anterior bucket support brace being connected to said second elongate member; a posterior bucket support brace 30 having a first end and a second end, one end of said posterior bucket support brace being connected to said first elongate member, and the other end of said posterior bucket support brace being connected to said second elongate member.
Referring to FIG. 4, a removable bucket 70 is removably attached by bucket support means 71 to at least two parts of said frame of FIG. 3, said parts of said frame being chosen from the group consisting of a first elongate member 10, a second elongate member 20, an anterior bucket support brace 80, and a posterior bucket support brace 30, and said removable bucket is disposed between said first and second elongate members, posterior to said anterior bucket support brace, and anterior to said posterior bucket support brace; and a steering wheel 60. Said steering wheel is disposed between said first and second elongate members, posterior to said anterior resting brace 40, and anterior to said anterior bucket support brace 80. Said wheel support means comprises an axle, said axle having a first end extending from one side of said wheel and a second end extending from the other side of said wheel, a first wheel support member 51 extending between and being attached to the first end of said axle and said first elongate member, and a second wheel support member 52 extending between and being attached to the second end of said axle and said second elongate member.
Referring to FIG. 5, said steering wheel 60 is rotatably attached to the axle 61 of a wheel support means. The posterior resting brace 90 comprises a leg 91 and a folding support arm 92. The folding support arm is hinged at hinge 93 and hingedly connected to said leg at hinge 96. The posterior resting brace is hingedly connected to elongate member 20 by hinges 94 and 95. Although not shown, a second posterior resting brace is attached in like manner to elongate member 10. One or more cross braces can be attached between the legs of the posterior resting braces for additional support. All of the hinges can lock in place for safety during operation.
FIG. 1 illustrates another embodiment of the wheelbarrow of this invention wherein the frame is constructed without the anterior bucket support brace. FIG. 2 illustrates the frame of FIG. 1.
The parts of the frame can be made of wood, metal, plastic or rubber. The parts of the frame can be connected to other parts of the frame by means of conventional fasteners, such as screws, bolts, and braces or by conventional joints, such as tongue in grove, dovetail, or mortise joints. However, it is noted that an additional benefit of the design of the frame is that the frame can be molded in one piece from plastic, rubber, metal or wood particles.
In accordance with the preferred embodiment of this invention, the bucket is made of a flexible nylon weave which is covered on both sides by a flexible polyurethane material. However, any flexible material, including fabrics made from polyester fibers, plastics, polyethylene, natural fibers, flexible rubber and canvas, can be used in making the bucket. Typically, the flexible bucket is constructed with a bottom panel, two side panels and a rear panel, wherein the anterior of the bottom panel extends to the top of the side panels. In another embodiment, the flexible bucket is constructed with a front panel, a bottom panel, two side panels and a rear panel. However, it should be noted that the bucket can be of a variety of shapes.
In the preferred embodiment, the bucket support means consists of flexible straps. These flexible straps are sewn to the fabric, extend over the frame and are reflected back onto the bucket where they are attached to the body of the bucket by snaps, hook and eye, or any other suitable fastening means. However, for the flexible bucket, the bucket support means can consist of straps, hooks, or any other suitable fastener, to enable the bucket to be removably attached to the frame.
In a further embodiment of this invention, the removable bucket can be made of a rigid material, wherein said rigid material is selected from the group consisting of wood, plastic, inflexible rubber and metal. When a rigid, removable bucket is employed, the bucket support means may consist of straps or hooks. Straps can be extended from one part of the frame to another, allowing the bucket to rest upon the straps or straps can pass through eyes in the bucket and around parts of the frame and then fastened onto themselves with snaps, hook and eye, or any other suitable fastening means. Hooks may pass through eyes in the rigid bucket, allowing the bucket to be suspended from the frame. The bucket may be molded with hook-like extensions which can be draped over the frame allowing the bucket to be suspended.
Another aspect of the preferred embodiment is the provision of a rigid bucket insert, 72 in FIG. 1, for use in the bucket made of flexible material, wherein said insert is made of a rigid material selected from the group consisting of wood, plastic, rubber and metal. In the preferred embodiment, the bucket insert is contoured to the shape of part, usually the bottom, of the bucket. One use of the rigid insert is to allow shoveling without damage to the flexible bucket. Another use of the rigid insert is to provide a flat surface for transport when such a flat surface is desirable.
In the preferred embodiment, the axle is below the plane defined by the elongate members. This feature allows the frame to rest flat against a wall for storage.
In the preferred embodiment, at least one cross brace extends between the legs of two posterior resting braces. Furthermore, in the preferred embodiment, all of the hinges, 93, 94, and 95, of the posterior resting braces lock in position for added safety.
In the preferred embodiment, the legs of the posterior resting braces fold up against the bottom of the frame. However, as an alternative design choice, the hinges can be mounted so that the legs fold up to lie in the same plane as the first and second elongate members.
A further optional feature is the ring, 73 in FIG. 1, which can be used to hang the bucket or the wheelbarrow for storage. Other rings or devices can be attached to the frame to allow hanging the frame with or without the bucket.
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A folding wheelbarrow which is durable and also easy to store. The legs fold up against the frame and the wheel is suspended below the frame. This construction allows the topside of the frame to rest flush against a wall for storage.
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FIELD
[0001] A system for sampling emission products from an emissions source, for example combustion engines including gasoline engines, diesel engines, and natural gas engines for subsequent measurement and analysis of the emission products.
BACKGROUND
[0002] Emissions of pollutant chemicals have increased orders of magnitudes in the past 100 years due primarily to anthropogenic releases associated with industrial, agricultural, domestic, and recreational activity. Current research indicates that there are very strong correlations between the increase in these emissions and an overall increase in atmospheric temperatures (i.e. global warming) and an increased number of Category 4 and 5 hurricanes per annum. Furthermore, it is believed that ambient particulate matter in aerosol phase may include potentially toxic components. Researchers also believe that particulate matter and gases from industrial activities and vehicles may cause various health problems, such as asthma. These correlations between emissions of pollutant chemicals and the negative impact on environment and human health has led to more stringent worldwide emission standards for automobiles and other vehicles, as well as power plants, mines, and other industries.
[0003] In the United States, emission standards are set by the Environmental Protection Agency (EPA) as well as state governments (e.g. California Air Resource Board (CARB)). As of this writing, all new vehicles sold in the United States must meet the EPA's “Tier 1” emission standard. A more stringent standard, “Tier 2,” is being phased in for automobiles and should be completed by 2009. For diesel engines, on-road trucks and other vehicles will be required to meet more stringent standards by 2010 and off-road vehicles such as construction vehicles will be subject to Tier IV regulations. Accordingly, attaining ultra low emissions has become a top priority for combustion researchers as federal and state regulations continuously reduce the allowable levels of pollutants that can be discharged by engines, power plants, and other industrial processes.
[0004] In order to meet the emission standards of today and the future, researchers have made, and are continually striving to make, improvements to combustion engines, for example heavy duty diesel engines, gas combustion engines, power-generating gas turbines, and the like, and other emission sources. In addition to these developments, researchers are endeavoring for better methods and devices of measuring smaller particulate matter and low level gases and quantifying the chemical compositions of emissions.
[0005] Generally, chemical composition analysis of fine particulate matter, gases, and volatile and semi-volatile organic compounds from emissions sources consists of three major steps: (1) Representative conditioning and sampling; (2) Chemical analysis; and (3) Data analysis and explanation. The effective accuracies of Steps (2) and (3) are both dependent on step (1). For without an accurate and precise sampling procedure, no analysis of that sample could be said to represent valid data. Accordingly, without valid analysis, a full and complete explanation of the sample would not be available.
[0006] A conventional system for assessing particle mass and quantifying chemical composition of emission gases mixes emission gas with filtered air in a mixing chamber. The conventional system is illustrated in FIG. 1 , and includes a sampling port 2 that feeds exhaust gases to a diluter 4 , forming the mixing chamber, where the exhaust gases are diluted with the filtered air. The diluted gas mixture is then sampled by a sampling train 6 . However, this system has many well recognized disadvantages. First, the partial/full/partial dilution sampling system in this conventional system would introduce more errors than a full/partial/full system. Second, the conventional system allows only for assessment of single type of compound. Accordingly, multiple sample runs are required to detect each of the chemical compounds necessary for a full compound assessment (particulate matter, volatile organics, semi-volatile organics, and gases, etc.) Furthermore, these measurements are made with different samples each time, and may add to inherent errors that are unavoidable to this system. These errors may lead to inaccurate measurements and quantification of data.
[0007] Work at the University of Wisconsin-Madison attempted to improve the conventional system. University of Wisconsin scientists used a device called an “augmented sampling system” to study the chemical composition and to assess particle size of diesel engine exhaust. See Chol-Burn Kweon, David E. Foster, James J. Schauer, and Shusuke Okada, “Detailed Chemical Composition and Particle Size Assessment of Diesel Engine Exhaust” SAE 2002-01-2670, Fall SAE Meeting 2002. The “augmented sampling system” disclosed by Kweon et al includes a secondary dilution tunnel for the diesel exhaust and a residence time chamber with radial sampling ports near the base of the residence time chamber. The secondary dilution tunnel of the augmented sampling system mixes filtered air with an emission gas sample without regard to temperature gradient between the surface of the dilution tunnel and the emission gas. This may lead to a high degree of particle loss and accordingly less accurate sampling due to thermophoresis.
[0008] Thermophoresis, or Ludwig-Soret effect, is thought to be related to Brownian movement biased by a temperature gradient. The thermophoretic force is a force that arises from asymmetrical interactions of a particle with the surrounding gas molecules due to a temperature gradient. Generally, a particle is repelled from a hotter surface and attracted to a cooler surface. Thus, as emission particles travel through a sampling system, cooler surface temperature of the system as compared to the emission gas would lead to greater thermophoretic force on the emission particles.
[0009] In the Kweon et al. augmented sampling system, the residence time chamber is heated to reduce thermophoresis. However, the heated residence time chamber is likely to fail in achieving realistic atmospheric conditions, as the addition of heat may underestimate the particulate matter emissions due to the reduced effects of nucleation and condensation and may also affect secondary reactions of volatile organic compounds and semi-volatile organic compounds and formation of secondary organic compounds.
[0010] A system that allows more accurate and precise sampling of emission products is needed, thereby contributing to better measurement and analysis of the emission products.
SUMMARY
[0011] A system is provided for sampling emission products from an emissions source, for example combustion engines including gasoline, diesel and natural gas engines, for subsequent measurement and analysis of the emission products. The system has particular use in quantifying particle size distributions and chemical species from low emissions sources. The results of the analysis can be used to formulate decisions on changes in engine design strategy, and can be used to determine the effectiveness of aftertreatment systems on the emissions source.
[0012] The system uses a full/partial/full approach and includes an isokinetic sampling nozzle, a dilution apparatus, a residence time chamber, a plurality of sampling probes within the residence time chamber, and a plurality of sampling trains connected to the sampling probes to take simultaneous representative emission samples for subsequent analysis.
[0013] The dilution apparatus is designed to be thermophoretic-resistant to reduce the thermophoretic force on emission particles, thereby reducing particulate matter losses. In addition, the dilution apparatus is designed to simulate atmospheric dilution, mixing and cooling processes, enabling the sampled gas and the dilution gas to thoroughly mix and cool to ambient temperature, allowing gas-phase organics in the sampled gas to nucleate and condense to their usual aerosol phase.
[0014] The residence time chamber is designed to provide sufficient time for gas-to-particle conversion, which involves the diffusion limited transport of supersaturated vapor onto existing particles. Preferably, the residence time chamber is designed to provide at least 30 seconds of residence time. During this time, the sample flow and concentrations within the residence time chamber also become uniformly distributed before entering the sampling probes.
[0015] The sampling probes are aligned coaxial to the flow direction within the residence time chamber (i.e. isoaxial) with the inlets of the probes facing into the direction of flow. This improves collection of the emission samples since the samples do not need to turn sharp corners to enter the probes. The plurality of sampling trains connected to the sampling probes permit the simultaneous sampling of different materials, including, but not limited to, volatile and semi-volatile organic, gas-phase, and particulate matter samples.
[0016] A method of sampling emission products from an emissions source is also provided. The method includes directing a sample of a gas stream from the emissions source into a dilution apparatus. In the dilution apparatus, heat is exchanged between the gas stream sample and a dilution gas to cool the gas stream sample, and thereafter the dilution gas is introduced into the gas stream sample to mix with the gas stream sample. The gas mixture is then directed to a residence time chamber, and a sample of the gas mixture is taken from the residence time chamber through a sampling probe having an inlet that is substantially parallel to a direction of flow of the gas mixture within the residence time chamber.
[0017] In one embodiment, a system for sampling emission products from an emissions source comprises a dilution apparatus connected to a sampling probe to receive a gas stream sample. The dilution apparatus includes an inlet through which the gas stream sample enters, a dilution gas inlet through which dilution gas enters the dilution apparatus, and an exit through which a mixture of dilution gas and the gas stream sample exits the dilution apparatus. A dilution gas source is connected to the dilution gas inlet of the dilution apparatus for supplying dilution gas. A residence time chamber is connected to the dilution apparatus and receives therefrom the gas mixture. The residence time chamber includes a plurality of isoaxial sampling probes disposed inside the chamber. Further, a sampling train is connected to each of the isoaxial sampling probes.
[0018] In another embodiment, a system for sampling emission products from an emissions source comprises a dilution apparatus connected to a sampling probe to receive a gas stream sample. The dilution apparatus includes an inlet through which the gas stream sample enters, a dilution gas inlet through which dilution gas enters the dilution apparatus, an exit through which a mixture of dilution gas and the gas stream sample exits the dilution apparatus, and a plurality of holes axially spaced from the dilution gas inlet which allow introduction of the dilution gas into the gas stream sample. In addition, the dilution apparatus is configured so that the dilution gas exchanges heat with the gas stream sample prior to being mixed with the gas stream sample. A dilution gas source connected to the dilution gas inlet of the dilution apparatus, and a residence time chamber that is connected to the dilution apparatus receives therefrom the gas mixture. Further, a plurality of sampling trains are connected to the residence time chamber.
[0019] In yet another embodiment, a system for sampling emission products from an emissions source comprises a dilution apparatus connected to a sampling probe to receive a gas stream sample. The dilution apparatus includes a longitudinal axis, an inlet through which the gas stream sample enters, a dilution gas inlet through which dilution gas enters the dilution apparatus, and an exit through which a mixture of dilution gas and the gas stream sample exits the dilution apparatus. A dilution gas source is connected to the dilution gas inlet of the dilution apparatus, and a residence time chamber is connected to the dilution apparatus and receives therefrom the gas mixture. The residence time chamber includes a longitudinal axis that is substantially perpendicular to the longitudinal axis of the dilution apparatus. Further, a plurality of sampling trains are connected to the residence time chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 illustrates a sampling system according to the invention connected to a dilution tunnel for sampling emissions from an engine.
[0021] FIG. 2 illustrates the sampling system separate from the dilution tunnel.
[0022] FIG. 3 is a cross-sectional view of the dilution apparatus taken along the longitudinal axis thereof.
[0023] FIG. 4 is a detailed view of the perforations in the inner tube.
[0024] FIG. 5 is a cross-sectional view of the residence time chamber taken along line 5 - 5 in FIG. 2 .
[0025] FIG. 6 is a cross-sectional view taken along line 6 - 6 in FIG. 5 .
[0026] FIG. 7 illustrates exemplary flow trains connected to the residence time chamber.
[0027] FIG. 8 illustrates additional exemplary flow trains connected to the residence time chamber.
[0028] FIG. 9 is a flow chart of an exemplary sampling method of the invention.
DETAILED DESCRIPTION
[0029] With reference to FIG. 1 , a system 10 for sampling emission products from an emissions source 12 is illustrated. The system 10 is constructed to simultaneously sample a number of different emissions products emitted from the emissions source 12 . The samples can then be analyzed to permit chemical characterization of the emissions products with respect to air toxics.
[0030] The system 10 will be described herein as being applied to the sampling and chemical characterization of diesel emission exhaust from an emissions source 12 in the form of a diesel engine. However, the concepts described herein can be used to great advantage in sampling a number of other types of gases from a number of other types of emissions sources, both stationary and mobile. Examples of other types of gases includes, but is not limited to, gas combustion engine exhaust, turbine engine exhaust, and atmospheric gas. Examples of other types of emissions sources includes, but is not limited to, gas combustion engines, turbine engines, power plants, manufacturing plants, exhaust stacks, etc.
[0031] As shown in FIG. 1 , the entire exhaust from the engine 12 is ducted to a dilution tunnel 16 through suitable piping 18 . Filtered dilution air 20 is introduced into the tunnel upstream of the discharge for the engine exhaust, with the dilution air 20 then mixing with the engine exhaust in the tunnel 16 to dilute and cool the exhaust gas.
System
[0032] With reference to FIGS. 1-2 , the system 10 includes a dilution apparatus 22 , a residence time chamber 24 , a plurality of sampling probes 26 a, b, . . . n ( FIGS. 7 and 8 ) within the residence time chamber, and a plurality of sampling trains 28 a, b, . . . n ( FIGS. 9 and 10 ) connected to the sampling probes to take simultaneous representative emission samples for subsequent analysis.
[0033] The dilution apparatus 22 is connected to a sampling probe 30 that extends into the dilution tunnel 16 . The probe 30 collects a gas stream sample from the engine 12 and directs the gas stream sample to the dilution apparatus 22 . The inlet of the probe 30 is preferably iso-kinetic and positioned proximate the center of the dilution tunnel 16 to minimize boundary effects caused by the walls of the tunnel 16 . In the dilution apparatus 22 , the sampled gas is diluted with dilution gas, cooled to ambient temperature, and thoroughly mixed with the dilution gas.
[0034] The result is a full/partial/full dilution scheme, where the entire exhaust stream is initially diluted within the dilution tunnel 16 , a portion of the exhaust stream is sampled by the sampling probe 30 , and the entire portion of the gas sample is then diluted in the dilution apparatus. This full/partial/full dilution scheme is an improvement over conventional partial/full/partial dilution schemes, which direct only a portion of the exhaust stream into the dilution tunnel 16 . As a result, the number of particles seen in resulting samples is low compared to a full/partial/full dilution scheme.
[0035] The gas mixture is then fed to the residence time chamber 24 which is designed to provide sufficient time for gas-to-particle conversion, which involves the diffusion limited transport of supersaturated vapor onto existing particles. The gas flow also becomes uniformly distributed before entering the sampling probes 26 a, b, . . . n. The samples probes 26 a, b, . . . n simultaneously collect multiple samples of the gas mixture and feed the samples to the sampling trains 28 a, b, . . . n which are constructed to take various samples of the gas. Preferably, the sampling trains are configured to sample unregulated chemical species within the gas samples, for example volatile and semi-volatile organics, gas-phase compounds, and particulate matter.
[0036] The components of the system 10 are preferably made of inert materials, including, but not limited to, stainless steel, plastic or polymer materials, such as TEFLON, and plastic or polymer coated aluminum such as TEFLON-coated aluminum. In addition, the use of electrically non-chargeable materials, such as 304, 316 and 316L stainless steels, can also be used to reduce electrostatic deposition of charged particles that are typically polarized during combustion processes. In addition, the system 10 is preferably devoid of materials, for example oils, greases, rubbers and the like, that could outgas organics to avoid contamination of the gas stream and gas samples.
[0037] Further, the system 10 is preferably configured to minimize vapor and particulate losses. For example, the system is designed to promote smooth flow transitions within the system 10 .
Dilution Apparatus
[0038] With reference to FIGS. 1-4 , the dilution apparatus 22 is designed to be thermophoretic-resistant to reduce the thermophoretic force on emission particles, thereby reducing particulate matter losses. In addition, the dilution apparatus 22 preferably simulates atmospheric dilution, mixing and cooling processes, enabling the sampled gas and the dilution gas to thoroughly mix and cool to ambient temperature, allowing gas-phase organics in the sampled gas to nucleate and condense to their usual aerosol phase.
[0039] The sampled gas collected by the sampling probe 30 enters the dilution apparatus 22 through an inlet 32 . As shown in FIGS. 3-4 , the dilution apparatus 22 has a cylindrical housing 34 with a first end 36 that includes the inlet 32 , a second end 38 and an interior space. An inner cylindrical wall 40 is located concentrically with the housing 34 , with the cylindrical wall 40 having a first end 42 adjacent the first end 36 of the housing and a second end 44 adjacent the second end 38 of the housing. The cylindrical wall 40 divides the interior space into a static pressure chamber 46 defined between the housing 34 and the wall 40 and that extends generally from the first end 42 of the wall to the second end 44 of the wall 40 , and a mixing chamber 48 that extends generally from the first end of the wall to the second end of the wall.
[0040] The wall 40 has circumferentially and axially distributed perforations 50 near the first end 42 thereof that place the static pressure chamber 46 in communication with the mixing chamber 48 . In addition, the housing 34 has a plurality of evenly, circumferentially spaced inlet ports 52 near the second end 44 thereof that open into the static pressure chamber 46 for introducing a dilution gas into the static pressure chamber 46 . The inlets ports 52 communicate with a plenum 54 defined around the circumference of the housing 34 , and dilution gas is fed to the plenum 54 from a dilution gas source 56 . If desired, the dilution gas source 56 can be a source of over-pressure, such as a compressor, and a regulator 57 , such as a valve, can be used to regulate the flow of dilution gas into the dilution apparatus. The gas source 57 and/or regulator 57 can be used to control the amount of dilution gas that is fed to the dilution apparatus, thereby changing the dilution ratio of the gas stream sample and the dilution gas.
[0041] In use, the sampled gas enters the mixing chamber 48 of the dilution apparatus through the inlet 32 as shown by the arrows in FIG. 3 . In addition, dilution gas is introduced into the static pressure chamber 46 through the inlets ports 52 . As the dilution gas flows toward the first end 42 as shown by the arrows in FIG. 3 , it exchanges heat with the sampled gas in the mixing chamber 48 . In an alternative embodiment, insulation material can be provided on the wall 40 to keep the inner part of the wall 40 the same temperature as the sample gas, thereby lowering the effect of thermophoresis.
[0042] Once the dilution gas reaches the perforations 50 , it flows radially inward into the mixing chamber 48 to mix with the sampled gas. FIG. 3 illustrates the flow of dilution air into the mixing chamber 48 . The perforation holes 50 create jets of dilution air that impinge upon the sampled gas to create turbulent mixing with the sampled gas. Preferably, the perforation holes 50 are configured to generally evenly distribute the dilution gas into the mixing chamber. In the illustrated embodiment, the holes 50 are circumferentially and axially evenly spaced about the wall 40 . Mixing of the dilution gas and the sampled gas also cools the sampled gas.
[0043] The dilution gas is at a temperature lower than the sampled gas, so that the sampled gas is cooled through heat exchange with the static pressure chamber and as a result of mixing with the dilution gas, allowing gas-phase organics in the sampled gas to nucleate and condense to their usual aerosol phase in the atmosphere. Preferably, the sampled gas is cooled to a temperature that is at least within 5° C. of ambient temperature by the time the mixture of sampled gas and dilution gas reaches the exit of the dilution apparatus. More preferably, the sampled gas is cooled to ambient temperature by the time the mixture of sampled gas and dilution gas reaches the exit of the dilution apparatus. In certain embodiments, the sampled gas can be cooled to a temperature below ambient temperature.
[0044] In addition, because the sampled gas is cooled to at or near ambient temperature, temperature differences between the exterior of the apparatus 22 and the gas mixture within the mixing chamber 48 is reduced, thereby reducing the thermophoretic force acting on particles in the flow. This reduces particle loss as the gas sample flows through the dilution apparatus 22 .
[0045] The number and size of the perforation holes 50 is chosen based on the gas being sampled, the gas temperature, and the desired dilution rate. For diesel engine exhaust, the holes can provide between 20% to 80% porosity, have diameters ranging from about 0.125 inch to about 0.5 inch, and extend over a length L w of the wall 40 ranging from about 0.06 inches to about 15 inches ( FIG. 3 ). In addition, the dimensions of the dilution apparatus 22 are chosen based on the temperature of the sampled gas and the flow rate. With reference to FIG. 3 , for diesel engine exhaust, the length L c of the mixing chamber 48 can vary between 18.0 inches to 63.0 inches, the housing can have a diameter D between 3.0 inches and 10.5 inches, and the gap G defining the static pressure chamber between the wall 40 and the housing 34 can vary between 0.2 inches and 2.0 inches.
[0046] As shown in FIG. 3 , a reducing cone 58 is connected to the end of the housing 34 and defines an exit 60 for the mixture of sampled gas and dilution gas from the dilution apparatus 22 . The reducing cone 58 includes a first constant diameter section 62 that connects to the housing 34 , a tapered section 64 that reduces in diameter to reduce the diameter of the flow path, and a second constant diameter section 66 that defines the exit 60 and which is directly connected to the residence time chamber 24 . The reducing cone 58 helps to provide a smooth flow transition of the gas mixture from the dilution apparatus 22 to the residence time chamber 24 .
[0047] Further details on the dilution apparatus 22 can be found in copending U.S. patent application Ser. No. ______ (Attorney Docket No. 20069.21US01), filed on ______, and titled Thermophoretic-Resistant Gas Dilution Apparatus For Use in Emissions Analysis, which application is incorporated herein by reference.
Residence Time Chamber
[0048] The residence time chamber 24 is best illustrated in FIGS. 1 , 2 , 5 and 6 . The chamber 24 includes a housing 70 having a first end 72 and a second end 74 . In the illustrated embodiment, the housing 70 is oriented generally vertically so that the longitudinal axis of the housing 70 is oriented vertically and generally perpendicular to the longitudinal axis of the dilution apparatus 22 which is disposed generally horizontally.
[0049] The housing 70 is connected to the reducing cone 58 of the dilution apparatus 22 at the first end 72 . Preferably, the first end 72 is in the form of a conical section, with the cone opening or facing downward. The gas mixture is received into the conical section 72 , with the conical section helping to promote a smooth flow transition of the gas mixture from the dilution apparatus to the residence time chamber. Likewise, the second end 74 is in the form of a conical section, with the cone opening or facing upward. The conical section 74 helps to promote a smooth flow transition from the residence time chamber to an exit port 76 located at the bottom of the conical section 74 .
[0050] The housing 70 , except for the conical sections 72 , 74 , is generally cylindrical and has a constant diameter from the conical section 72 to the conical section 74 . The housing 70 provides sufficient time for gas-to-particle conversion within the gas mixture, and allows the gas flow to become uniformly distributed. Preferably, the housing 70 provides at least 30 seconds of residence time for the gas flow from the time the gas flow enters the housing 70 to the time the gas flow reaches and enters one of the sampling probes. A residence time of 30 seconds can be provided by a housing 70 with a height of about 57 inches and a diameter of about 12.0 inches.
[0051] As shown in FIGS. 5 and 6 , the sampling probes 26 a, b, . . . n are disposed inside of the housing 70 to simultaneously collect multiple samples of the gas mixture and feed each sample to the sampling train 28 a, b, . . . n. The sampling probes are aligned coaxial to the flow direction to achieve isoaxial and isokinetic sampling. In the illustrated embodiment, 8 sampling probes are provided, with each of the sampling probes 26 a, b, . . . n extending upward with the inlets to the probes facing upward toward the oncoming flow. To avoid boundary flow effects of the housing wall, the sampling probes are preferably spaced inwardly from the housing wall. Because the sampling probes are isoaxial and face upward toward the oncoming flow, sampling is improved because the sampled flow does not need to turn sharp corners to enter the probes.
[0052] Further details on the residence time chamber and the sampling probes can be found in copending U.S. patent application Ser. No. ______ (Attorney Docket No. 20069.20US01), filed on ______, and titled Residence Time Chamber and Sampling Apparatus, which application is incorporated herein by reference.
Sampling Trains
[0053] The gas samples entering the sampling probes 26 a, b, . . . n are directed to the sampling trains 28 a, b, . . . n. The sampling trains can be configured to take samples of any kind of matter within the gas samples. Preferably, the sampling trains are configured to sample unregulated chemical species within the gas samples, for example volatile and semi-volatile organics, gas-phase compounds, and particulate matter.
[0054] Examples of suitable sampling trains are illustrated in FIGS. 7 and 8 . As shown in FIG. 7 , sampling trains 28 a, 28 b, 28 c each begin with a PM2.5 cyclone separator 80 that can be operated at a flow rate of 16.7 liters/min (lpm) for removing particles that are about 2.5 microns and above. Flow through the trains 28 a, 28 b, 28 c is controlled by downstream critical flow orifices 82 in series with a rotary vacuum pump 84 via a manifold 86 . A rotameter prior to each critical flow orifice can be used to monitor the flow rate. A filter 88 , for example a two stage TEFLON membrane filter, is disposed after the separator 80 to filter out material from the sampled gas. The filters 88 can then be analyzed for collected material. When the filters 88 are TEFLON membrane filters, analysis can be conducted for total mass, particulate matter sulfate ions, and particulate matter trace elemental composition.
[0055] The sampling trains 28 d, 28 e, 28 f illustrated in FIG. 7 are similar to the sampling trains 28 a, 28 b, 28 c. However, the illustrated trains 28 d, 28 e, 28 f utilize a filter 90 , preferably a two stage quartz fiber filter, in series with a polyurethane foam (PUF) cartridge 92 . An adsorption material substrate, such as an XAD™ substrate, could be used in place of the PUF cartridge in the case of higher flow rates. When the filters 90 are quartz filters, particle-phase organic compounds can be collected to analyze for particulate matter organics, nitro-PAH particulate matter, and particulate matter hydrocarbon distribution. In the case of PUF cartridges, semi-volatile organic compounds can be collected to analyze for semi-volatile organic compounds, semi-volatile nitro-PAH, and semivolatile hydrocarbon distribution.
[0056] With reference to FIG. 8 , a sampling train 28 g that is designed for high flow samples is illustrated. The sampling train 28 g is connected to the exit port 76 at the bottom of the conical section 74 . The sampling train 28 g is not connected to a sampling probe. Instead, the sampling train samples the remainder of the gas flow that is not sampled by the sampling probes as the gas flow remainder exits through the bottom of the residence time chamber 24 . The train 28 g includes a PM2.5 cyclone separator 100 that can be operated at a flow rate of 92 liters/min (lpm) for removing particles that are about 2.5 microns and above, followed in series by a filter 102 , for example a quartz filter, a PUF cartridge 104 (or XAD substrate), critical flow orifices 156 , and a rotary vacuum pump 106 . This kind of sampling train 28 g is suitable for use in collecting samples for polycyclic aromatic hydrocarbon analysis from low emission sources. The sampling train 28 g can also include a flow meter 154 , shown in FIGS. 1 and 2 .
[0057] FIG. 8 also illustrates a gaseous sampling train 28 h which can be run in parallel to the sampling trains 28 a - f. The sampling train 28 h includes two Dinitrophenyl-Hydrazine (DNPH) cartridges 110 arranged in parallel to collect samples which are subsequently analyzed for carbonyl species. The cartridges 110 can have different flow rates, for example about 1.5 lpm and about 0.3 lpm. The flow rate can be controlled by critical flow orifices 112 in series with the rotary vacuum pump 106 . In addition, the train 28 h can include two volatile organic compound (VOC) tubes 114 arranged parallel to the DNPH cartridges to collect samples for hydrocarbon speciation. The flow rates through the VOC tubes 114 can range from about 10 standard cubic centimeter (SCCM) to 50 SCCM, controlled by two separate mass flow controllers 116 in series with the vacuum pump 106 . The mass flow controllers 116 can also be used to collect mass flow, volumetric flow, pressure, and temperature data. If desired, one or two filters prior to the DNPH cartridges 110 and VOC tubes 114 can be used to collect large particles.
[0058] An additional sampling train 28 i can be used to measure particle size distributions for steady-state and transient operations. In addition, a sampling train 28 j can include temperature, humidity, and pressure sensors to monitor the residence time chamber conditions.
[0059] Other types of sampling trains for collecting other types of materials within the sampled gas can be used. The sampling trains described herein are intended to be exemplary and not intended to be limiting.
[0060] Further details on the sampling trains can be found in U.S. patent application Ser. No. ______ (Attorney Docket No. 20069.20US01), filed on ______, and titled Residence Time Chamber and Sampling Apparatus.
[0061] The method of operation of the system 10 and of sampling exhaust gas from the engine 12 is apparent from the preceding description. With reference to FIG. 9 , a sample of the exhaust gas from the engine is initially directed into the dilution apparatus 22 , through the sampling probe 30 . Next, in the dilution apparatus, the gas sample is cooled by the dilution gas and the dilution gas and the gas sample are mixed. The gas mixture is then directed to the residence time chamber, and a sample, preferably a plurality of simultaneous samples, of the gas mixture is taken from the residence time chamber through a sampling probe having an inlet substantially parallel to a direction of flow of the gas mixture within the residence time chamber. The sample is then directed to a sampling train which is configured to remove a desired material from the sample for subsequent analysis.
[0062] The invention may be embodied in other forms without departing from the spirit or novel characteristics thereof. The embodiments disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the invention is indicated by the appended claims rather than by the foregoing description; and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
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A system for sampling emission products from an emissions source, for example combustion engines including gasoline, diesel and natural gas engines, for subsequent measurement and analysis of the emission products. The system includes a dilution apparatus, a residence time chamber, a plurality of sampling probes within the residence time chamber, and a plurality of sampling trains connected to the sampling probes to take simultaneous representative emission samples for subsequent analysis. The system has particular use in quantifying chemical and toxic trace species from emissions sources. The results of the analysis can be used to formulate decisions on changes in engine design strategy, and can be used to determine the effectiveness of aftertreatment systems on the emissions source.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to an electro-hydrostatic actuator that is ideally suited to control the positioning of a valve or any other similar device.
[0002] More specifically, this invention relates to a compact electrically operated linear actuator integrates all controls and components so rapidly and efficiently heat dissipation and cooling to component parts is provided.
[0003] Current demands on power generation systems and valve controls require that the actuators be electrically controlled and include fail safe features. In many countries, linear actuator of the type herein disclosed also require certification when employed in an environment where an explosion might take place as for example in controlling valves utilized in gas or oil pipelines or in certain processing plants where volatile chemicals are used in the process. In order to gain certification, many of the actuators are housed in rather bulky complex structures, external power supply and controls that are costly to construct and difficult to service and maintain in the field. Typically, the electronic control of the actuator is designed to be located in separate remote housing having a non-hazardous controlled environment. The cabling between the actuator and the controller can be relatively long which can lead to signal transmission loses and other related difficulties.
[0004] The invention presently here provides a solution to electrical control actuation within a compact package designed to meet uniform cooling and protection for use in hazardous environments.
[0005] In U.S. Pat. No. 2,631,431 to Gerbe, there is disclosed an electrohydraulic actuator in which an electric motor is located in a tank filled with oil. The motor is equipped with a hollow shaft and the shaft of a pump impeller is slidably contained within the hollow motor shaft. The impeller can turn with the motor shaft while at the same time moving longitudinally along the axis of the motor shaft. The pump impeller is situated inside a hollow piston that is secured to a piston rod. The piston rod extends upwardly and passes out of the tank through the top wall of the tank. In operation, the motor drives the impeller at a speed so as to increase the pressure of the oil on one side of the piston to a level wherein the piston and piston rod are displaced upwardly to reposition any type of device that is secured to the piston rod. A weight or spring is used to return the piston to its home position when the motor is de-energized.
[0006] Although the Gerbe device provides for improved motor cooling, the electronic controls for the motor are situated at a location remote from the tank housing and is therefore subject to all the problems associated with transmission lines of any appreciable length. Furthermore, because the electrical unit associated with the actuator must be housed in its own non-hazardous container, the system is costly to maintain.
SUMMARY OF THE INVENTION
[0007] It is therefore a primary object of the present invention to improve electro-hydrostatic actuators.
[0008] It is a further object of the present invention to package both the electrical and mechanical components of an electro-hydrostatic actuator in a single non-hazardous housing.
[0009] A still further object of the present invention to provide fluid cooling to both the mechanical and electrical components of an electro-hydrostatic actuator.
[0010] Another object of the present invention is to provide a more compact, non-hazardous valve actuator.
[0011] Yet another object of the present invention is to reduce transmission loss typical of an electro-hydrostatic valve actuator.
[0012] These and other objects of the present invention are attained by an electro-hydrostatic actuator having a sealed housing filled with a dielectric fluid. A motor driven pump and electrical circuitry for controlling the pump are all immersed in the fluid contained within the housing. The pump is arranged to deliver fluid from the housing to a hydraulic cylinder to move the piston rod of the cylinder to a desired location along its available path of travel. In one form of the invention the piston rod is connected to the stem of a valve and serves to control the flow of a fluid through the valve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a further understanding of these and objects of the present invention, reference will be made to the following detailed description of the invention which is to be read in association with the accompanying drawings, wherein:
[0014] [0014]FIG. 1 is a perspective view illustrating an electro-hydrostatic actuator embodying the present invention;
[0015] [0015]FIG. 2 is an exploded view in perspective showing the outer housing removed from the internal components of the actuator;
[0016] [0016]FIG. 3 is an enlarged exploded view in perspective of the internal components of the actuator;
[0017] [0017]FIG. 4 is a schematic diagram illustrating the functional relationship between the actuator components;
[0018] [0018]FIG. 5 is a partial view in section showing a pressure compensating unit employed in the practice of the present invention;
[0019] [0019]FIG. 6 is a perspective view illustrating a further embodiment of the invention;
[0020] [0020]FIG. 7 is an enlarged perspective view showing the internal components of the actuator illustrated in FIG. 6; and
[0021] [0021]FIG. 8 is a front elevation in section of the actuator illustrated in FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Turning initially to FIGS. 1 - 3 there is illustrated a linear electro-hydrostatic actuator, generally referenced 10 , that embodies the teachings of the present invention. Although, the actuator is ideally suited to control the positioning of a flow control valve, it should be evident from the disclosure below that the actuator is equally adaptable to control the positioning of a wide variety of devices. The actuator includes a cylindrical housing 12 that is seated upon a base plate 13 . The top of the housing is closed by a top cover 15 . Although not shown, the housing is provided with suitable seals preventing fluid from escaping from the housing.
[0023] As illustrated in FIGS. 2 and 3, a support block 17 is mounted upon the base which houses a brushless d.c. motor 18 within a motor compartment 19 . The motor includes a permanent magnet 20 that is mounted upon the rotor section 21 of the motor and windings 22 located upon the motor stator 23 . The motor is designed to yield high energy density due to low rotating inertia and has improved thermal performance due to the windings having a direct thermal path to the exterior surface of the motor. The brushless motor is commutated by an electronic controller 25 rather than by more conventional brushes and commutator bars. Accordingly, there are no brushes to wear out and little or no maintenance is required over the life of the motor.
[0024] An adaptor plate 29 is mounted upon the top of the support block over the motor compartment 19 . A gear pump 30 is, in turn, mounted upon the adaptor plate and the drive shaft 26 of the pump is connected to the rotor shaft of the motor by any suitable means. The outlet port 31 of the pump is connected to a supply channel 33 in the support block by a supply line 35 . The flow channel outlet is connected to a hydraulic cylinder 37 by means of a second supply line 38 . In this embodiment of the invention, the hydraulic cylinder is secured to the bottom surface 39 of the base plate. As will be described in further detail below, the piston rod 40 of the hydraulic cylinder may be connected to the stem of a plunger type valve to regulate the flow through the valve. Although the invention is herein described with the specific reference to a control valve, it should be evident that the actuator may be used to control any linear action type device without departing from the teachings of the present invention.
[0025] The interior of the housing is completely filled with a dielectric oil to totally immerse the motor, the pump and the controller in oil. The inlet to the pump is exposed to the reservoir of oil and as will be explained in greater detail below, the pump is arranged to deliver the oil to a chamber within the hydraulic cylinder on one side of a piston that is connected to the piston rod 40 .
[0026] The controller is mounted upon the base plate immediately adjacent to the support block 17 . The controller is microprocessor based and in addition to the motor communication circuitry, the controller contains circuitry relating to an actuator position loop as well as other status monitoring functions which will be described in further detail below. The motor control circuitry monitors the rotor position via a resolver 27 that is mounted concentric to the rotor and provides a sinusoidal current to the motor windings to control motor torque.
[0027] A solenoid valve 43 is also immersed in the oil reservoir and is placed in fluid flow communication with a bypass channel 44 formed in the support block 17 . The channel connects into the previously noted supply line channel 33 formed in the block. The solenoid valve is normally closed and is opened upon a signal from the controller in the event a fault is detected in one of the monitored function. Opening the solenoid valve causes the supply line to the hydraulic cylinder to be bypassed allowing oil on the pressure side of the piston to be returned rapidly to the reservoir.
[0028] A compensating unit 48 is mounted in the top cover 15 of the housing. The unit is shown in further detail in FIG. 5. The compensating unit 48 provides variable volume for fluid expansion and fluid surge. It also provides positive pressure to the oil reservoir 51 . The unit is housed within a cylindrical vessel 50 that opens through the top cover into the oil reservoir 51 of the adaptor housing. The cylindrical body of the unit passes through a suitable opening in the cover and a clamping flange 52 is secured to the top cover by any suitable means. A seal 53 is placed between the flange and the top cover to prevent fluid from passing between the two members. A piston 55 is mounted inside the vessel and a close sliding fit is provided between the piston and the inner wall of the vessel. A piston shaft 56 is secured at one end to the piston and passes upwardly through the top wall 57 of the vessel. The shaft is slidably contained within a brushing 58 mounted in the top wall of the vessel. A plate 59 containing an orifice 60 is secured to the bottom of the vessel and, in assembly, the plate is placed in contact with the oil contained in the reservoir so that the oil can pass into the chamber 61 below the piston. A compression spring 62 surrounds the piston shaft which acts to bias the piston downwardly with a given force into contact with the oil in the chamber. The piston shaft also provides a visual indication of the oil level within the reservoir.
[0029] A hermetically sealed connector 62 is also contained in the top wall of the housing through which electrical lines are passed into and out of the housing to provide power to the controller as well as carrying data signal to and from the controller.
[0030] The operation of the actuator will now be further explained with reference to the schematic drawing illustrated in FIG. 4 wherein the actuator is shown controlling a plug type valve 63 . As noted above, the brushless motor 18 is connected to pump 30 via drive shaft 26 . The motor is connected to the controller 25 by a suitable electrical line 65 . The microprocessor based controller is arranged to monitor the rotor position of the motor through the resolver 27 which communicates with the controller via data line 66 .
[0031] The pump 30 is arranged to deliver oil from the reservoir 51 to the hydraulic cylinder 37 through supply line 38 . The reservoir is shown for explanatory purposes as a tank with the understanding that the controller, the motor and the pump are all completely immersed within the reservoir. A piston 68 is contained within the hydraulic cylinder that divides the cylinder into an upper chamber 70 and a lower chamber 71 . The piston is attached to piston rod 40 which in turn passes out of the cylinder through bottom wall 72 . The extended end of the piston rod is equipped with a flange 74 . The stem 75 of the valve is similarly equipped with a flange 77 and a spring 78 is interposed between the two flanges. The spring is arranged to normally hold the valve in a closed position when the pump is inoperative.
[0032] To open the valve, the pump is activated and oil under pressure is delivered into chamber 71 beneath the piston causing the piston to rise within the cylinder and thus lift the valve from its valve seat. A linear variable displacement transducer (LVDT) 80 is operatively associated with the piston rod and provides position data to the controller via line 81 . Using data provided by the resolver and the LVDT, the controller can set the valve to any desired position within its operating range. Any fluid that might accumulate in the upper chamber of the hydraulic cylinder is exhausted back to the reservoir via discharge line 83 .
[0033] The solenoid activated trip valve 43 is mounted in the bypass channel 44 and is arranged to open in response to a trip signal from the controller sent over trip line 85 . Opening the solenoid valve provides a path for high pressure oil in the supply line to be discharged rapidly back to the reservoir thereby permitting the control valve to close.
[0034] A pressure transducer 86 is mounted in the reservoir to provide pressure information to the controller by means of line 87 . The oil temperature in the reservoir is also provided to the controller by a thermal sensor 88 via data line 89 . A fluid level sensor 90 is mounted in the reservoir and provides oil level data to the controller via data line 91 .
[0035] Turning now to FIGS. 6 - 8 , there is illustrated a further embodiment of the invention in which the hydraulic cylinder is brought into a housing 100 along with the motor driven pump and the controller. In this embodiment of the invention the housing 100 is split into two sections that include an upper section 101 and a lower section 102 . The lower section is equipped with a contoured base that has a first vertically disposed compartment 105 that passes upwardly into the base through the bottom wall 106 of the lower housing section. A second vertically disposed compartment 107 is similarly passed upwardly into the base through the bottom wall of the lower section of the housing. The second compartment is in parallel alignment-adjacent to the first compartment.
[0036] As best illustrated in FIG. 7, the brushless motor 110 as described above is mounted upon a cover plate 111 and a gear pump 112 is mounted over the motor and is coupled to the motor shaft 112 . The motor stator is arranged to be supported in a stationary condition within the first compartment 105 as illustrated in FIG. 8 and the cover plate is secured to the base by screws to close the recess. With the top section of the housing removed, the pump is connected to the motor shaft and the mounting flanges 114 of the pump are secured by screws to a horizontally disposed shoulder 116 that surrounds the upper opening to the recess.
[0037] The hydraulic cylinder 120 is arranged to be slidably received in the second compartment through the bottom opening thereof. The cylinder is supported in an upright position upon a second cover plate 121 that is arranged, in assembly, to close the bottom opening of the compartment. Again, with the upper section of the housing removed, the cylinder manifold 122 is mounted upon the top of the cylinder and is secured in place using suitable screws. A supply line 125 is connected at one end to the outlet of the pump and at the other end to the inlet channel 127 of the cylinder manifold. A solenoid activated trip valve 126 is secured to one side of the manifold and is connected into the inlet channel of the manifold by means of a bypass channel (not shown).
[0038] Turning once again to FIG. 8, the actuator controller 130 is mounted in the upper section 101 of the housing. The upper section of the housing as well as the two cover plates 111 and 121 are sealed in assembly against the lower section of the housing using suitable seals 132 to render the housing leak proof. The interior cavity 133 of the housing is filled with a dielectric oil which totally immerses all of the component parts of the system contained within the housing. As should now be evident, any heat that is generated by the actuator is rapidly transferred to the walls of the housing and dissipated into the surrounding ambient.
[0039] A piston 140 is contained within the hydraulic cylinder 120 and a piston rod 141 is secured to the piston and passes out of the housing through cover plate 121 . A blind hole 142 passes downwardly through the piston and the piston rod and a linear variable displacement transducer (LVDT) 145 is contained within the hole. The LVDT is arranged to pass upwardly through the cylinder manifold and is connected to the controller to provide piston rod position data to the controller. A resolver 147 , as described above, is mounted upon the rotor of the motor and sends rotor position information to the controller. Although not shown, pressure, temperature and fluid level sensors are mounted within the housing which also sends data to the controller for processing. Inlet and outlet leads are passed into and out of the housing by means of sealed connectors 150 and 151 . A compensator unit 160 as described above is mounted in the top wall of the upper section of the housing.
[0040] As noted above, the piston rod of the actuator may be connected to the stem of a plunger type valve and a spring employed to return the piston to a home position when the pump is de-energized.
[0041] While the present invention has been particularly shown and described with reference to the preferred mode as illustrated in the drawing, it will be understood by one skilled in the art that various changes in detail may be effected therein without departing from the spirit and scope of the invention as defined by the claims.
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An electro-hydrostatic actuator having a sealed housing filled with a dielectric fluid. A motor driven pump and electronics for controlling the pump are all immersed in the fluid. The pump is arranged to deliver fluid from the housing to a hydraulic cylinder to control the positioning of the piston rod. A solenoid operated valve is integrated as a bypass or tip valve for quick fail safe position. The actuator is ideally suited to control various types of plunger valves. In one embodiment of the invention, the hydraulic cylinder is located outside of the housing and in another embodiment the cylinder is located inside of the housing.
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BACKGROUND
This invention relates to the field of annular-nozzle burners. In particular, this invention concerns a method and apparatus for the introduction of a fuel air mixture into a combustion chamber in a predetermined fuel/air ratio and at a predetermined velocity to obtain high peak temperatures from a compact flame.
In many conventional dryers and burner systems, a solid fuel is mixed with a primary-air carrier and ejected into a combustion chamber. The primary air may be a proportion of the total air required for complete combustion ranging from less than ten percent up to 100 percent. Additional air needed to complete the combustion is then added to the combustion chamber as secondary air. Typically, the secondary air is preheated and enters the combustion chamber at temperatures as high as 1500° F. where it is mixed with the primary air and fuel mixture to complete combustion of the fuel. The primary air-fuel mixture, on the other hand, must be kept below 400° F. to prevent premature combustion or coal dust explosion; and, it is normally kept at or below 180° F.
Existing burner systems such as Deussner et al. (U.S. Pat. No. 4,428,727) and Eckelmann (U.S. Pat. No. 4,373,900) employ the assumption that the maximum temperature obtainable from the combustion flame is limited by the rate of mixing of the fuel with the primary and secondary air. In this respect, existing theory requires that the secondary air be intimately mixed with the fuel/air stream for rapid and complete combustion of the fuel. Thus, current burners have concentrated on methods for inducing rapid convective type mixing of the primary air/fuel with the secondary air.
Existing burner systems also take cognizance of the abrasive wear of pulverized fuel on the burner structure. This results in a controlled fuel stream of relatively low velocity. Additionally, in kiln environments the combustion chambers are often only about 160-200 or so feet long and impingement of the flame on the side walls and far end of the kiln substantially decreases the life of the kiln refractory. Construction of kilns long enough to accommodate the longer flames than have otherwise been desired, on the other hand, has caused a significant increase in the cost of the kiln. Accordingly, lower fuel-air velocities of only about 2500 to 6000 feet per minute have been used to prevent the flame from impinging on the walls of the kilns.
Recent burner developments have also focused on use of deflecting vanes to obtain a spiraling or helical motion to produce a rapid, turbulent mixing of the fuel air stream with the secondary air. Thus, turbulators have been used with and without high velocity air jets to promote such mixing.
The above-described methods have provided excellent mixing of the secondary air with the primary air/fuel stream but, the high temperatures necessary to produce acceptable products in kilns and the like have not always been achieved.
A great deal of effort has also been expended in reducing the amount of the noxious nitrogen oxides (NOx) released from coal burning facilities. The traditional approach to controlling the NOx emissions is to decrease the oxygen concentration and flame temperature by recycling combustion gases. This approach has the disadvantage, however, of increasing the energy consumed in recycling and reheating these recycled gases to the flame temperatures.
In view of the foregoing, it is an object of the instant invention to provide an improved method of burning fuel and an improved burner system to overcome the shortcomings of conventional burners described above.
It is a further object of the instant invention to provide a more efficient annular-nozzle burner that can provide higher peak flame temperatures without damaging the related burner structure or refractory walls.
An alternative object of the invention is to provide an annular-nozzle burner having acceptable NOx levels while reducing the energy-consuming steps of recycling and reheating of exhaust gases.
An advantage of the invention is that it provides a smaller, shorter flame that is essentially anchored to the nozzle so as to permit smaller combustion chambers and reduce the amount of flame impingement on refractory-surface walls. An additional advantage of the invention is an improvement in products that are heated by the burners and method of the invention.
A further advantage of the invention results from an unexpected increase in annulus life even though the invention provides high peak flame temperatures.
A still further advantage of the invention stems from the flame being better stabilized or "anchored" to the burner than those of comparable existing burners. In this respect, where pulverized particulate fuels are employed, it is customary to first use gas or oil-fired flames to heat the refractory walls at a controlled rate until sufficiently hot to maintain combustion of the particulate fuel upon changeover. The instant invention, however provides a core flame which easily stabilizes combustion of the particulate fuel on the burner and permits a more rapid change-over from the more expensive start-up fuels to the desired particulate fuels. In this respect, the following description of the invention will refer to "particles" of fuel. Such use of "particles", however, is not limited to pulverized, particulate fuels, but includes molecules of gas and droplets of liquid fuels as will be clear from the examples herein relating to various fuels. Similarly, although the invention is described in terms of annular-nozzle burners having a cylindrical cross-section, such burners can also have cross-sections that are other than cylindrical.
As a result of much testing and evaluation by the instant inventors, it has been determined that the customary maximizing of convective mixing of secondary air with the primary air-fuel stream has been counterproductive; and, contrary to popular thought, has not provided the most desirable temperatures and flame configurations. Indeed, it is customary for the primary air/fuel mixture to be intensely mixed with secondary air specifically in order to disperse the fuel particles. The instant inventors have found, however, that it is undesirable to increase the average distance between particles.
SUMMARY OF THE INVENTION
The method of the invention employs an annular-nozzle burner wherein a compact flame is generated by inhibiting dispersion of the fuel particles and concentrating the fuel particles in a primary combustion area of the flame so that a high rate of radiant heat transfer is maintained between the fuel particles. This, of course, is the opposite of the theories applied to conventional annular-nozzle burners, but, as will be noted below, has resulted in vastly-improved operation. In this respect it has previously been determined that heat in a high temperature flame is transferred primarily by radiation; and, the rise in temperature as the fuel leaves the burner is primarily a function of radiant heat transfer from hot fuel particles to cold fuel particles. Accordingly, a given particle's temperature is also a function of its distance from adjacent burning particles; and, the instant invention employs these principles to obtain improved results.
In accordance with another aspect of the invention it has been determined that the NOx in the exhaust gases can be substantially reduced by maintaining the primary combustion area in a reducing atmosphere; and, this is accomplished by preventing excess oxygen from reaching the burning particles.
It has previously been determined that the rate of burning of a solid fuel particle is a function of the oxygen that is available at its surface. The oxygen transfer from the fuel/air stream to a given fuel particle, however, is dependent upon the oxygen's gaseous diffusion through a boundary layer surrounding the particle to its burning surface.
Based on the above, it has been determined that a method of improving the rate of oxygen transfer to a particle's burning surface is to increase the relative velocity differential between given particles and the secondary air; and, it is believed that this causes a decrease in the thickness of the boundary layer. In one embodiment of the invention, for example, pulverized solid fuel is carried at a high speed through an annular nozzle by primary air into the combustion chamber where it passes through relatively stationary secondary air and it has been found that this interaction vastly improves combustion.
In accordance with another aspect of the invention the annular nozzle includes an inner core area and an outer fuel-entry annulus; and, it has been found that by using relatively small amounts of primary air to force the particulate fuel through the annulus at relatively high velocities of at least about 7000 fpm and above, the resulting fuel/air flow is essentially linear and, moreover, creates a low-velocity vortex effect in the core area. This low-pressure area provides a core flame along the flame's axis. Further, this low pressure, low velocity region at the core serves to anchor the flame on the burner tip in such a manner that the flame is not blown out even at fuel/air velocities of over 20,000 fpm. Moreover, this effect can be further increased by maintaining a high ratio between the outer dimension of the fuel-entry annulus and its cross-sectional area to thereby increase the volume of the core-flame area.
In the above regard, the use of "linear" is not to be confused with "laminar flow". "Linear" is used here in the sense that a given particle moves essentially only in an axial direction with little dispersion--much like "plug flow" in a pipe.
The characteristics of the annular-nozzle burner constructed and operated in accordance with the above principles result in a very compact, intense flame, which allows use of a much smaller, more efficient furnace. Moreover, in certain embodiments, a better product is produced in greater quantities than with much larger furnaces using conventional annular-burner systems. Still further, the method and apparatus of the invention have the additional advantage of permitting the controlled buildup of a protective coating on the furnace walls which, in some instances, can considerably postpone the need for expensive repairs.
BRIEF DESCRIPTION OF THE DRAWINGS
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, wherein the same reference characters refer to the same parts throughout the various views. The drawings are not necessarily drawn to scale. Instead, they are merely presented so as to illustrate principles of the invention in a clear manner.
FIG. 1 is a schematic representation of an annular-nozzle burner used in the practice of the method of the invention;
FIG. 2 is an enlargement of a portion of FIG. 1;
FIG. 3 is an enlargement of a portion of FIG. 1 and includes additional elements for other embodiments of the invention;
FIG. 4 is an end view of an annular nozzle employed in one of the examples of the invention;
FIG. 5 is a cross-sectional view taken along lines 5--5 of FIG. 4;
FIG. 6 is an end view of another annular nozzle employed in one of the examples of the invention;
FIG. 7 is a sectional view taken along the line 7--7 of FIG. 6;
FIG. 8 is an end view of yet another annular nozzle employed in one of the examples of the invention;
FIG. 9 is a sectional view taken along the line 9--9 of FIG. 8;
FIG. 10 is an end view of still another annular nozzle employed with still another example of the invention; and
FIG. 11 is a sectional view taken along the lines 11--11 of FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a schematic representation of an annular-nozzle burner 11 installed in a furnace having refractory walls 13. A primary air-fuel annulus 15 is formed between an exterior pipe 17 and an inner pipe 19. A center core 21 of the burner 11 may be open or may be closed by a refractory plug 23. Secondary air enters the combustion chamber through conventional means and surrounds flame 27 in areas 25.
The primary air and fuel are blown by a fan means 26 through the annulus 15 into the combustion chamber where they are ignited to form an intense compact flame 27. A burnout point 29 is the distance from the nozzle at which approximately 95 percent of the fuel has burned. A peak flame-temperature-point line 31 is represented by an inner line which, in a preferred embodiment, is approximately 0.4 cm from the outer surface of the flame 27.
The annular-nozzle burner 11 also promotes combustion in a low velocity, low pressure region in an inner core 33 of the flame 27. As shown, this inner core 33 of the flame produces a vortex effect creating a fuel ignition point very close to or at the tip of the burner 11. In this respect, the refractory plug 23 can serve as an igniter when used.
FIG. 2 is an enlarged illustration of the annular burner 11 and shows a machined cylindrical insert 35 which extends back from the tip about 4 to 12 times the width 37 of the annulus 15. The surface of the insert 35 is machined smooth to remove any substantial burrs or the like and assists in the production of a linear flow of the fuel-primary-air mixture from the annulus 15 of the annular-nozzle burner 11.
FIG. 2 also illustrates a pilot light port 39 from which burning gas can be initially ejected to ignite the flame 27 on startup. Alternately, an igniter can be extended from the port 39 to perform the same function.
FIG. 3 shows an additionally-enlarged schematic illustration of an alternate burner 11 with an inner annulus 41 formed between the pipe 19 and the outer annulus 15. This inner annulus 41 is formed by an annular insert 43 between the pipe 19 and the annulus 15 and provides a passage for either an alternate fuel or a starting fuel such as gas or oil. In this respect, the inner annulus 41 also contains a machined insert 46 corresponding to the machined insert 35 in the primary annulus. Radial air passages 45 may also be peripherally positioned around the insert 43 as shown to lead from the inner annulus 41 to the primary air-fuel annulus 15 in FIG. 3. Although, as suggested above, it is sometimes desirable to have a controlled build-up in the refractory walls, these jets of air from passages 45 are used to selectively disturb the linear flow and selectively modify the flame from its compact, intense configuration to a long bushy flame for dislodging any excessive buildup of material on the refractory lining.
The diameter of the outer annulus 15 can be varied at a constant cross-sectional area to provide the desired high-velocity linear flow and still produce the desired compact, intense flame 27.
In operation, the primary air and the incoming fuel, such as pulverized coal or the like, are blown by the fan through the fuel annulus 15. The primary air can be quite limited in quantity and is injected at a high velocity of at least about 7,000 fpm to carry the fuel into the combustion chamber of the furnace.
Because of the essentially linear flow of the primary air and fuel particles, the fuel particles remain in close proximity. As they pass into the combustion chamber the thickness of their boundary layers is reduced as the fuel particles and primary air are moved at a higher velocity through the secondary air in the combustion chamber. This then allows for more rapid diffusion of oxygen through the boundary layer to the burning surfaces of the particles so that the particles are then ignited by the radiation heat from the already-ignited particles. The high velocity primary air and fuel mixture then complete the burning.
The vortex effect of the inner core 33 of the flame 27 maintains the fuel ignition point very close to the tip of the burner even at the highest fuel-air stream velocities. The high velocity of the fuel-air stream extends the life of the annulus by causing a cooling effect at the entry of annulus 15 into the combustion chamber.
Tests using the annular nozzle in the manner described above have been conducted with a great deal of success. Even with pulverized coal, an intense, very high tip flame was produced that was compact and was as short as only 20 feet in length. Moreover, the tests showed the method and apparatus of the invention to be substantially more efficient than the convection-mixing type burners. Still further, the concept of the annular nozzle used as described above is applicable with similar results to both liquid and gaseous fuels.
In the above regard, it is the increased particle velocity in combination with the limited amount of primary air in a linear-flow mode that is believed to cause the increase in the rate of combustion and the high peak flame temperatures which result in such a significant reduction in the fuel usage per ton of product. In addition, in some instances, the higher temperature has the distinct advantage of producing a better product. In a cement kiln embodiment, for example (as compared with products produced by conventional means) the product produced by the method of the invention had a smaller crystal size, higher strength and a desirably lower alkali content.
At the same time, the measurable NOx produced from the above described method of using an annular-nozzle burner has been substantially reduced without resorting to the energy-sapping recycling of combustion gases. Hence, the invention has wide utility and can be applied to other types of burners used in commercial and utility boilers or the like to lead to considerable fuel savings; a reduction in the amount of recycled combustion air; and, an effective control for nitrogen oxides.
EXAMPLE I
FIGS. 4 and 5 represent a modification of a burner of the type described in U.S. Pat. No. 4,428,727. The furnace in which this example was employed was of the "indirect" firing type wherein pulverized, dried coal was collected in a cyclone and filter collector and then carried through annulus 15' by primary air at ambient temperature.
An outer pipe 50 had an inner diameter of 12 inches and the width of the annulus 15' was 0.75 inches. Pulverized coal at a rate of 5-7 tons per hour and primary air at about 3600 cfpm were passed through the annulus 15' at a maximum velocity of about 19,557 fpm. In this respect, peak flame temperatures increased as velocities through annulus 15' increased and NOx was significantly reduced by lowering excess air to a minimum. In this respect, carbon monoxide monitors were used to control inlet devices for air to reduce excess oxygen to less than 1.5 percent oxygen so that NOx in the exhaust gases was reduced to below 400 parts per million.
At maximum firing capacity primary air was approximately ten percent of the total combustion air with secondary air being the balance.
During normal operation there was no flow through an inner core 52. Indeed, any flow in the inner core had a negative effect on peak flame temperatures. Small amounts of primary air, however, were diverted by a means not shown from the coal conveying line to the inner core 52 for short periods of time (less than one hour) in order to change the flame shape by substantially increasing its cross-sectional area until undesirable buildups were removed from the refractory walls.
EXAMPLE II
The furnace of this example was of the direct feed type wherein pulverized coal was blown directly to the burner after being dried and pulverized. In direct-fired furnaces, primary air is usually a higher percentage of combustion air and, since it comes directly from the coal mill, is already at an elevated temperature. In this respect, in the embodiment of this example, the primary air from the coal mill was at a temperature of between about 150° and 180° F.; and, at maximum firing capacity, primary air was between about 33 and 40 percent of total combustion air--secondary air making up the balance.
The furnace of this particular embodiment was used in connection with a rotary cement kiln; and, immediately upon startup of the apparatus using the method of the invention, a significant improvement in flame shape was observed. Moreover, significant increases in clinker quality and thermal-energy efficiency were also noted. Still further, the kiln produced 7 percent more product per unit-time with no additional fuel input; and, a desirable low-alkali cement was obtained without the addition of calcium chlorides and without reducing kiln capacity.
The annular burner of FIGS. 6 and 7 was used with pulverized coal/coke at a rate of about 10 tons per hour and primary air at a rate of between about 14,000 and 18,000 cfpm at estimated maximum velocities of between about 14,560 and 18,725 feet per minute.
The inner diameter of the outer pipe 54 was 151/2 inches and the diameter of inner pipe 56 was 8 inches, leaving a width of annulus 15" of 3.75 inches. In this respect, the pipe 56 extended from the tip 58 to a reduced-area portion 60 located about 12 inches from the tip 58.
EXAMPLE III
The FIGS. 8 and 9 embodiments were used in connection with an acetylene-fired burner. Primary air at between 0 to 10 cfpm was used with acetylene at between 5 to 10 cfpm at velocities ranging from about 7330 fpm to 29,335 fpm.
Outer pipe 62 had an inner diameter of 1 inch; an inner pipe 64 had an outer diameter of 0.9375 inch; and, the annulus 15'" had a width of 0.03125 inch. A plug 66 was affixed to the inner part of inner pipe 64 to provide an orifice 68 having a diameter of 0.34 inch. In this respect, it is noted that suitable inner pipe supports such as 66 were included in the embodiments of FIGS. 4-11.
Acetylene gas from cylinders was fed into the annulus 15'" with various amounts of compressed air. Even at lower velocities the flame was relatively short (about 10-12 inches) and approximated 1.5 inches in diameter at its maximum point. Contrary to what would be expected, as air/fuel velocity was increased, the ignition point came closer and closer to the burner tip. Initially, for example, the ignition point was 0.5 to 0.75 inches from the tip. At maximum velocity, however, the ignition point appeared to be anchored to the tip and the flame length shortened to 7-8 inches. The flame also became more luminescent as velocity was increased; and, at maximum air/fuel flows obtainable from the equipment being employed it was not possible to "blow out" the flame or cause the ignition point to leave the burner tip.
During normal operation the orifice 68 was plugged. When the plug was removed and very small amounts of air (less than 1 cubic foot per minute) were delivered through orifice 68 at very low velocities, however, the flame appeared to be slightly more intense, but somewhat longer. More than a very minimum amount of such air through orifice 68 caused dispersion and disruption of the flame and created black smoke.
In a comparative study, the annulus 15'" was blocked and an orifice corresponding to 68 was fabricated to have the same cross-sectional area as the annulus 15'". Except as noted, other parameters were the same. In this respect, at fuel-air velocities of about 7,000 fpm, the burner had a flame about 2 feet long and 0.75 inches in diameter with an ignition point approximately 0.5-0.75 inches off the burner tip. The flame, however, was considerably more yellow and produced a significant amount of black smoke. As velocities were increased to 10,000-15,000 fpm, the flame lengthened without a significant increase in diameter and the ignition point moved further from the tip. As velocities were increased still further, the flame moved off of the tip approximately 3 inches and was then blown out. Maximum flame length attained prior to blowout was approximately 36 inches.
EXAMPLE IV
In this example, an outer pipe 72 had an inner diameter of 4 inches and an inner plug 74 had an outer diameter of 2 inches to provide a 1 inch wide annulus 15"".
The fuel was natural gas at 25-50 cfpm; the primary air volume was between about 250 and 500 cfpm; and, estimated velocities were between about 4200 and 8400 fpm.
The above-described embodiment was used in connection with a vertical combustion chamber. The burner was tested with and without the inner core 74 of FIGS. 10 and 11. Without the inner core the ignition point for the burner flame was in excess of two feet from the tip and, even at lower velocities, the flame was unstable. At higher velocities the flame was erratic and easily blown out. With the inner core 74 installed, the ignition point was approximately 0.25 inches from the burner tip even at lower velocities and the flame was very stable. A visible blue flame was noted at the center of the burner tip. After the tests were complete, a discoloration was noted in the center of the inner-core plug 74 indicating that ignition was actually taking place at or near the tip.
Based upon data collected thus far it appears that the maximum ratio of the outer diameter to the inner diameter of the annulus 15 is about 2.0; and, the numeric ratio of the outer diameter to the area of the annulus should be more than about 0.1. For most embodiments the minimum efficient operating velocity at the discharge from the annulus 15 into the combustion chamber is about 7000 fpm; the minimum length of the smooth annular surface represented by insert 35 in FIG. 3 is about equal to the width of the annulus 15, but a preferred length of the smooth annular surface corresponding to insert 35 is between about four and 12 times the width of the annulus 15.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
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A method and apparatus for burning fuel in an annular-nozzle burner wherein a compact flame is generated by inhibiting the dispersion of fuel particles and concentrating the fuel particles in a primary combustion area having a high rate of radiant heat transfer between the fuel particles by maintaining a sufficiently high velocity of the fuel particles and causing them to undergo esentially linear flow in a direction substantially parallel to the axis of the burner.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. patent application Ser. No. 08/687,754, filed Jul. 25, 1996 now U.S. Pat. No. 5,712,934, priority of the filing date of which is hereby claimed under 35 U.S.C. § 120.
FIELD OF THE INVENTION
The present invention relates in general to a sensor system, and more particularly to a sensor system that includes a fiber optical sensor for detecting and signaling the presence of fluids.
BACKGROUND OF THE INVENTION
Briefly, fiber optic technology relates to the transmission of light through a light conducting material such as optical glass, fused silica, and certain plastics. The choice of a particular material depends on the intended use of the light transmission system, and takes into consideration the properties of the fiber including its refractive index, light transmittance, as well as thermal and chemical characteristics. The size (e.g., diameter and length) and configuration of the fiber optic device is also selected based on the intended use. Devices derived from light conducting materials having relatively large diameters are referred to as light pipes. In contrast, thin filaments having significantly smaller radii (e.g., from 100 to 3,000 micrometers, μm) are commonly referred to as optical fibers.
Known systems are designed so that light travels through an optical fiber by total internal reflection. Light entering the optical fiber is retained by and guided through the fiber, ultimately exiting at the other end. Basically, as light is propagated through the fiber, rather than escaping from the fiber, light striking the surface of the fiber is reflected. The extent of light reflection at the fiber surface, and conversely the loss of light from the fiber due to refraction, is a function of the indices of refraction of the fiber and its surrounding medium. For example, light incident on a high-to-low refractive index boundary (such as the interface between an optical fiber and air) at any angle greater than the critical angle is 100% reflected at the interface. Typical refractive indices for optical fibers range from about 1.2 to about 1.8, whereas the refractive index of air is 1.0003. The critical angle is a property of the light conducting material and defined as the smallest angle with the normal to the boundary at which total internal reflection occurs. Thus, for light propagated through a high-index material and striking the walls at greater than the critical angle, no refractive loss of light from the fiber occurs and the light is channeled through the fiber by total internal reflection.
In practice, despite the highly efficient transmission of light by total internal reflection in optical fibers, some light loss from the fiber inevitably occurs. Light losses may include, for example, refractive loss resulting from incident light striking the fiber walls at less than the critical angle. Additional losses may also be attributed to optical impurities present within the fiber, which may scatter or absorb light traveling through the fiber.
In addition to the light losses noted above, the attenuation of light intensity through an optical fiber may result from engagement of a fiber with a medium having a refractive index approaching the index of the fiber. For example, when an optical fiber is engaged by a liquid having a relatively high refractive index, such as water (refractive index 1.33) or gasoline (refractive index 1.38), light loss from the fiber may occur.
Using these principles, the detection of liquid levels by fiber optic sensing is well known. Numerous fiber optic devices and methods exist for the measurement of fluid levels, such as fuel in a storage tank. Many of these devices and methods take advantage of the attenuation of light intensity through a light-conducting medium by refractive loss as a consequence of engaging the optical fiber with a refractive medium such as a liquid.
Relying on this operating principal, U.S. Pat. No. 4,187,025 to Harmer discloses a light guide having alternating curvatures (e.g., S- or W-shaped light guides) to produce a light signal corresponding to the refractive index of a liquid in contact with the guide. When immersed in a liquid, the alternating curvatures of the light guide provide refractive passage of an amount of light that is variable and depends on the refractive index of the liquid. For these curvatures, the ratio of radius of curvature to the radius of the cylindrical light guide core is preferably between 3 and 5. The alternating curvature configuration of the device provides for enhanced sensitivity compared to a curved section bent in a single direction, such as the U-shaped device disclosed in U.S. Pat. No. 4,082,959 to Nakashima et al.
U.S. Pat. No. 4,287,427 to Scifres discloses several configurations of a fiber optical light guide useful for detecting liquids based on the various liquids' indices of refraction. The disclosed configurations include U-shaped and coiled light guides which, on immersion in a liquid, lose transmitted light as a function of the refractive index of the liquid.
A fiber optic detection system having a single fiber optic element in a U-shaped configuration and having a light variable loop section is disclosed in U.S. Pat. No. 5,362,971 to McMahon et al. Light transmitted through the light variable loop section escapes from the fiber when the loop section is contacted with a medium. For this system, the higher the index of refraction of the medium, the greater the amount of escaping light.
The devices noted above all share the characteristic of transmitting light through a smooth and continuous optical light guide. Optical guides having distinct reflective and refractive surfaces have also been employed to measure liquid levels. U.S. Pat. No. 3,995,169 to Odden discloses a U-shaped light pipe having planar internal reflecting surfaces positioned at both bends of the pipe. The planar surfaces act to reflect light from one arm of the pipe to the other arm without appreciable light loss when the refractive index of the surrounding medium is less than that of the light pipe. However, when the reflecting surfaces are immersed in a liquid, the planar surfaces become refractive surfaces and provide for the refraction of light from the light pipe to the surrounding liquid.
The use of reflective/refractive surfaces in optical devices to measure the presence of a liquid in contact with the surface, such as described above, is well known. Many of these optical devices include such surfaces present in conical configurations. In these optical devices, light is transmitted to the conical tip of the light guide where light is either: a) reflected across the tip and then returned via the light guide to a photodetector, when the conical tip of the guide is not in contact with a refracting medium such as a liquid; or b) refracted into the surrounding medium when the cone is immersed in a liquid. See, e.g., U.S. Pat. No. 3,384,885 to Forbush, U.S. Pat. No. 3,535,933 to Pliml, U.S. Pat. No. 3,553,666 to Melone, U.S. Pat. No. 3,683,196 to Obenhaus, and U.S. Pat. No. 3,8321,235 to Bouton et al.
In addition to the use of refractive surfaces in cone-shaped optical devices, refractive surfaces have also been incorporated into fiber optic sensors. A fiber optic probe system sensor having a refracting surface is disclosed in U.S. Pat. Nos. 4,851,817 and 5,005,005 to Brossia et al. The disclosed optical fiber has a U-shaped configuration similar to those noted above for Scifres and McMahon. However, in contrast to the above-noted optical fibers, the optical fiber in Brossia provides a sensor portion having a rough, abraded refracting surface in the light path. The abraded refracting surface provides an opportunity for light to refract from the fiber and into the sensed medium. The more abraded the fiber, the more opportunities for energy passing through the fiber to interact with the sensed medium.
The devices noted above use refractive light loss from a light guide to sense the presence of a refractive medium in contact with the guide. However, in addition to light loss from an optical fiber through refraction, light loss from a fiber may also occur through evanescent wave losses.
As used herein, the term "evanescent wave" refers to electromagnetic radiation that results from the propagation of light through a light-conducting medium, and that is present outside of the light-conducting medium. When light is transmitted through a high index of refraction medium the evanescent wave (or field) is produced in the adjacent lower index of refraction material and has intensity only within a fractional wavelength distance from the interface between the two mediums. The intensity of the evanescent wave decreases exponentially with distance from the fiber core (i.e., E=E o e - αr where E is the intensity of the evanescent wave, E o is the light intensity in the optical fiber, and α relates to the differences in the index of refraction of the two mediums, and r is the distance from the fiber core). The presence in the field of a medium that absorbs light of the wavelength of the transmitted light will result in light loss from the fiber.
Just as for refractive light loss from optical fibers, sensors and related methods have been devised to exploit evanescent wave loss from optical fibers as a means for measuring or monitoring, for example, liquid levels in a tank or reservoir. For example, U.S. Pat. No. 4,287,427 to Scifres describes a liquid-level monitor including a fiber optic light guide having a fiber consisting of a core material surrounded by a cladding material. While most of the guided light is confined to the core, a small amount of light is present in the cladding. If the cladding is removed or is sufficiently thin, the evanescent wave in the thin cladding or, in the absence of cladding, near the outer edge of the core interacts with the surrounding medium. Several configurations of the fiber optic light guide are disclosed including partially and fully cladded, coiled and U-shaped fibers. For this device, evanescent wave loss from the fiber occurs primarily when the wavelength of the guided light matches the absorbance wavelengths of the surrounding medium.
A fiber optic evanescent wave sensor system is described in U.S. Pat. No. 5,291,032 to Vali et al. The sensor system includes a light source, detector, and a cladded optical fiber having a reflector at one end. In the system, infrared light matching the absorbance wavelengths of hydrocarbons, such as those present in fuels, is transmitted into the fiber. The cladding layer is sufficiently thin to permit evanescent wave light loss to the environment. When the fiber is immersed in an absorbing medium, evanescent wave loss occurs as a function of the length of the fiber immersed in the liquid. The amount of light returned to the detector by reflection from the end of the fiber is indicative of the depth of fiber immersion and amount of liquid present.
Accordingly, despite the number and variety of optical fiber sensors and methods for sensing various environmental parameters, there remains a need in the art for improved optical sensors that are highly sensitive, low cost, durable, compact, portable and suitable for field installation. The present invention seeks to fulfill these needs and provides further related advantages.
SUMMARY OF THE INVENTION
Briefly, the present invention provides an optical sensor that uses an optical fiber to detect the presence of a medium present in a sensed environment. The sensor produces a signal corresponding to the amount of evanescent wave light loss from the optical fiber to an absorbing medium in contact with the fiber.
In one aspect, the present invention provides an optical sensor comprising a light source, a light detector and signal generator, and an optical fiber extending between the light source and detector. The optical fiber includes a sensing length comprising a return bend in the fiber, where the return bend has a bend radius less than or equal to 2.5 times the radius of the optical fiber. In a preferred embodiment, the bend radius is less than or equal to twice the radius of the optical fiber. In one embodiment, the sensing length of the sensor's optical fiber further includes a planar sensing surface. In a preferred embodiment, the planar sensing surface has a maximum length of about twice the radius of the return bend.
In another embodiment, the optical sensor further includes a signal processor for output signaling, and for indicating the detection of a medium in the environment.
In yet another embodiment, the optical sensor includes a beamsplitter positioned between the light source and the sensing length to provide electronic feedback to the light source supply to control and regulate its emission.
In still another embodiment, the optical sensor includes an analyte-specific coating on the fiber's sensing length.
In another aspect of the present invention, a method is provided for detecting the presence of a medium in an environment comprising contacting the sensing length of the optical sensor of this invention with the medium. The method of the present invention is useful in detecting the presence of any medium in contact with the sensor's sensing length that absorbs light at the wavelength or wavelengths emitted by the sensor's light source. The method of this invention is particularly useful in detecting the presence of water, hydrocarbons, hydrocarbons in water.
In a further aspect, the present invention provides a sensing system that includes a sensor capable of detecting and signaling the presence of fluid in an enclosure. The system, which may be installed or incorporated within electronics and communications enclosures that house fluid-sensitive components, is useful in the early detection and warning of fluid leaks into such enclosures. In addition to a sensor, the system may include a means for conducting fluids entering the enclosure to the sensor, and absorbent material to absorb any entering fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic representation of an optical sensor of the present invention;
FIGS. 2A and 2B are schematic representations of portions of the optical sensor of the present invention;
FIGS. 3A and 3B are circuit diagrams for a representative optical sensor of the present invention;
FIGS. 4A and 4C are diagrammatic side elevations of sensor modules of an optical sensor of the present invention, and FIG. 4B is a diagrammatic end elevation of the sensor module shown in FIG. 4A;
FIG. 5A is a diagrammatic side elevation of a representative molded sensor of the present invention, and FIG. 5B is a diagrammatic end elevation of the molded sensor shown in FIG. 5A;
FIG. 6 is a schematic representation of an optical sensor of the present invention that includes a beamsplitter;
FIGS. 7A and 7B are diagrammatic side elevations of representative embodiments of sensor packages in accordance with the present invention;
FIGS. 8A and 8B are schematic representations of portions of the optical sensors of the present invention that include an analyte-specific coating;
FIG. 9 is a graph that illustrates the sensitivity of a representative optical sensor of this invention in the detection of water; and
FIG. 10 is a schematic representation of a sensor system of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In one aspect, the present invention provides an optical sensor that uses an optical fiber carrying an evanescent wave associated with an internal beam of light. The sensor produces a signal corresponding to the amount of evanescent wave light loss to a medium present in the sensed environment. In another aspect of the present invention, a method for sensing a medium present in a sensed environment is provided.
As used herein, the term "medium" refers to any substance, the presence of which may be detected by the sensor of the present invention. Generally, the medium may be a any fluid, including a gas or liquid, that absorbs light at the wavelength(s) emitted by the sensor's light source. In certain instances, the medium may also be a solid having absorbance properties as noted above.
The term "sensed environment" refers generally to the environment surrounding the sensor of the present invention and includes any medium, as defined above, in contact with the sensor's sensing length and/or sensing surface.
The terms "amount of light" and "intensity of light" are used interchangeably and refer to the number of photons that, for example, are generated by the light source, travel through the optical fiber, are present in the evanescent wave, and are received at the light detector.
In general, as illustrated in FIG. 1, a first embodiment of the invention provides a optical sensor 10 having a light source 12 for generating light, a light detector and signal generator 14 for receiving light and generating variable signals dependent on the amount of light received, and an optical fiber 20 extending between the light source to the light detector and signal generator. The sensor includes a housing 16 to facilitate the convenient incorporation of the sensor into an environment, and a signal processor 18 connected to the light detector and signal generator for output signaling and indicating the detection of a medium in the sensed environment.
In operation, light is transmitted from the light source 12 through the optical fiber to the light detector 14 where a variable signal is generated depending on the amount of light received at the detector. In the absence of a light absorbing medium in the sensed environment, the amount of light received at the detector will be substantially the amount of light that is generated by the light source. In contrast, when a light-absorbing medium is present in the sensed environment, light transmission through the fiber will be attenuated, and the amount of light received at the detector will be the difference between the amount of light generated by the light source and the amount of light absorbed by the medium in the sensed environment. The greater the amount of light absorbed by the medium, the less the amount of light received at the detector.
Referring now to FIG. 2A, the optical fiber 20 of the optical sensor of the present invention has, in general, a return bend or U-shaped configuration that provides a guide for the light generated by the source and received at the detector. The optical fiber has a sensing length 26 that provides for the passage of light by evanescent wave into a medium in contact with the sensing length. Light generated by the source is guided through input arm 22 of the fiber to sensing length 26, and on to the detector through output arm 24. The sensing length of the optical fiber includes the return bend portion of the fiber. In a preferred embodiment, the sensing length comprises a sharp return bend (e.g., 180°) in the fiber having a bend radius R, defined as half the distance between input arm 22 and output arm 24 as indicated in FIG. 2A, that is less than or equal to 2.5 times the radius r of the optical fiber core (i.e., R/r≦2.5). In a particularly preferred embodiment, the bend radius R is less than or equal to twice the radius r of the optical fiber core (i.e., R/r≦2.0).
In another embodiment of the optical sensor of this invention, the sensor's sensing length further includes a planar sensing surface. Referring to FIG. 2B, the sensing surface 28 is located at the apex formed by the return bend in the optical fiber. A medium in contact with the sensor's sensing length and/or the sensing surface and capable of absorbing light at the wavelength(s) emitted by the light source can be detected by the optical sensor of this invention.
The sensing surface of the optical fiber is a planar optical surface. The sensing surface may be prepared by micromachining the apex of a return bent optical fiber to provide such a planar and smooth (i.e., optical) surface. As noted above, the optical sensor of this invention operates on the principal of evanescent wave sensing and, as such, the sensing surface is not a refraction/reflection surface. Rather, the planar optical surface of the sensing surface is smooth and free from grooves and/or other aberrations including striations to minimize refractive loss from the fiber. The smooth, nonrefractive sensing surface is also located at the apex of the optical fiber bend so as to further minimize refraction of light from the fiber. The positioning of the sensing surface is such that, unlike the refracting/reflecting surfaces of the prior art devices noted above, the sensing surface does not extend to the outer periphery of the bend where refraction may readily occur. Thus, to minimize direct refractive light loss from the fiber, the sensing surface is centered at the apex of the return bend and has one end 28a substantially aligned with the innermost edge of the light path of the input arm 22 and the other end 28b substantially aligned with the innermost edge of the light path of the output arm 24. In a preferred embodiment, the sensing surface is centered at the apex of the return bend of the fiber and has a maximum length of about 2R. The position and length of a sensing surface having a length of about 2R, noted by dashed vertical lines designated a and b, is shown in FIG. 2B.
As noted above, the sensing surface has a maximum length of about 2R, and optical sensors of the present invention include sensors having sensing surface lengths less than 2R. The length of the sensing surface may be varied depending on the sensing application. In general, the greater the length of the sensing surface, the greater the sensitivity of the optical sensor. Preferably, the length of the sensing surface is between about R and 2R. It will be appreciated that as the length of the sensing surface decreases and approaches zero as the lower limit, the sensing surface becomes a point, and the sensing length of the sensor of the invention comprises a smooth return bend. Accordingly, in addition to optical sensors that include sensing surfaces having lengths up to 2R, optical sensors having diminishingly small sensing surfaces, such as those having a sensing length comprising a smooth return bend, are also within the scope of the present invention. Nevertheless, a planar sensing surface of substantial length is preferred.
It can be demonstrated that the sensitivity of the optical sensor of this invention is attributable to the sharpness of the fiber's return bend. It can also be demonstrated that the planar sensing surface further enhances the sensor's sensitivity. Although not presented or intended to limit the scope of the invention, it is believed that the sharpness of the fiber's bend optimizes the evanescent wave present in this portion of the fiber, and that the planar sensing surface coupled with the fiber's sharp return bend further optimizes the evanescent wave. It is believed that the sharp return bend tends to concentrate the density of multimode reflections normal to the tangent of the apex (i.e., increase the number of reflections per unit distance along the fiber) which has the effect of creating a continuous evanescent wave (or evanescent field) along fiber's return bend apex and, when present, the planar sensing surface. Accordingly, by virtue of its shape and configuration, the optical fiber of the present invention is particularly well-suited to generating an enhanced evanescent surface wave thereby probing a medium in contact with the sensing length and/or sensing surface. In fact, the high sensitivity of the optical sensor of the present invention is a direct result from the fiber's shape and configuration. Variations in the dimensions of the sensing surface may be made to achieve the detection and quantitation of specific media.
The performance characteristics of the optical sensors of the present invention are described and summarized in Examples 2 and 3. In Examples 2 and 3, the characteristics of the optical sensors of this invention having R/r≦2.5 and sensing lengths comprising either a smooth return bend or a planar sensing surface are compared to various other devices including sensors incorporating straight fibers and bent fibers having bend radii greater than 2.5. Example 2 describes the performance characteristics of representative sensors in the detection of water, and the detection of oil in water is described in Example 3.
The optical fiber useful in the present invention is made of a light conducting material. A number of suitable fibers are commercially available from a variety of manufacturers including Mitsubishi Cable Co., AT&T, Belden, SIECOR, and Spectran. In the context of the present invention, the optical fiber includes a fiber core made of a light conducting material and, optionally, a cladding material surrounding the fiber core. For embodiments of the optical sensors of this invention that employ cladded optical fibers, the cladding is removed from the fiber in the region of the sensing length. Light conducting materials include any materials capable of conveying light by multiple internal reflections. Suitable materials include plastic materials, such as polystyrene, polyacrylate, and polymethylmethacrylate materials, and glass materials such as quartz, silica glass, borosilicate glass, lead glass, and fluoride glass materials. Preferred optical fibers include plastic fibers having diameters from about 250 to about 2000 μm, and glass fibers having diameters from about 50 to about 250 μm. Suitable optical fibers are essentially transparent to the wavelength(s) of light generated by the light source, may be either single or multimode fibers, and may include fibers having specific transmission modes and wavelength bands. In a preferred embodiment, the optical fiber is a multimode plastic fiber having a diameter of 1000 μm, such as commercially available from Mitsubishi Cable America, Inc., New York, N.Y. (Eska™).
The light source of the optical sensor serves to generate light, and may be selected based on the sensing application where the source's output wavelength is matched with the wavelength of absorbance of the medium to be sensed. In a preferred embodiment, the light source emits light at a wavelength or wavelengths in the red and/or near-infrared region of the spectrum, i.e., from about 600 to about 1500 nm. In general, light sources useful in the optical sensor of this invention include tungsten light sources, light-emitting diodes, and laser diodes. Suitable laser diodes include diodes composed of gallium arsenide (GaAs) and aluminum gallium arsenide (AlGaAs) materials, which are electroluminescent and emit in the near-infrared (i.e., 1050 and 1150 nm, respectively). Other suitable light sources include light-emitting diodes having peak emission wavelengths at, for example, 850 nm, 880 nm, 940 nm (available from Clairex Technologies, Plano, Tex., as models CLC216PR, CLC211PR, and CLC112PR, respectively), 950 nm, and 1300 nm (available from Siemens Optoelectronics, Inc., as models SFH450 and STL51007G, respectively). In a preferred embodiment, the light source is a light-emitting diode having a wavelength of emission centered at about 950 nm, commercially available from Siemens Optoelectronics, Inc.
The light detector and signal generator of the optical sensor receives light from the light source and generates variable signals dependent on the amount of light received at the detector. Suitable light detectors include any photodetector, such as a photodiode or phototransistor, capable of responding to light emitted from the light source. Preferably, the light detector has a photosensitivity (i.e., photoresponse) over at least the bandwidth of the source's emission wavelengths. Light detectors useful in the optical sensor of this invention include, for example, models SFH350 and the SRD0021x series photodetectors commercially available from Siemens Optoelectronics Inc., and models CLC400 CLC600 series photodetectors available from Clairex Technologies. In a preferred embodiment, the light detector is a phototransistor, such as model SFH350, commercially available from Siemens Optoelectronics Inc. As noted above, the optical sensor may also include a signal processor connected to the light detector and signal generator to process and output signals from the signal generator to indicate the presence of a selected medium in the environment.
The electronic components of a representative optical sensor of this invention are shown in the circuit diagrams of FIGS. 3A and 3B. With reference to FIGS. 3A and 3B, power for the light emitting diode D2 can be provided by a constant current source 102 based on a three terminal adjustable regulator 104, such as a National Semiconductor LM317LZ. Regulator 104, in turn, receives input power (12 volts DC) through an input filter R1, C1. For the photodetector D1 and the signal processing circuit 106, power is supplied by a voltage source 108 which also can be based on a three terminal adjustable regulator 110 (LM317LZ) receiving power (12 volts DC) through the input filter R1, C1. The output from the photodetector is applied to a voltage divider R7, R8, with the maximum voltage across resistor R8 limited by a Zener diode CR1. The voltage across resistor R8 is filtered by a two-stage filter R9, C2 and R10, C3, before being amplified by a chopper-stabilized operational amplifier circuit (U3:A). The processing circuit then subtracts a reference voltage (found at the junction of R14 and R15) from the amplified voltage, and further amplifies the voltage difference at another operational amplifier (U3:B). This amplified, offset voltage is the output.
The optical sensor may include a housing to form a sensor module to facilitate the convenient incorporation of the sensor into an environment. The housing for the optical sensor may take any one of a variety of forms depending on the sensing application. For example, the housing may be a cylindrical sleeve of plastic and/or metal that surrounds the optical fiber and seals the light source and detector, as well as the signal generator and processor, from the sensed environment. In the sensor module, the sensing length of the optical fiber is exposed to the environment for sensing of a selected medium. Alternately, the housing may be a sensor sleeve, such as described above, further including a threaded surface such that the sensor may be inserted and secured into an environment by a threaded sensor receiving means. Representative sensor modules are illustrated in FIGS. 4A and 4C.
The housing used to form the sensor module may, under certain circumstances, impose the bend radius in the optical fiber useful in the sensor of the present invention. For example, in one embodiment, the sensor module housing is a cylindrical sleeve having an outer diameter of about 0.2 inches (with a nominal wall thickness of about 0.02 inches). The use of a 1000 μm (0.04 inch) diameter optical fiber in a return bend configuration with such a housing results in a separation of about 0.08 inches (R=0.04 inch) between the input and output arms of the fiber. In such a configuration, the bend radius R (0.04 inch) is equal to twice the fiber radius r (0.02 inch), i.e., R/r=2.0. Such a configuration is distinguished from the configurations of the prior art sensors noted above that contain bent optical fibers having R/r>>2.
Referring to FIG. 4A, in one embodiment the sensor module 30 has a cylindrical body 32 that encompasses optical sensor 10. In this embodiment, the input and output arms of optical fiber 20 are enclosed in housing 16, and sensing length 26, including optional sensing surface 28, extend from the housing to permit engagement of the sensing surface with a medium present in the sensed environment. In an embodiment of this sensor module, the cylindrical body 32 extends to a length of at least the outer reach of sensing length 26 and optional sensing surface 28, and further provides channels 34 in cylindrical body 32 as a means for permitting the engagement of a medium with sensing surface 28. An end elevation of the sensing end of the sensor module depicting sensing surface 28 and channels 34 is shown in FIG. 4B. A sensor module 30 having a threaded body 36 that encompasses optical sensor 10 is shown in FIG. 4C. As noted above for the sensor module having a cylindrical body, sensing length 26 and optional sensing surface 28 may either extend from or be recessed in threaded body 36. In embodiments having a recessed sensing surface, the threaded body may include channels for the engagement of a medium with the sensing surface.
In a preferred embodiment, the optical sensor of the present invention is a molded sensor made of a plastic light conducting material such as polymethyl methacrylate. The molded sensor includes the optical sensor components noted above (e.g., the light guide having a sensing length, the light source, and the light detector) where the source and detector are fitted into the plastic mold. A representative molded sensor is illustrated in FIG. 5A. Referring to FIG. 5A, the light source 12 and light detector and signal generator 14 of molded sensor 40 are located in cylindrical body 42 of the molded sensor. Extending from the cylindrical body 42 are input arm 22, sensing length 26 including sensing surface 28, and output arm 24. An end elevation of the molded sensor is shown in FIG. 5B.
The molded sensor offers the advantage of ease of production including the uniform manufacture of the return bend and, optionally, the planar optical surface of the fiber's sensing length. An additional advantage of the molded sensor is that no leakage of liquid from the environment into the sensor can occur.
In one embodiment, the optical sensor includes a beamsplitter positioned in the path of the light generated by the source. Referring to FIG. 6, in one embodiment the sensor has beamsplitter 50 positioned along input arm 22 between light source 12 and sensing length 26. The beamsplitter directs a portion of the generated light to a second light detector and signal generator 52 such that the intensity of the light generated by the source may be monitored. The beamsplitter and associated second light detector and signal generator provide a means for calibrating the intensity of the source and allow for the quantitation of the amount of light loss from the sensing length of the optical fiber by comparing the amount of light received at light detector 14 and the second light detector.
Alternatively, a phototransistor may be positioned directly along input arm 22 to provide electronic feedback to the light source supply to control and regulate the intensity of the light emitted from the source.
The optical sensor of the present invention may be employed in a number of configurations and sensing environments to monitor and report conditions and changes in conditions measurable by the sensor. As noted above, to best sense the presence of a particular medium, the sensor's light source emission wavelength or wavelengths should overlap to at least some extent with the absorbance wavelengths of the medium sought to be detected. In the context of the present invention, sensors having light sources emitting red and near-infrared wavelengths are particularly useful in detecting the presence of water and hydrocarbons such as fuels including gasoline and oil. As used herein, the term "hydrocarbon" refers to a substantially organic compound that includes carbon-hydrogen (i.e., C--H) bonds.
The sensor of the present invention may be located in certain environments where, for example, the presence of water may be hazardous to the smooth functioning of certain components such as electrical components present in an electrical box. In such an application, a sensor may be installed in the box in such a position that any water that finds its way into the box ends up in contact with the sensing length and/or sensing surface of the sensor. In the event that water does collect and contacts the sensing length and/or sensing surface, the attenuation of light through the optical fiber of the sensor accompanying the contact of water results in the generation of an output signal indicating the presence of water in the electrical box. Notice of the presence of water in the box allows for action to be taken to service the particular box and avoid any costly damage that would result from unnoticed and unattended accumulation of water in the box.
Thus, in another aspect, the present invention provides a sensor system that includes a sensor capable of detecting and signaling the presence of fluid in an enclosure. The system can be integrally formed with or installed within an enclosure that contains one or more fluid-sensitive components including, for example, electronic and communications connections or splices. In accordance with the sensor system, fluid entering the enclosure is conducted to the sensor which detects the presence of the fluid and transmits a signal via a communications line to a communications control center. Upon receipt of this information, action may be taken to service the enclosure and thereby prevent damage to the fluid-sensitive component(s) housed within the enclosure. Because the sensor generates a signal in advance of fluid entering that portion of the enclosure housing the fluid-sensitive component(s), a prompt response to the sensor's signal can avoid costly damage to the enclosed components.
The sensor system of the present invention is particularly useful in connection with splice closure systems. The term "splice closure system" generally refers to a device that encloses electronic and/or communication cable splices (i.e., connections) including fiber optic splices, mechanical and fusion splices, which are useful in a variety of applications including aerial, building, direct buried and underground applications. Splice closure systems are well known in the art and may take any one of a number of forms or configurations. Generally, splice closure systems are designed to protect sensitive electronic and communication splices from damage that may otherwise result from exposure to hostile environmental conditions including temperature extremes, sunlight, wind, and precipitation such as rain, sleet, and snow. Among other protections, these closure systems seek to prevent moisture from entering the closure and causing damage to the water-sensitive components contained within the enclosure. The sensor system of the present invention can be incorporated into a splice closure system to provide a means for monitoring moisture within such a closure.
As noted above, the sensor system can be integrally formed with or installed within an enclosure that houses fluid-sensitive components. The sensor is preferably incorporated into the enclosure in a position such that a fluid entering the enclosure contacts the sensor prior to traveling to and potentially damaging the enclosure's fluid-sensitive component(s). In addition to the sensor, the system preferably includes a means for conducting any fluid entering the enclosure to the sensor and an absorbent material to absorb any fluid entering the enclosure.
A schematic illustration of a representative sensor system associated with a typical enclosure for housing fluid-sensitive components (i.e., a splice closure system) is shown in FIG. 10. The splice closure system depicted in FIG. 10 is a common closure configuration having input and output cables extending from one end of the closure. It will be appreciated that other closure configurations, including closures having input and output cables extending from opposite ends of the closure, are within the scope of the present invention and would benefit from the advantages afforded by sensor system of this invention. In such an embodiment, the closure can include two sensor systems, corresponding to each cable port, located near each end of the closure. It will also be appreciated that, depending on the particular closure system, the closure can include any one of a variety of means for securing and sealing the closure's cover to the closure's base. One such means, a clamp and O-ring seal, is illustrated in FIG. 10.
Referring to FIG. 10, the illustrated splice closure system generally includes base 102, dome 104, splice organizer tray 106, O-ring seal 108, and clamp 110. Clamp 110 secures dome 104 to base 102 and provides a seal through O-ring 108. The O-ring forming the dome/base seal is preferably made from a water impervious elastomeric material. Dome 104 further includes ports 112 for receiving input (i.e., feeder) and output (i.e., distribution) cables. The cables are organized and spliced in the closure on tray 106.
As shown in FIG. 10, the representative sensor system includes sensor 120, a fluid conducting means 122 (or 124 shown in broken line), and absorbent barrier 126. In a typical splice closure system, the sensor is powered from a source associated with either the input and/or output cables, and the sensor signals the presence of fluid in the closure through a communication line, for example, optical fibers associated with the cables noted above.
The sensor is generally positioned between the closure's primary seal and the closure's fluid-sensitive components. Referring again to FIG. 10, when dome 104 is secured to base 102, sensor 120 is positioned between O-ring 108 and absorbent barrier 126. In the embodiment illustrated in FIG. 10, absorbent barrier 126 is a ring-shaped barrier in communication with the interior surface of base 102 and having an aperture of size sufficient to permit tray 106 to pass unimpeded into the closure's base. Barrier 126 is a continuous ring mounted in the closure base and includes an absorbent material, preferably a superabsorbent polymeric material. In its sealed configuration, absorbent barrier 126 is positioned between sensor 120 and the closure's fluid-sensitive components located on tray 106. As a result of this configuration, any fluid entering the closure through the dome/base connection is first directed by a conducting means to the sensor, where it is detected. and its presence signalled. Any fluid migrating beyond the sensor and toward the fluid-sensitive component located on tray 106 is intercepted and absorbed by the absorbent barrier. Thus, barrier 126 provides the closure with a measure of protection during the period of time between the sensor's initial signaling of the presence of fluid in the closure and servicing of the closure.
Suitable sensors useful in the system of the present invention include any sensor capable of detecting and signaling the presence of a fluid, for example, water or moisture. Preferably, the sensor is an optical sensor such as a sensor of the present invention described above.
Generally, the sensor is positioned in the enclosure to be sensed such that any fluid that enters the enclosure collects at or near the sensor for ready detection. Accordingly, the sensor is generally positioned at the enclosure's lowest point, for example, at the lowest point of the enclosure's floor. The fluid conducting means can include any one of a number of means including, for example, a fluid conduit and other routing means. As shown in FIG. 10, a preferred means for conducting a fluid to the sensor is helical groove 122 (i.e., a "racetrack"), which encircles the interior circumference of base 102 between O-ring 108 and sensor 120. In another preferred embodiment, the fluid conducting means is flange 124 extending inwardly from the interior surface of base 102 and in communication with sensor 120. Fluid entering the closure and travelling toward the sensor encounters flange 124 and is conducted to the sensor.
Employing the advantages offered by the sensor of the present invention with regard to the sensor's ability to detect the presence of hydrocarbons such as fuels in water, the sensor may be incorporated into a sensor package, such as a flotation device, and located in bodies of water (e.g., rivers, streams, ponds, and lakes) to detect fuel spills. An example of such an embodiment is illustrated in FIG. 7A. Referring to FIG. 7A, sensor module 30 is positioned in a flotation device 70 made of buoyant material. Flotation device 70 is designed to float on a liquid surface and permit contact of sensing length 26 and/or sensing surface 28 with the surface of the liquid.
The sensor of the present invention may also be incorporated into a sensor package useful as a liquid level monitoring device. In one embodiment, a plurality of sensor modules may be embodied to determine the level of a particular fluid such as the level of water in a storage tank, the level of fuel in a fluid tank, or the level of a liquid such as water or oil in a well site. An example of such a sensor package is illustrated in FIG. 7B. Referring to FIG. 7B, sensor modules 30 are adjacently positioned in liquid level monitoring device 80 such that when the liquid level is sufficient to immerse a portion of the device, one or more of sensing lengths 26 and/or sensing surfaces 28, corresponding to the portion of the device immersed in the liquid, contacts the liquid medium and generates a signal which is sent to signal processor 18. Monitoring device 80 may optionally include shutters 82 which may be controlled so as to open and allow for the sampling of an environment once the monitoring device has been positioned in the particular environment.
In another embodiment, the optical sensor further includes an analyte-specific coating. This embodiment renders the sensor useful in measuring specific analytes (e.g., chemicals and biochemicals) that may be present in a medium, as well as medium parameters including pH and ionic strength. As used herein, the term "analyte-specific coating" refers to a deposit or coating of a material onto either the optical fiber's sensing length or the fiber's sensing surface. The deposited or coated material interacts with a specific analyte present in a medium and the interaction is measurable by the sensor of the present invention. Basically, the interaction between the analyte-specific coating of the sensor and the specific analyte present in the solution results in some change that is measurable by the evanescent wave produced by the sensor of the present invention. Operationally, on contacting the analyte-specific coating with a medium containing an analyte that specifically interacts with the coating, light loss from the fiber occurs in an amount directly proportional to the amount of specific analyte interacting with the analyte-specific coating. Thus, the presence and, if calibrated, the quantity of a specific analyte present in a medium may be determined.
Referring to FIGS. 8A and 8B, analyte-specific coating 60 is applied to and located on the optical sensor's sensing length 26 and sensing surface 28, respectively.
As noted above, the interaction between any two materials that results in a change in the amount light lost from the optical fiber may be suitably measured by the sensor of the present invention. The analyte-specific coating may be a chemical such as an indicator compound; a biochemical or biological molecule such as an enzyme, antibody, or nucleic acid; or a membrane that selectively binds a particular chemical or biochemical. Suitable chemical coatings include, for example, organic and inorganic compounds that, on exposure to a medium containing certain other chemicals, biochemicals, or metal ions, undergo a change in their absorbance properties. The use of specific biochemical binding partners or specific binding pairs, including receptor molecules and their ligands, antibodies and their ligands, and complementary nucleic acid sequences, are also within the scope of this embodiment of the present invention. In such embodiments, one member of the specific binding pair (e.g., a receptor) may serve as analyte-specific coating to detect as the analyte, the other member of the pair (e.g., its ligand). Synthetic membranes that undergo changes in their absorbance properties in response to parameters of a medium, such as pH, ionic strength, or the presence of certain chemicals including metal ions and dissolved gases such as oxygen and carbon dioxide, and biochemicals including biological species, may also be useful as analyte-specific coatings in the sensor of this invention.
In another aspect of the present invention, a method of detecting a medium in an environment is provided. In the method, a medium is detected by contacting the sensing length and/or sensing surface of the optical sensor described above with the medium. When the medium in contact with the sensing length and/or sensing surface absorbs light at the wavelength(s) emitted by the light source, light transmission through the optical fiber is attenuated and the amount of light received at the detector is decreased in an amount proportional to the nature and amount of the medium sensed relative to the light received in the absence of the absorbing medium.
Optical sensors of the present invention that employ broadband light sources and a multimode waveguides are useful in detecting any fluid that has an absorbance band within the bandwidth of the sensor defined by the emission bandwidth of the sensor's light source. The term "broadband light source" refers; to the band of wavelengths emitted by the sensor's light source. The term "multimode waveguide" refers to the capacity of the light conducting material of the input arm, sensing length, and output arm of the sensor to transmit light of all phases.
The characteristics of the optical sensor of the present invention render methods for detecting substances that absorb in the red and/or near-infrared region of the spectrum particularly effective. For example, when the medium sought to be detected is water (or a primarily aqueous medium), the use of a light source emitting at about 850 nm is effective in detecting as little as 0.1 μL of water present on the sensor's sensing surface. FIG. 9 graphically illustrates the decrease in output signal of a representative optical sensor of this invention as a function of the volume of water in contact with the sensor's planar sensing surface. The sensitivity of representative optical sensors of this invention in the detection of water is presented in Example 2.
The high sensitivity of the method is due to the unique configuration of the sensor of this invention, and also due to the broadband absorbance of water in the near-infrared region of the spectrum. The method takes advantage of the broad near-infrared absorbance of water with the wavelength(s) of light generated by sensor source. The absorbance of water increases greatly from about 400 nm and continues to increase into the far infrared beyond 4000 nm. Thus, the most sensitive methods for detecting water utilizing the sensor of this invention employ wavelengths of light in water's broad absorbance band (i.e., the wavelength(s) at which the greatest amount of the evanescent wave produced by the sensor is absorbed by water in contact with the sensing surface).
As shown in Table 1 of Example 2, the effective detection of water is achieved by the optical sensors of this invention having return bends with R/r about 2.0. For the sensor having a smooth return bend (see Table 1, entry 8), a 58% decrease in output signal was observed when the sensing length was contacted with water. The result demonstrates that the return bend with R/r about 2 is responsible for the high sensitivity achieved by the sensors of the present invention. As indicated in Table 2 of Example 2, the onset of the sensor's high sensitivity occurs when R/r is decreased to less than about 2.5. A dramatic decrease in output signal (87%) was observed for the sensor having a planar sensing surface (see Table 1, entry 9). The result demonstrates that the high sensitivity achieved by the sensors of this invention having a return bend with R/r<2.5 is further enhanced by the presence of the sensing surface located on the apex of the return bend.
Sensitive methods for detecting hydrocarbons, such as those contained in fuels, also exploit the strong absorbances of these substances in the near-infrared region of the spectrum. The near-infrared absorbances are due to C--H bonds present in all hydrocarbons. Typical near-infrared absorbance bands for these substances occur at about 1200 nm (1.2 μm ) and 1400 nm (1.4 μm) and have bandwidths of about 50 nm. Accordingly, the most sensitive methods for detecting hydrocarbons utilizing the sensor of this invention employ sources emitting light at or near these wavelengths.
Where it is desirable to detect the presence of a substance in an environment, the most sensitive method employs a wavelength of light unique to that substance, i.e., a selective sensor. However, if the detection of a particular class of substances is desired, the method should employ a wavelength band common to all substances in the class. If the detection of one substance in the presence of another is desired, and each has a unique wavelength of absorbance, then either may be detected in the presence of the other by appropriate wavelength selection. The use of a common absorbance wavelength may be successful when one substance absorbs more strongly at the wavelength than the other. In such an instance, the method may utilize a wavelength where the substance present in the lowest amount has the greatest absorbance relative to the absorbance for the predominant substance.
In addition to detecting a substance such as water or a hydrocarbon, the method of the present invention may also be useful in detecting one substance in the presence of another, for example, detecting a substance present in a medium, such as a hydrocarbon in water. The method utilizes the sensor of this invention employing a light source emitting at a wavelength of light commonly absorbed by both substances, but more strongly absorbed by the hydrocarbon. In a preferred embodiment, the method utilizes the sensor of this invention employing a light source emitting at about 950 nm.
The effective and sensitive detection of oil in water by the sensor of this invention is shown in Table 3 of Example 3. In these experiments, the sensors were contacted with the surface of water upon which was dispersed 6×10 -4 μL oil per square millimeter. As observed in the water sensitivity experiments, no significant output signal decrease was observed for sensors having optical fibers with return bends where R/r>2. However, a significant decrease in signal was observed for the sensors of the present invention having R/r=2.0. For the representative sensor having a smooth return bend, a signal decrease of about 85% was observed (see Table 3, entry 8). A 10-fold greater decrease in signal, a decrease of about 98%, was found for the representative sensor having a sensing surface at the apex of the return bend (see Table 3, entry 9).
These results indicate that the sensors of the present invention are useful in detecting the presence of one fluid, an oil or fuel, in the presence of another, water. Such usefulness is unique to the optical sensors of the present invention and is a distinguishing characteristic over the known optical sensors noted above.
The following examples are offered by way of illustration, not limitation.
EXAMPLES
Example 1
The Manufacture of a Representative Optical Sensor
In this Example, the manufacture of a representative optical sensor of the present invention is described. As noted above, the optical sensor includes a light source, a light detector and signal generator, an optical fiber, and a signal processor. The signal processor is an electronic circuit having the components arranged on a circuitboard in a configuration as described above and as shown in the circuit diagram in FIGS. 3A and 3B. The sensor is assembled by preparing the optical fiber, mounting one end of the fiber into the light source (i.e., the photocell or light-emitting diode), mounting the other end of the fiber into the light detector, securing the fiber to the source and detector through the use of either black adhesive tape or heatshrink tubing, and soldering the light source and light detector on the circuitboard as indicated in the circuit diagram. Depending upon the particular application, the assembly including optical fiber, light source and detector, and circuitboard may be installed in a suitable housing.
The optical fiber is prepared by cutting a piece of fiber to the desired length and polishing its ends. The cladding is then removed from the fiber over the sensing length portion of the optical fiber. The fiber is then bent into the desired return bend configuration by warming and bending around a cylinder having the desired bend radius. If the optical sensor is to include a sensing surface, the sensing surface is prepared by machining the optical fiber such that a planar surface is formed at the apex of the return bend of the optical fiber.
To evaluate the performance characteristics of the sensors of this invention, representative optical sensors were assembled as described above. The sensors included a 1000 μm (0.04 inch, r=0.02 inch) diameter polymethylmethacrylate optical fiber (AMP Optimate), a light-emitting diode having a peak emission at 950 nm (SFH450, Siemens Optoelectronics, Inc.), and a phototransistor (SFH350, Siemens Optoelectronics, Inc.), and accompanying electronic circuitry as shown in FIGS. 3A and 3B. For the optical sensor having a sensing surface, a planar surface having a length of 0.040 inch was prepared by machining the apex of the return bend of the fiber. The performance characteristics of the representative optical sensors assembled from the components noted above are presented in Examples 2 and3.
Example 2
Performance Characteristics of Representative Optical Sensors: Water Sensitivity
In this Example, the performance characteristics of representative optical sensors prepared as described above in Example 1 are summarized. The sensitivity of the optical sensors in detecting water was compared to other optical fiber-based sensing devices having identical light source, detector, and signal processor, and differing only in the configuration of the optical fiber (i.e., bend radius and sensing surface). The water sensitivity of each of the sensors was determined by immersing the sensing length of each in water. The sensing length for each was prepared by removing the cladding on a 0.7 inch portion of the fiber. The signal-processing circuit was set for a regulated 6.5 volts DC supply with a 5.0 volt output of the sensor. For each sensor output signal measurements were made in air, water, and again in air after drying subsequent to water immersion. The results are summarized in Table 1.
TABLE 1______________________________________Sensitivity of sensor output signal as a function ofoptical fiber configuration: water detection Bend Radius Output Signal Signal R (volts) DecreaseConfiguration (inches) R/r Air Water Dry (%)______________________________________1 no bend -- -- 5.00 5.00 5.00 --2 1.33 66.5 5.00 5.00 5.00 --3 0.41 20.5 4.98 4.98 4.98 --4 0.28 14.0 4.97 4.96 4.97 <15 0.25 13.0 4.97 4.96 4.97 <16 0.15 7.5 4.95 4.92 4.95 <17 0.10 5.0 4.93 4.87 4.92 1.28 smooth bend 0.04 2.0 4.91 2.08 4.91 589 sensing surface 0.04 2.0 4.80 0.63 4.80 87______________________________________
The results in Table 1 show that the representative optical sensors of the present invention having R/r=2.0 were the most sensitive sensors. The results demonstrate that the sharp return bend of the optical fiber of the sensors of the present invention are critical in providing a highly sensitive sensor for detecting water.
Referring to Table 1 above, less than a 1% decrease in output signal was observed until the optical fiber bend radius was decreased to a value of R/r of about 7.5. A decrease in R/r to 5.0 provided only a 1.2% decrease in output signal. A dramatic decrease in output signal of about 58% was observed for a representative sensor of the present invention with R/r=2.0 (see Table 1, entry 8). Furthermore, the representative optical sensor having a planar sensing surface provided enhanced sensitivity compared to the sensor having a smooth return bend. On contact with water, the decrease in output signal for the sensor having a planar sensing surface was observed to be about 87% (see Table 1, entry 9).
The stability of the sensor of this invention is demonstrated by the output signal observed after blow drying the fiber. In each case, the output signal returned to its original value in air indicating that the sensor may be reliably used to continuously monitor changes in its environment.
To more closely examine the effect of sensor configuration, particularly the sensitivity of bend radius (i.e., R/r) on the sensors' detection of water, the output signal for several optical fiber configurations, each having a smooth bend, was measured as described above. The results are summarized in Table 2.
TABLE 2______________________________________Sensitivity of sensor output signal as a function ofoptical fiber configuration: water detection Signal DecreaseConfiguration R/r Air Water (%)______________________________________1 3.25 4.86 4.77 1.92 3.05 4.83 4.70 2.73 2.75 4.82 4.66 3.34 2.50 4.73 3.68 22______________________________________
The results of Table 2 demonstrate that the sensor output signal decreases dramatically with R/r and that high sensor sensitivity onset occurs at about R/r=2.50. Accordingly, the optical sensors of the present invention have R/r≦2.50, and preferably R/r about 2.0.
Example 3
Performance Characteristics of a Representative Optical Sensor: Oil in Water Sensitivity
In this Example, the performance characteristics of representative optical sensor of the present invention in detecting the presence of oil in water are described. The optical sensors used in this Example were prepared as described in Examples 1 and 2 above. An oil-in-water mixture was prepared by dropping 20 μL of oil (SAE 30 motor oil) into a container filled with water and having a surface area of about 33,000 mm 2 and allowing the oil to spread over the surface of the water overnight. The sensing length for each optical fiber for each sensor was contacted with the water's surface and the signal output recorded. The results are presented in Table 3.
TABLE 3______________________________________Sensitivity of sensor output signal as a function ofoptical fiber configuration: oil in water detection Bend Radius Output Signal Signal R (volts) DecreaseConfiguration (inches) R/r Air Oil/Water (%)______________________________________1 no bend -- -- 5.01 5.01 --2 1.33 66.5 5.01 5.01 --3 0.41 20.5 4.99 4.99 --4 0.28 14.0 4.99 4.99 --5 0.25 13.0 4.99 4.99 --6 0.15 7.5 4.97 4.98 --7 0.10 5.0 4.97 4.88 1.88 smooth bend 0.04 2.0 4.87 0.51-0.90 869 sensing surface 0.04 2.0 4.80 0.013-0.065 99______________________________________
The results in Table 3 show that the most sensitive detection of oil in water is achieved using the representative optical sensors of the present invention having R/r=2.0. A dramatic decrease in the signal output (on average about an 86% decrease) is observed for the optical sensor of the present invention having a smooth return bend (see Table 3, entry 8) compared to the other sensors having greater bend radii. The observed decrease is also significantly greater than that observed when the sensor was contacted with water alone as shown in Example 2, Table 1, entry 8. The optical sensor having a planar sensing surface (see Table 3, entry 9) shows about a tenfold greater change in signal output (on average about a 99% decrease) upon contact with the oil-in-water surface as compared to water alone. The large decreases in output signal noted above were observed by contacting the sensor's sensing length with the water's surface upon which was dispersed about 6×10 -4 μL oil per square millimeter. These results illustrate that the sensitivity of the optical sensors in detecting oil in water is significantly greater than their sensitivity to water alone, and thus the sensors are ideal for monitoring the presence of oils in water and useful in continuous monitoring of ground water or water supplies for contamination by hydrocarbons such as fuels and oils.
While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
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There is disclosed a sensor system comprising a sensor for detecting and signaling the presence of a fluid in an enclosure. The sensor system can be installed or incorporated within electronics and communications enclosures that house fluid-sensitive components and is useful in the early detection and warning of fluid leaks into such enclosures. In addition to the sensor, the system includes a means for conducting fluids entering the enclosure to the sensor and absorbent material to absorb any entering fluid.
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[0001] This application is a continuation of PCT from PCT Patent Application No. PCT/CN2008/000880 filed on Apr. 30, 2008, entitled “AN ENDOSCOPE SIMULATION INSTALLMENT AND ITS SYSTEM AND ITS SIMULATION METHOD”, the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a simulation practice equipment to simulate surgical instruments and particularly to an endoscope simulation apparatus that is simply structured and provides improved simulation.
BACKGROUND OF THE INVENTION
[0003] Endoscope is a commonly used instrument in minimally invasive surgery and has been widely used in various types of surgical operations. It takes a long training for a surgeon using the endoscope proficiently. The training generally needs to perform on living bodies or corpse samples. Such a training opportunity usually is rare for students studied in medical schools or interns. Therefore, it generally takes a very long time to verse in the skill. In order to overcome such a problem of lack of practical training and operation opportunities, many analog simulation systems have been developed. With advanced development of computer technology, such simulation systems now can combine with simulation image software to achieve desirable simulation effect. However, the simulation equipment for endoscope operation at present still cannot achieve real simulation effect. Its main drawback results from adopting a gear structure which limits rotation angle thus free rotation angle is small. Moreover, the gear structure is complex and easily malfunctions, and is costly to fabricate, repair and maintain. Furthermore, the conventional structure merely simulates rotation and insertion/drawing slide movements of the endoscope, and cannot simulate the conditions of encountering damping and obstacles while the endoscope is inside a human body. As a result, the conventional analog simulation apparatus can accomplish merely operational practice, but cannot provide tactile feeling, or called hand-touch feel that is the most important skill during surgical operation for doctors. Hence even after using the conventional simulation apparatus for practice for a long time, a lengthy practical operation still is needed to develop the skill required.
SUMMARY OF THE INVENTION
[0004] The primary object of the present invention is to overcome the deficiency of the conventional technique by providing an endoscope simulation apparatus that offers improved simulation, is simply structured and can be fabricated at a lower cost.
[0005] Another object of the invention is to provide a high quality simulation apparatus to achieve controllable simulation or feedback simulation.
[0006] The endoscope simulation apparatus according to the invention includes a bracing rack, a spheroid and a controlling bar. The spheroid is held in the bracing rack and turnable freely. The controlling bar slidably runs through a passage formed in the center of the spheroid to control rotation of the spheroid. The bracing rack has an inner side spaced from the spheroid to hold at least two direction sensors therebetween. The controlling bar has a depth sensor located thereon. The controlling bar is a simulated endoscope to control rotation of the spheroid and also is movable for insertion and drawing. The invention adopts the turnable spheroid structure and can be turned at a greater angle and provide improved simulation over the conventional gear structure. Through the direction sensors and depth sensor that are linked to a computer, the rotational angle and inserted depth of the simulated endoscope can be measured. The invention is constructed in a simple structure with fewer elements, thus the cost is lower. It also employs a common interface to link the computers. The simulation system can be configured by users by merely installing corresponding simulation software. Students or interns require only a computer installed with analog software, then can do exercise, even at home. It is desirable for teaching and training.
[0007] To achieve sliding agility and freedom of the spheroid, the apparatus of the invention provides at least two rotational bracing decks between the inner side of the bracing rack and the spheroid. Each rotational bracing deck has rolling balls on the top to incorporate with sliding of the spheroid. In general, three rotational bracing decks are provided between the inner side of the bracing rack and the spheroid. The three rotational bracing decks are located on planes running through the center of the spheroid, and spaced evenly from each other relative to the center of the spheroid. Another alternative is to provide four rotational bracing decks between the inner side of the bracing rack and the spheroid that are spaced from each other in a regular tetrahedron. The regular tetrahedron has a gravity center coincided with the center of the spheroid. Because of such an even distribution structure of the rotational bracing decks, the stability of the apparatus improves. It also provides sufficient moving space for the controlling bar, such that the free rotation angle is not limited, thus also improves simulation effect.
[0008] The invention also provides a turning angle sensor between the passage and the controlling bar to measure the rotational angle of the controlling bar relative to the spheroid. The turning angle sensor can measure the turning angles while the controlling bar is in the simulation process, and is adaptable to some special types of endoscopes.
[0009] The sensors mentioned above may adopt optical sensors or mechanical sensors. The passage in the spheroid can be a non-closed or closed structure. For the non-closed structure, the depth sensor is held inside the spheroid between the passage and the controlling bar. Such a structure is more stable and precise, and can select optical sensors or mechanical sensors. For the closed structure, the depth sensor can be located at one end of the passage facing a distal end of the controlling bar. Such a structure is more compact, but can use only the non-contact optical sensors.
[0010] The direction sensor can be an optical sensor or mechanical sensor according to actual requirement. In order not to hinder rotation or constrain the rotational angle or range of the controlling bar, the direction sensor generally is installed adjacent to the rotational bracing deck, preferably at the top portion of the rotational bracing deck.
[0011] The present invention further provides a damper means between the bracing rack and the spheroid, or between the spheroid and the controlling bar, or both. The damper means can really simulates that the endoscope encounters resistance or is obstructed by tissue inside a human body without further insertion or rotation. The damper means has a manual regulator or a feedback automatic regulator, or both manual and feedback automatic regulators. The manual regulator allows users to adjust resistance of rotation and insertion according to actual requirements. The feedback automatic regulator is linked to a computer and automatically adjusts the resistance and restricts the position of rotation and insertion according to human body structure in the analog software, thereby a high quality simulation can be accomplished. By installing the damper means, simulation of real tactile feeling can be realized in operating endoscope to get real simulation effect. This effect can even be further enhanced by inputting patients' data pending to surgical operation to the computer to practice simulated surgical operation.
[0012] In order not to hinder rotation of the controlling bar and constrain rotational angle or range thereof, like the direction sensor, the damper means also is installed adjacent to the rotational bracing deck, preferably on the top portion of the rotational bracing deck.
[0013] The cross section of the controlling bar and the passage are formed at a non-circular structure so that the controlling bar can be served as a rotational shaft to control rotation of the spheroid to achieve rotation simulation of the endoscope merely through the direction sensors. The cross section of the controlling bar and passage generally are in a regular polygon, preferably a regular hexagon.
[0014] The controlling bar also has a distal end with a simulated endoscope handle and a control button to provide real handling feel or operation of the endoscope. Different types of endoscope handles can be changed to perform simulation practices of different types of endoscopes or endoscope-like surgical instruments, such as electrotomes of minimally invasive surgery and electric forceps. The turning angle sensor can measure the rotational angle of these instruments and transmit to the computer to perform analog.
[0015] The aforesaid sensors and damper means have data lines with signals thereof to be integrated and analyzed through a serial port, and transmitted to the computer through a standard interface to implement control and operation of the surgical simulation software easier.
[0016] Based on the endoscope simulation apparatus previously discussed, the invention further provides an endoscope simulation system which includes a computer, simulation software installed in the computer and an endoscope simulation apparatus. The computer and endoscope simulation apparatus are connected through a data line. As previously discussed, the endoscope simulation apparatus also includes a bracing rack, a spheroid and a controlling bar. The spheroid is held in the bracing rack and turnable freely. The controlling bar is slidable relative to the spheroid and installed in a passage running through the center of the spheroid to control rotation of the spheroid. The bracing rack has an inner side spaced from the spheroid to hold at least two direction sensors therebetween. The controlling bar has a depth sensor located thereon. The simulation software establishes a human body internal space database and a human body internal image database. The human body internal space database and human body internal image database are used to build a virtual human body internal structure in the computer.
[0017] When the damper means is installed between the bracing rack and the spheroid, or between the spheroid and the controlling bar, or between both of them, the human body internal space database also has a built-in damping database which records resistance coefficient of movement of the endoscope in the human body internal structure and impenetrable locations.
[0018] Based on the system set forth above, the invention also provides a simulation method comprising the following steps:
[0019] 1. Computer establishes a human body internal virtual model based on the human body internal space database built by the simulation software and incorporates with the human body internal image database to set up a human body internal virtual scene displayed through a computer display device;
[0020] 2. initialize the location of a virtual endoscope and display the location of the virtual endoscope in the virtual scene through the display device;
[0021] 3. turn the spheroid through the controlling bar or insert and withdraw the controlling bar, and the direction sensors or depth sensor sends data of rotational spatial angles and insertion/withdrawing depths through a data line to the computer;
[0022] 4. simulation software accumulates the data of the rotational spatial angles and insertion/withdrawing depths with the location of the virtual endoscope and displays the location of the virtual endoscope in the virtual scene after rotated through the display device; and
[0023] 5. the direction sensors, depth sensor, simulation software and computer repeat steps 3 and 4 at a constant frequency, and the display device continuously displays different locations of the virtual endoscope in the virtual scene to form continuous dynamic images.
[0024] The method further includes the following steps:
[0025] 6. the controlling bar is served as a shaft to turn the spheroid, and the direction sensors or turning angle sensor sends angular data of the rotation of the spheroid via the data line to the computer;
[0026] 7. the simulation software accumulates the angular data with the angle of the virtual endoscope, and displays the location of the virtual endoscope in the virtual scene after rotated through the display device; and
[0027] 8. the direction sensors, angle sensor, simulation software and computer repeat steps 7 and 8 at a constant frequency, and the display device continuously displays different angles of the virtual endoscope in the virtual scene to form continuous dynamic images.
[0028] When the endoscope simulation apparatus also is equipped with a feedback automatic adjustment damper means, additional steps are included as follow:
[0029] 9. the simulation software obtains rotation and insertion/withdrawing damping coefficients of the virtual endoscope from the damping database based on the location of the virtual endoscope in the virtual scene, and sends to the feedback automatic adjustment damper means; and
[0030] 10. the feedback automatic adjustment damper means automatically adjusts resistance of rotation and insertion/withdrawing of the spheroid and the controlling bar based on the damping coefficients.
[0031] The feedback automatic adjustment damper means can simulate resistance received by the endoscope moving and turning in a human body to provide a real hand-touch feel of using the endoscope.
[0032] The invention provides improved simulation, a simpler structure, rationalized design, higher stability, easy use, lower cost and can be fabricated in a mass production, and is suitable to teaching, learning and practice to simulate real situations to get surgical tactile feel. It even can be used for surgical rehearsal practice. The invention further is adaptable to endoscope-like equipment, thus provides diversified applications. Compared with the conventional techniques, the invention provides a higher level of reality simulation, and greater adaptability and usability, and offers a significant aid for surgeons to verse in skills. It provides a great improvement over the conventional techniques.
[0033] The foregoing, as well as additional objects, features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a schematic view of the structure of the first embodiment of the invention;
[0035] FIG. 2 is a longitudinal cross section of the main body according to FIG. 1 ;
[0036] FIG. 3A is a transverse cross section of the main body according to FIG. 1 ;
[0037] FIG. 3B is an enlarged view in FIG. 3A ;
[0038] FIG. 3C is an enlarged view in FIG. 3A ;
[0039] FIG. 3D is a schematic view of operation principle of sensors;
[0040] FIG. 3E is an enlarged view in FIG. 3A ;
[0041] FIG. 4 is a perspective view of the main body according to FIG. 1 ;
[0042] FIG. 5 is a schematic view according to FIG. 4 in a use condition;
[0043] FIG. 6 is a schematic view according to FIG. 4 in another use condition;
[0044] FIG. 7A is a longitudinal cross section of the main body of the second embodiment;
[0045] FIG. 7B is an enlarged view in FIG. 7A ;
[0046] FIG. 8 is a schematic view of the second embodiment showing the positional relationship between the rotational bracing deck and the spheroid;
[0047] FIG. 9A is a longitudinal cross section of the main body of the third embodiment;
[0048] FIG. 9B is an enlarged view in FIG. 9A ;
[0049] FIG. 10 is a schematic view of the structure of the forth embodiment;
[0050] FIG. 11 is a schematic view of the structure of the fifth embodiment;
[0051] FIG. 12 is a schematic view of the structure of an endoscope simulation system;
[0052] FIG. 13 is a flowchart of a simulation method for simulating movement of an endoscope;
[0053] FIG. 14 is a flowchart of the simulation method for simulating rotation of an endoscope; and
[0054] FIG. 15 is a flowchart of the simulation method for simulating endoscope damping.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
[0055] The endoscope simulation apparatus according to the invention, referring to FIG. 1 , includes a bracing rack 1 , a spheroid 2 and a controlling bar 3 . The spheroid 2 is turnable freely in the bracing rack 1 . The controlling bar 3 is slidable relative to the spheroid 2 and installed in a passage running through the center of the spheroid 2 as marked by an arrow in the drawing. The bracing rack 1 is an open type. The controlling bar 3 controls the spheroid 2 to rotate in the bracing rack 1 , and has one end fastened to a handle 4 to facilitate user grasping. The handle 4 is a simulated handle of an endoscope and has a button 41 located thereon. The handle 4 and the controlling bar 3 adopt a structure that can be assembled and disassembled easily so that different types of the handles 4 can be changed to simulate different types of endoscopes, or even other handles of surgical instruments to facilitate practice of other endoscope-like surgical equipment, such as electric shears of minimally invasive surgery, electric surgical scalpels and the like. The apparatus is connected to a computer through an electric cable 51 and a common interface 52 at a distal end thereof, such as USB. The computer has corresponding simulation software installed therein to show virtual human body internal structure to provide simulation practice for the endoscope.
[0056] Also referring to FIGS. 2 and 3A , there are three rotational bracing decks 6 located between an inner side of the bracing rack 1 and the spheroid 2 . The three rotational bracing decks 6 are located respectively on a plane running through the center of the spheroid 2 , and are spaced evenly from one another at 270 degrees on the inner side of the bracing rack 1 . Each rotational bracing deck 6 has rolling balls 61 on the top slidably incorporated with the spheroid 2 as shown in FIG. 3B . Such the rolling balls aims to enhance mobility of the spheroid 2 during sliding. There are two direction sensors 71 located between the inner side of the bracing rack 1 and the spheroid 2 , and there is a depth sensor 72 located between the interior of the spheroid 2 , passage and controlling bar 3 as shown in FIGS. 3C and 3E . The two direction sensors 71 aim to measure direction alterations of the spheroid 2 rotating relative to the bracing rack 1 . The depth sensor 72 aims to measure insertion and withdrawing depth of the controlling bar 3 in the passage of the spheroid 2 . The measured data of the aforesaid movements are recorded in the computer as parameter input of the simulation software to show movements of the endoscope in the virtual human body internal structure. Refer to FIG. 3D for operation principle of the sensors. In this embodiment, optical sensors are employed and they function as an optical mouse. The direction sensor 71 emits light to the surface of the spheroid 2 and receives the reflective light from the surface of the spheroid 2 through an optical sensor for data record and image comparison, thereby the rotational angle and distance of the spheroid 2 can be obtained.
[0057] Refer to FIGS. 4 , 5 and 6 for the invention in use conditions. Through the handle 4 (not shown in the drawings) at one end of the controlling bar 3 , the rotation of the spheroid 2 can be controlled in the bracing rack 1 . Because of the structure of the spheroid 2 and the arrangement and configuration of the rotational bracing decks, sufficient angles can be provided while simulating rotation of the endoscope to imitate real surgical equipment. Referring to FIG. 5 , the controlling bar 3 can be inserted and withdrawn in the spheroid 2 at a depth to meet insertion requirement of the endoscope during actual surgery. Referring to FIG. 6 , the controlling bar 3 can be formed in hexagon or polygons to drive the spheroid to turn clockwise or counterclockwise.
[0058] By means of the construction set forth above, the apparatus of the invention can provide improved simulation. The apparatus of the invention is simply structured, well designed, easier to use, lower cost, offers higher stability and can be fabricated in a mass production, thus is desirable for teaching, learning and practice.
Embodiment 2
[0059] Referring to FIG. 7A and also FIG. 1 , the endoscope simulation apparatus in this embodiment includes a bracing rack 1 , a spheroid 2 held in the bracing rack 1 and turnable freely, and a controlling bar 3 running through a passage formed in the middle of the spheroid 2 . The passage and controlling bar 3 are formed at a cross section of a regular hexagon. The bracing rack 1 in this embodiment is formed in a semi-closed structure which differs from the embodiment 1. The inner side of the bracing rack 1 and the spheroid 2 are interposed by four rotational bracing decks 6 spaced from one another in a regular tetrahedron. The gravity center of the regular tetrahedron is overlapped with the center of the spheroid 2 as shown in FIG. 8 . Such a structure greatly improves the stability of the apparatus, and also provides sufficient movement space for the controlling bar 3 . As the semi-closed structure is adopted, the front end of the passage of the spheroid 2 is sealed as shown in the drawings. The depth sensor 72 is an optical distance sensor installed at the front end of the passage opposing the front end of the controlling bar 3 . To enhance integration of the structure, the direction sensors 71 in the embodiment are installed at the top portions of the rotational bracing decks 6 as shown in FIG. 7B .
Embodiment 3
[0060] This embodiment is an improvement of the embodiment 2 previously discussed, with an extra manual damper means 81 abutting the rotational bracing deck 6 as shown in FIG. 9A . Since different portions in a human body form different resistance to the endoscope, users can adjust rotational resistance of the spheroid 2 based on usual practice experiences or skilled doctors based on their experiences to practice strength control during using the endoscope. In this embodiment, the manual damper means 81 includes a handle, bolt and a damper to adjust damping force through turning of the bolt against the bracing rack 1 as shown in FIG. 9B .
Embodiment 4
[0061] This embodiment is a further refinement formed by incorporating the advantages of the previous embodiments. It adopts a semi-closed bracing rack 1 and three rotational bracing racks 6 like the embodiment 1, with the depth sensor 72 held in the spheroid 2 between the passage and the controlling bar 3 . It also has two direction sensors 71 installed on the top portions of the rotational bracing decks 6 , and a passage and controlling bar 3 formed at a cross section of a regular hexagon like the embodiment 2. Such a structure provides sufficient simulation angular space to imitate rotation of the endoscope and desired stability. There is a feedback automatic adjustment damper means 82 installed on the third rotational bracing deck 6 that has a feedback automatic adjustment device driven electrically to receive control information sent by the computer to adjust rotation damping. There is another feedback automatic adjustment damper means 83 installed between the controlling bar 3 and the spheroid 2 on one side opposing the depth sensor 72 to receive control information from the computer to adjust insertion and withdrawing damping. The direction sensors 71 , depth sensor 72 , and feedback automatic adjustment damper means 82 and 83 have data lines integrated to connect to the computer through an USB interface 52 . Adopted the feedback automatic adjustment damper means provides the benefit of limiting the simulated rotation and insertion and withdrawing of the endoscope based on driving of the simulation software in the computer, thereby can achieve real simulation of moving the endoscope in a human body and encountered resistance. This provides great training aid to foster surgical tactile feel for doctors.
Embodiment 5
[0062] This embodiment is a further improvement based on the embodiment 4 previously discussed. It includes an additional manual damper means 81 like the embodiment 3, and a turning angle sensor 73 between the controlling bar 3 and the spheroid 2 . The passage and controlling bar 3 are formed at a circular cross section. The direction sensors 71 , depth sensor 72 , turning angle sensor 73 , and feedback automatic adjustment damper means 82 and 83 have data lines integrated to connect to the computer through an USB interface 52 . The turning angle sensor 73 can feed back turning angles of the controlling bar 3 during simulation process to the computer. It is applicable to simulation practice of some special endoscopes, or other surgical equipment, especially asymmetrical electric surgical scalpels and shears and the like.
[0063] As a conclusion, the structures provided by the invention are not limited to the embodiments set forth above. The apparatus of the invention is not limited to simulation of the endoscope as single surgical equipment. In practice, two identical simulators can integrate signals through a serial port and send them into the computer to drive the software to process as desired. In such a process two handles of the two simulators can be used cooperatively to practice operation of two hands in a coordinated manner. Other similar structures shall be covered by the scope of the invention.
[0064] Based on the endoscope simulation apparatus previously discussed, the invention further provides an endoscope simulation system as shown in FIG. 12 that includes a computer 9 , simulation software 10 installed in the computer 9 and an endoscope simulation apparatus. The computer and endoscope simulation apparatus are connected through a data line 51 . The simulation software 10 establishes a human body internal space database 101 and a human body internal image database 102 . The human body internal space database 101 has a built-in damping database 103 .
[0065] The endoscope simulation system is implemented according to a simulation method that includes the steps as follow, referring to FIG. 13 :
[0066] 1. the computer establishes a human body internal virtual model based on the human body internal space database of the simulation software and incorporates with the human body internal image database to set up a human body internal virtual scene displayed through a display device of the computer;
[0067] 2. initialize the location of a virtual endoscope and display the location of the virtual endoscope in the virtual scene through the display device;
[0068] 3. turn the spheroid through the controlling bar or insert and withdraw the controlling bar, and the direction sensors or depth sensor sends data of the rotational spatial angles and insertion/withdrawing depths through the data line to the computer;
[0069] 4. the simulation software accumulates the data of the rotational spatial angles and insertion/withdrawing depths with the location of the virtual endoscope and displays the location of the virtual endoscope in the virtual scene after moved through the display device; and
[0070] 5. the direction sensors, depth sensor, simulation software and computer repeat steps 3 and 4 at a constant frequency, and the display device continuously displays different locations of the virtual endoscope in the virtual scene to form continuous dynamic images.
[0071] The simulation method of turning the virtual endoscope is similar to the method of moving previously discussed, and includes the following steps, referring to FIG. 14 :
[0072] 6. the controlling bar is served as a shaft to turn the spheroid, and the direction sensors or turning angle sensor sends angular data of the rotation of the spheroid via the data line to the computer;
[0073] 7. the simulation software accumulates the angular data with the angle of the virtual endoscope, and displays the location of the virtual endoscope in the virtual scene after rotated through the display device; and
[0074] 8. the direction sensors, angle sensor, simulation software and computer repeat steps 7 and 8 at a constant frequency, and the display device continuously displays different angles of the virtual endoscope in the virtual scene to form continuous dynamic images.
[0075] When the endoscope simulation apparatus is equipped with a feedback automatic adjustment damper means and can perform damping simulation, the damping simulation includes additional steps as follow, referring to FIG. 15 :
[0076] 9. the simulation software obtains rotation and insertion/withdrawing damping coefficients of the virtual endoscope from the damping database based on the location of the virtual endoscope in the virtual scene, and sends to the feedback automatic adjustment damper means; and
[0077] 10. the feedback automatic adjustment damper means automatically adjusts resistance of rotation and insertion/withdrawing of the spheroid and the controlling bar based on the damping coefficients.
[0078] On locations where the virtual endoscope cannot pass through, such as bones and the like tissues in the human body, the damping coefficient is infinite, then the feedback automatic adjustment damper means brakes the spheroid or controlling bar without moving.
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An endoscope simulation apparatus aims to offer improved simulation, a simpler structure and can be fabricated at lower costs. The endoscope simulation apparatus comprises a bracing rack, a spheroid and a controlling bar. The spheroid is held in the bracing rack and turnable freely. The controlling bar is slidable relative to the spheroid in a passage running through the center of the spheroid to control rotation of the spheroid. The bracing rack has an inner side spaced from the spheroid to hold at least two direction sensors. The controlling bar has a depth sensor. The controlling bar is a simulated endoscope and also is insertable and retractable. The invention can be turned at a greater angle and provide improved simulation through the turnable spheroid. Through the direction sensors and depth sensor that are linked to a computer, the turning angle and insertion depth of the simulated endoscope can be measured.
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FIELD OF INVENTION
[0001] This invention concerns the technical field of treatment of cellulose containing material for the manufacturing of nanocellulose (microfibrillated cellulose). Also disclosed is nanocellulose manufactured in accordance with said method and uses of said cellulose.
BACKGROUND
[0002] In WO2005080678 a method for the modification of lignocellulosic materials is disclosed. Cellulose fibres are treated with an aqueous electrolyte-containing solution of an amphoteric cellulose derivative for at least 5 minutes at a temperature of at least 50° C. The pH during the treatment is approximately 1.5-4.5 or higher than 11; or the concentration of the electrolyte is approximately 0.0001-0.05 M if the electrolyte has monovalent cations, or approximately 0.0002-0.1 M if the electrolyte has divalent cations. Further said document relates to products obtained by the above mentioned method and uses of said products for manufacturing paper with a high wet strength.
[0003] However nothing is mentioned in the above document about manufacturing of nanocellulose or similar.
[0004] In Wågberg et al (2008) the reaction between chloroacetic acid and lignocellulose fibres is described as a pre-treatment to ease delamination in a homogenizer in order to create nanocellulose or microfibrillar cellulose. However, attachment of carboxymethylcellulose polymers to the lignocellulosic fibres is not described.
[0005] Through U.S. Pat. No. 4,341,807 further a method for manufacturing a microfibrillated cellulose or nanocellulose is disclosed by using homogenization. A problem when manufacturing nanocellulose from pulp is however the clogging of the homogenizer, when the pulp is pumped through high pressure fluidizers/homogenizers. Another problem is the excessive energy consumption during homogenization, unless the pulp before refining is subjected to some type of physiochemical pretreatment. Thus there is a need for a process wherein the clogging problem and the excessive energy consumption can be alleviated and/or avoided.
SUMMARY OF THE INVENTION
[0006] The present invention solves the above problem by providing according to a first aspect a method for providing a nanocellulose involving modifying cellulose fibers wherein the method comprises the following steps:
[0000] i) treating cellulose fibers for at least 5 minutes with an aqueous electrolyte-containing solution of an amphoteric carboxymethyl cellulose (amphoteric CMC) or a derivative thereof, preferably a low molecular amphoteric CMC or a CMC derivative thereof, whereby the temperature during the treatment is at least 50° C., and at least one of the following conditions apply:
A) the pH of the aqueous solution during the treatment lies in the interval of approximately 1.5-4.5, preferably in the region 2-4; or B) the pH of the aqueous solution during the treatment is higher than approximately 11; or C) the concentration of the electrolyte in the aqueous solution lies in the interval of approximately 0.0001-0.5 M, preferably approximately 0.001-0.4 M, if the electrolyte has monovalent cations (such as Na 2 SO 4 ), or in the range of approximately 0.0001-0.1 M, preferably approximately 0.0005-0.05 M, if the electrolyte has divalent cations (such as CaCl 2 ),
ii) adjusting the pH by using a basic and/or an acidic liquid into a pH range of from about 5 to about 13, preferably the pH is adjusted to a pH from about 6 to about 12, and
iii) treating said material in a mechanical comminution device, thus providing said nanocellulose.
[0010] This invention thereby involves attachment of amphoteric CMC polymers to lignocellulosic fibres as a pre-treatment before homogenization with the purpose of manufacturing nanocellulose. The attachment of amphoteric CMC polymers has proven to have several benefits, as outlined below.
[0011] The attachment of amphoteric CMC polymers decreases the energy consumption considerably and makes it possible to avoid clogging problems. Furthermore, it increases the anionic charge density of the fibres, which facilitates the delamination and, furthermore, enables delamination at much lower charge densities than if the charges would have been introduced by for instance any carboxymethylation reaction. Moreover, the CMC attachment process is aqueous based, which is beneficial since no other solvents than water is needed.
[0012] By using amphoteric CMC polymers, the attachment is easier and the attachment degree is increased as compared to anionic CMC.
[0013] Condition C is preferably combined with either of conditions A or B in step i), when applicable. The treated cellulose fibers may also after step i) be washed first with an acidic liquid and thereupon an essentially neutral liquid, preferably water.
[0014] The present invention also provides, according to a second aspect, a modified lignocellulosic material (nanocellulose) obtained by the method according to the first aspect. The attached amount of amphoteric CMC to lignocellulosic fibres is in the interval of from 5 to 250 milligram amphoteric CMC/gram dry fibre, preferably from 7 to 200 milligram amphoteric CMC/gram dry fibre and more preferably from 10 to 150 milligram amphoteric CMC/gram dry fibre. The attachment of amphoteric CMC as described herein advantageously enables an aqueous pre-treatment process for the manufacture of nanocellulose with less energy consumption and without the risk of clogging. This effect is attained by attachment of relatively small amounts of amphoteric CMC which results in lower charge densities than if a carboxymethylation reaction would have been used. Naturally, the anionic charge density of the amphoteric CMC used in the method influences the amount of CMC needed. CMC of high anionic charge density lowers the amount of CMC needed.
[0015] The present invention also provides according to a third aspect use of the lignocellulosic material (nanocellulose) of the second aspect in cosmetic products, pharmaceutical products, food products, paper products, composite materials, coatings, hygiene/absorbent products, films, emulsion/dispersing agents, drilling muds and to enhance the reactivity of cellulose in the manufacture of regenerated cellulose or cellulose derivatives or in rheology modifiers.
DETAILED DESCRIPTION OF THE INVENTION
[0016] It is intended throughout the present description that the expression “amphoteric cellulose derivative” embraces any cellulose derivative comprising simultaneously both cationic and anionic moieties. Further said amphoteric cellulose derivative is preferably an amphoteric cellulose derivative which still is net, negatively charged, but comprises a less amount of cationically active groups. Still further preferred said cellulose derivative is an amphoteric CMC (CMC=carboxymethyl cellulose) derivative, especially preferred is an amphoteric CMC derivative with a preferred anionic molar substitution degree between 0.3 and 1.2, i.e. D.S=0.3-1.2 and the viscosity may be approximately 25-8,000 mPa at a concentration of 4%.
[0017] This CMC derivative may further have been cationized in a, for the skilled person, well known manner to a substitution degree between 0.00001 and 1.0, preferably 0.00001 and 0.4. The cationization is preferably performed by the introduction of at least one ammonium function; most preferred a secondary, tertiary or quaternary ammonium function (or a mixture thereof) into the derivative.
[0018] It is intended throughout the present description that the expression “mechanical comminution device” means any device which may be suitable for providing a nanocellulose (a microfibrillated cellulose) as set out above, and said device may e.g. be a refiner, a fluidizer, a homogenizer or a microfluidizer.
[0019] According to a preferred embodiment of the first aspect of the present invention there is provided a method wherein said cellulose fibres (cellulose material) is present in the form of a pulp, which may be chemical pulp, mechanical pulp, thermomechanical pulp or chemi(thermo)mechanical pulp (CMP or CTMP). Said chemical pulp is preferably a sulphite pulp or a kraft pulp.
[0020] The pulp may consist of pulp from hardwood, softwood or both types. The pulp may e.g. contain a mixture of pine and spruce or a mixture of birch and spruce. The chemical pulps that may be used in the present invention include all types of chemical wood-based pulps, such as bleached, half-bleached and unbleached sulphite, kraft and soda pulps, and mixtures of these. The consistency of the pulp during manufacture of nanocellulose may be any consistency, ranging from low consistency through medium consistency to high consistency.
[0021] The preferred concentration of amphoteric cellulose derivative is approximately 0.02-4% w/w, calculated on the dry weight of the fiber material. A more preferred concentration is approximately 0.04-2% w/w, and the most preferred concentration of additive is approximately 0.08-1% w/w.
[0022] According to a preferred embodiment of the first aspect of the present invention there is provided a method wherein the cellulose fibres are treated for approximately 5-180 minutes; a preferred treatment (adsorption) period is approximately 10-120 min.
[0023] According to a preferred embodiment of the first aspect of the present invention there is provided a method wherein the temperature during the treatment is in excess of approximately 50° C., preferably at least approximately 100° C., and most preferred up to approximately 120° C. The method according to the invention may thus be carried out at a pressure in excess of atmospheric pressure. Suitable equipment and working conditions for this will be obvious for one skilled in the arts.
[0024] According to a preferred embodiment of the first aspect of the present invention there is provided a method wherein condition C applies together of either condition A or condition B in step i).
[0025] According to a preferred embodiment of the first aspect of the present invention there is provided a method wherein said cellulose fibers is contained in a pulp, preferably a sulphite pulp or a kraft pulp.
[0026] The preferred concentration of pulp is approximately 0.5-50%, a more preferred concentration interval is approximately 5-50%, and the most preferred concentration interval is approximately 10-30%. Such high concentration mixes are known to one skilled in the arts within the relevant technical field, and are suitable for use in association with the present invention.
[0027] Preferred features of each aspect of the invention are as for each of the other aspects mutatis mutandis. The prior art documents mentioned herein are incorporated to the fullest extent permitted by law. The invention is further described in the following examples in conjunction with the appended figures, which do not limit the scope of the invention in any way. Embodiments of the present invention are described in more detail with the aid of examples of embodiments and figures, the only purpose of which is to illustrate the invention and are in no way intended to limit its extent.
FIGURES
[0028] In the appended FIGS. 1-7 , resulting products after homogenisation are shown as set out in the examples part below. More specifically:
[0029] FIG. 1 shows Case C which gave rise to an MFC gel.
[0030] FIG. 2 shows Case D which gave rise to an MFC gel.
[0031] FIG. 3 shows Case E which gave rise to an MFC gel.
[0032] FIG. 4 shows Case F which gave rise to an MFC gel.
[0033] FIG. 5 shows Case H which gave rise to an MFC gel.
[0034] FIG. 6 shows Case K which did not give rise to an MFC gel.
[0035] FIG. 7 shows Case L which gave rise to an MFC gel.
EXAMPLES
Cases A-F
[0036] Pulp: Commercial never dried bleached sulphite pulp (Domsjö ECO Bright, Domsjö Fabriker)
Procedure:
[0000]
1. The never dried pulp was first dispersed in deionised water. Two litres of deionised water was added to 30 grams of pulp and was then dispersed with 10000 revolutions in a laboratory disintegrator in accordance to (ISO 5263-1:2004).
2. The pulp was then ion-exchanged into its hydrogen counter-ion form. Firstly, the HCl was added to the pulp to a concentration of 10 −2 M (pH is 2). The pH was held at 2 for 30 minutes. Then the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
3. The pulp was then ion-exchanged into its sodium counter-ion form. Firstly, the NaHCO 3 was added to the pulp to a concentration of 10 −3 M and NaOH was then added to reach a pH of 9. The pH was held at 9 for 30 minutes. Then the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
4. Amphoteric-CMC with an anionic degree of substitution of 0.64, cationic degree of substitution of 0.048 and an intrinsic viscosity of 2.0 was dissolved in deionised water.
5. The CMC-attachment was carried out in accordance to Laine et al. (Laine, J. et al. (2000) Nordic Pulp and Paper Research Journal 15(5), page 520-526). Conditions during attachment: pulp concentration=20 gram/litre; temperature=120° C.; treatment time=2 hours; CaCl 2 -concentration=0.05 M; water=deionised water. Different amounts of CMC was added for the different cases, A-F (Case A=0 mg CMC/g fibre, Case B=10 mg CMC/g fibre, Case C=20 mg CMC/g fibre, Case D=40 mg CMC/g fibre, Case E=80 mg CMC/g fibre, Case F=120 mg CMC/g fibre).
6. After the CMC-attachment treatment, the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
7. The pulp was then ion-exchanged into its sodium counter-ion form as described above in step 2 and 3.
8. The pulps (2% concentration in deionised water) were then homogenised with one pass through a Microfluidizer M-110EH (Microfluidics Corp.) at an operating pressure of 1750 bar. The chambers that were used had an inner diameter of 200 μm and 100 μm.
Cases G-H
[0045] Pulp: Commercial never dried bleached sulphite dissolving pulp (Domsjö Dissolving plus, Domsjö Fabriker)
Procedure:
[0000]
1. The never dried pulp was first dispersed in deionised water. Two litres of deionised water was added to 30 grams of pulp and was then dispersed with 10000 revolutions in a laboratory disintegrator in accordance to (ISO 5263-1:2004).
2. The pulp was then ion-exchanged into its hydrogen counter-ion form. Firstly, the HCl was added to the pulp to a concentration of 10 −2 M (pH is 2). The pH was held at 2 for 30 minutes. Then the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
3. The pulp was then ion-exchanged into its sodium counter-ion form. Firstly, the NaHCO 3 was added to the pulp to a concentration of 10 −3 M and NaOH was then added to reach a pH of 9. The pH was held at 9 for 30 minutes. Then the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
4. Amphoteric-CMC with an anionic degree of substitution of 0.64, cationic degree of substitution of 0.048 and an intrinsic viscosity of 2.0 was dissolved in deionised water.
5. The CMC-attachment was carried out in accordance to Laine et al. (Laine, J. et al. (2000) Nordic Pulp and Paper Research Journal 15(5), page 520-526). Conditions during attachment: pulp concentration=20 gram/litre; temperature=120° C.; treatment time=2 hours; CaCl 2 -concentration=0.05 M; water=deionised water. Different amounts of CMC was added for the different cases G-H (Case G=0 mg CMC/g fibre, Case H=80 mg CMC/g fibre).
6. After the CMC-attachment treatment, the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
7. The pulp was then ion-exchanged into its sodium counter-ion form as described above in step 2 and 3.
8. The pulps (2% concentration in deionised water) were then homogenised with one pass through a Microfluidizer M-110EH (Microfluidics Corp.) at an operating pressure of 1750 bar. The chambers that were used had an inner diameter of 200 μm and 100 μm.
Case I
[0054] Pulp: Commercial never dried bleached sulphite pulp (Domsjö ECO Bright, Domsjö Fabriker)
Procedure:
[0000]
1. The never dried pulp was first dispersed in deionised water. Two litres of deionised water was added to 30 grams of pulp and was then dispersed with 10000 revolutions in a laboratory disintegrator in accordance to (ISO 5263-1:2004).
2. The pulp was then ion-exchanged into its hydrogen counter-ion form. Firstly, the HCl was added to the pulp to a concentration of 10 −2 M (pH is 2). The pH was held at 2 for 30 minutes. Then the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
3. The pulp was then ion-exchanged into its sodium counter-ion form. Firstly, the NaHCO 3 was added to the pulp to a concentration of 10 −3 M and NaOH was then added to reach a pH of 9. The pH was held at 9 for 30 minutes. Then the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
4. Amphoteric-CMC with an anionic degree of substitution of 0.65, cationic degree of substitution of 0.048 and an intrinsic viscosity of 2.0 was dissolved in tap water.
5. The CMC-attachment was carried out in accordance to Laine et al. (Laine, J. et al. (2000) Nordic Pulp and Paper Research Journal 15(5), page 520-526). Conditions during attachment: pulp concentration=20 gram/litre; temperature=room temperature (around 20° C.); treatment time=2 hours; water=tap water; CMC addition=10 mg CMC/g fibre, no addition of extra electrolytes.
6. After the CMC-attachment treatment, the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
7. The pulp was then ion-exchanged into its sodium counter-ion form as described above in step 2 and 3.
8. The pulps (2% concentration in deionised water) were then homogenised with one pass through a Microfluidizer M-110EH (Microfluidics Corp.) at an operating pressure of 1700 bar. The chambers that were used had an inner diameter of 200 μm and 100 μm.
Case J
[0063] Pulp: Commercial never dried bleached sulphite pulp (Domsjö ECO Bright, Domsjö Fabriker)
Procedure:
[0000]
1. The never dried pulp was first dispersed in deionised water. Two litres of deionised water was added to 30 grams of pulp and was then dispersed with 10000 revolutions in a laboratory disintegrator in accordance to (ISO 5263-1:2004).
2. The pulp was then ion-exchanged into its hydrogen counter-ion form. Firstly, the HCl was added to the pulp to a concentration of 10 −2 M (pH is 2). The pH was held at 2 for 30 minutes. Then the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
3. The pulp was then ion-exchanged into its sodium counter-ion form. Firstly, the NaHCO 3 was added to the pulp to a concentration of 10 −3 M and NaOH was then added to reach a pH of 9. The pH was held at 9 for 30 minutes. Then the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
4. Anionic-CMC with an anionic degree of substitution of 0.57 and an intrinsic viscosity of 1.4 was dissolved in deionised water.
5. The CMC-attachment was carried out in accordance to Laine et al. (Laine, J. et al. (2000) Nordic Pulp and Paper Research Journal 15(5), page 520-526). Conditions during attachment: pulp concentration=20 gram/litre; temperature=120° C.; treatment time=2 hours; CaCl 2 -concentration=0.05 M; water=deionised water; CMC-dosage=80 mg CMC/g fibre.
6. After the CMC-attachment treatment, the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
7. The pulp was then ion-exchanged into its sodium counter-ion form as described above in step 2 and 3.
8. The pulps (2% concentration in deionised water) were then homogenised with one pass through a Microfluidizer M-110EH (Microfluidics Corp.) at an operating pressure of 1750 bar. The chambers that were used had an inner diameter of 200 μm and 100 μm.
Case K
[0072] Pulp: Commercial never dried bleached sulphite dissolving pulp (Domsjö Dissolving plus, Domsjö Fabriker)
Procedure:
[0000]
1. The never dried pulp was first dispersed in deionised water. Two litres of deionised water was added to 30 grams of pulp and was then dispersed with 10000 revolutions in a laboratory disintegrator in accordance to (ISO 5263-1:2004).
2. The pulp was then ion-exchanged into its hydrogen counter-ion form. Firstly, the HCl was added to the pulp to a concentration of 10 −2 M (pH is 2). The pH was held at 2 for 30 minutes. Then the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
3. The pulp was then ion-exchanged into its sodium counter-ion form. Firstly, the NaHCO 3 was added to the pulp to a concentration of 10 −3 M and NaOH was then added to reach a pH of 9. The pH was held at 9 for 30 minutes. Then the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
4. Anionic-CMC with an anionic degree of substitution of 0.57 and an intrinsic viscosity of 1.4 was dissolved in deionised water.
5. The CMC-attachment was carried out in accordance to Laine et al. (Laine, J. et al. (2000) Nordic Pulp and Paper Research Journal 15(5), page 520-526). Conditions during attachment: pulp concentration=20 gram/litre; temperature=120° C.; treatment time=2 hours; CaCl 2 -concentration=0.05 M; water=deionised water; CMC-dosage=80 mg CMC/g fibre.
6. After the CMC-attachment treatment, the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
7. The pulp was then ion-exchanged into its sodium counter-ion form as described above in step 2 and 3.
8. The pulps (2% concentration in deionised water) were then homogenised with one pass through a Microfluidizer M-110EH (Microfluidics Corp.) at an operating pressure of 1750 bar. The chambers that were used had an inner diameter of 200 μm and 100 μm.
Case L
[0081] Pulp: Commercial never dried bleached sulphite pulp (Domsjö ECO Bright, Domsjö Fabriker)
Procedure:
[0000]
1. The never dried pulp was first dispersed in deionised water. Two litres of deionised water was added to 30 grams of pulp and was then dispersed with 10000 revolutions in a laboratory disintegrator in accordance to (ISO 5263-1:2004).
2. The pulp was then ion-exchanged into its hydrogen counter-ion form. Firstly, the HCl was added to the pulp to a concentration of 10 −2 M (pH is 2). The pH was held at 2 for 30 minutes. Then the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
3. The pulp was then ion-exchanged into its sodium counter-ion form. Firstly, the NaHCO 3 was added to the pulp to a concentration of 10 −3 M and NaOH was then added to reach a pH of 9. The pH was held at 9 for 30 minutes. Then the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
4. Anionic-CMC with an anionic degree of substitution of 0.4 and an intrinsic viscosity of 15 was dissolved in deionised water.
5. The CMC-attachment was carried out in accordance to Laine et al. (Laine, J. et al. (2000) Nordic Pulp and Paper Research Journal 15(5), page 520-526). Conditions during attachment: pulp concentration=20 gram/litre; temperature=120° C.; treatment time=2 hours; CaCl 2 -concentration=0.05 M; water=deionised water; CMC-dosage=80 mg CMC/g fibre.
6. After the CMC-attachment treatment, the pulp was washed with deionised water on a büchner funnel until the conductivity of the filtrate was below 5 μS/cm.
7. The pulp was then ion-exchanged into its sodium counter-ion form as described above in step 2 and 3.
8. The pulps (2.6% concentration in deionised water) were then homogenised with one pass through a Microfluidizer M-110EH (Microfluidics Corp.) at an operating pressure of 1750 bar. The chambers that were used had an inner diameter of 200 μm and 100 μm.
Analysis
Conductometric Titration
[0090] The attached amount of anionic CMC on the fibres was determined by conductometric titration. The conductometric titration measures the total amounts of anionic groups, e.g. carboxyl acid groups, in the pulps. Prior to the titration, the pulp was washed to different counter-ion form as follows.
1. First the pulp was set to its hydrogen counter-ion form. A sample containing 2 g of dry pulp was dispersed in 1000 ml of deionised water and then 0.01 M HCl was added, fixing pH to 2. The excessive HCl was washed away after 30 minutes with deionised water on a büchner funnel until the conductivity was below 5 μS/cm. 2. Secondly, the pulp was set to its sodium counter-ion form. The pulp was dispersed in deionised water and then 0.001 M NaHCO 3 was added, pH was set to 9 using NaOH. After 30 more minutes the excessive NaOH and the NaHCO 3 were washed away with deionised water on a büchner funnel until the conductivity was below 5 μS/cm. 3. After this, the sample was once more set to its hydrogen counter ion form (see step 1) and washed to a conductivity below 5 μS/cm. 4. Finally, the total charge density of the pulps were determined with conductometric titration according to the procedure described by Katz et al. “The determination of strong and acidic groups in sulfite pulps”, svensk papperstidning no. 6/1984, page R48-R53.
[0095] The amount of attached CMC was evaluated by comparing the result from the anionic CMC pulps with the result from reference pulp, the amount of attached CMC could be determined.
Nitrogen Analysis
[0096] In order to evaluate the attached amount of amphoteric CMC, the nitrogen content in the pulps were measured. This was done since the amphoteric CMC's cationic groups contained nitrogen. The apparatus used was an Antek 7000 (Antek Instruments, Inc.) and the method was Pyro-chemiluminescence (combustion temperature=1050° C.). Before the actual measurements, a calibration curve was made with the amphoteric CMC in order to know how much nitrogen was present per mg CMC.
Intrinsic Viscosity of CMC
[0097] The intrinsic viscosity of the CMCs was measured in deionised water with 0.1 M NaCl at a temperature of 25° C.
Results
[0098]
[0000]
CMC
Added
Total
Attached
Results
Intrinsic
amount
Grafting/
charge
amount
in an
Anionic
Cationic
viscosity
of CMC
Temp.
density
of CMC
MFC
Case
Pulp
CMC
DS
DS
[dl/g]
[mg/g]
[° C.]
[μeq./g]
[mg/g]
Clogging
gel?
A
Sulphite
—
—
—
—
0
No
50.2
0
Yes
No
B
Sulphite
Amphoteric
0.65
0.048
2.0
10
Yes/120
60.9
10.7
Yes
No
C
Sulphite
Amphoteric
0.65
0.048
2.0
20
Yes/120
89.3
19.5
No
Yes
D
Sulphite
Amphoteric
0.65
0.048
2.0
40
Yes/120
124.7
40.5
No
Yes
E
Sulphite
Amphoteric
0.65
0.048
2.0
80
Yes/120
173.4
80.4
No
Yes
F
Sulphite
Amphoteric
0.65
0.048
2.0
120
Yes/120
231.3
113.4
No
Yes
G
Dissolving
—
—
—
—
0
No
30.3
0
Yes
No
H
Dissolving
Amphoteric
0.65
0.048
2.0
80
Yes/120
164.5
80.2
No
Yes
I
Sulphite
Amphoteric
0.65
0.048
2.0
10
Yes/20
50.9
0
Yes
No
J
Sulphite
Anionic
0.57
—
1.4
80
Yes/120
115.3
23.7
Yes
No
K
Dissolving
Anionic
0.57
—
1.4
80
Yes/120
107.8
28.2
No
No
L
Sulphite
Anionic
0.4
—
15
80
Yes/120
177.3
61.6
No
Yes
[0099] As can be seen in the table, it was not possible to homogenise the pulps without any CMC attachment due to clogging (Cases A and G). With the aid of amphoteric CMC it was possible to homogenise the pulp without clogging when the attachment level was above 23.6 mg/g (Cases C-F and H) and this resulted in an MFC gel. Lower attachment levels resulted in clogging (Case B). If the temperature during the CMC-attachment procedure was lowered to room temperature (Case I), no CMC was attached to the pulp and as a result it was not possible to homogenise due to clogging. In Cases J and K, anionic CMC was attached to the pulps. However, since the CMC was anionic the attachment level was lower and this made it impossible to make MFC. In Case J, sulphite pulp was used and this sample was possible to homogenise but did not result in a MFC gel. The dissolving pulp in Case K was not possible to homogenise due to clogging. All conditions in Case L, were the same as in Case J, but another anionic CMC was used instead. This CMC was easier to attach and as a result the attachment level was as high as 61.6 mg/g. Since the amount of CMC was higher it was possible to homogenise this sample and thereby produce an MFC gel. However, to reach this level three times more CMC was needed than if amphoteric CMC was used (compare with Case C). In the appended FIGS. 1-7 , the resulting products after homogenisation are shown.
[0100] Various embodiments of the present invention have been described above but a person skilled in the art realizes further minor alterations, which would fall into the scope of the present invention. The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. For example, any of the above-noted methods can be combined with other known methods. Other aspects, advantages and modifications within the scope of the invention will be apparent to those skilled in the art to which the invention pertains.
LIST OF DOCUMENTS APPEARING IN THE DESCRIPTION
[0000]
WO2005080678
U.S. Pat. No. 4,341,807
Laine et al. (Laine, J. et al. (2000) Nordic Pulp and Paper Research Journal 15(5), page 520-526) and
Katz et al. “The determination of strong and acidic groups in sulfite pulps”, svensk papperstidning no. 6/1984, page R48-R53.
Wågberg et al. “The Build-Up of Polyelectrolyte Multilayers of Microfibrillated Cellulose and Cationic Polyelectrolytes”. Langmuir (2008), 24(3), 784-795.
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A method for the manufacturing of nanocellulose. The method includes a first modification of the cellulose material, where the cellulose fibres are treated with an aqueous electrolyte-containing solution of an amphoteric cellulose derivative. The modification is followed by a mechanical treatment. By using this method for manufacturing nanocellulose, clogging of the mechanical apparatus is avoided. Also the nanocellulose is manufactured in accordance with the method and uses of the cellulose.
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RELATED APPLICATIONS
This application makes a claim of domestic priority to U.S. Provisional Patent Application No. 61/819,888 filed May 6, 2013, the contents of which are hereby incorporated by reference.
BACKGROUND
Clean service pressure relief valves provide overpressure relief in clean service (fluid) applications, such as the food service, dairy, pharmaceutical, medical, chemical and other industries. In such applications, the pressurized fluid is transported through a conduit network. Pressure relief valves may be disposed at appropriate locations in the network to allow a bypass path to be established in the event of an overpressure condition.
Clean service applications may be subjected to strict regulatory requirements to reduce the risk of contamination to the transported fluids. Such applications may require extensive cleaning and sanitizing operations after an overpressure condition has been experienced in the network.
SUMMARY
Various embodiments of the present disclosure are generally directed to an apparatus for forming a fluidic seal, such as in a clean service relief valve.
In accordance with some embodiments, a ring-shaped sealing member has an annular main body portion with an innermost surface at an innermost diameter, an outermost surface at an outermost diameter and opposing top and bottom flat surfaces which respectively extend between the innermost surface and the outermost surface. An annular first projection extends away from the top flat surface in a first direction, and an annular second projection extends away from the bottom flat surface in an opposing second direction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective representation of a clean service pressure relief valve constructed and operated in accordance with various embodiments of the present disclosure.
FIGS. 2A-2B provide cross-sectional representations of a clean service pressure relief valve in accordance with some embodiments. The valve is in a normally closed position in FIG. 2A , and in an open position in FIG. 2B .
FIG. 3 shows a top plan view of a sealing member of the valves of FIGS. 1-2 .
FIG. 4A is a cross-sectional representation of the sealing member along line 4 A- 4 A in FIG. 3 .
FIG. 4B is a cross-sectional representation of an alternative configuration for the sealing member of FIG. 3 .
FIG. 5 shows aspects of FIG. 2A in greater detail.
FIG. 6 is an exploded representation of components shown in FIG. 5 .
FIG. 7 generally depicts operation of a coupling mechanism of the valves of FIGS. 1-2 in accordance with some embodiments.
DETAILED DESCRIPTION
FIG. 1 is a perspective representation of a clean service pressure relief valve 100 in accordance with some embodiments. The valve 100 is provided to illustrate an exemplary environment in which various embodiments can be advantageously practiced.
The valve 100 is adapted to provide overpressure relief for a clean service application in which a clean fluid is transported through a conduit network (not separately shown). General features of the valve 100 includes a main body 102 , inlet port 104 , bypass path outlet port 106 , and a collapsible pin assembly 108 including a mechanically collapsible pin 110 , standoffs 112 , piston stops 114 , top support plate 115 and retention nut 116 .
The main body 102 is formed from separate lower, intermediate and upper housing members 118 , 120 and 122 . These respective members are secured together using upper and lower coupling rings 124 , 126 . The coupling rings are secured using respective fasteners 128 , 130 .
Within the main body 102 is a normally closed valve assembly (not separately shown in FIG. 1 ) that is in fluidic communication with the inlet port 104 . Inlet pressurized fluid at the inlet port 104 provides an upwardly directed force upon the valve assembly, which is retained in the normally closed position by the collapsible pin 110 .
At such time that the upwardly directed force exceeds a predetermined threshold, the pin 110 mechanically collapses in accordance with Euler's Law and the valve assembly moves to an open position. The valve assembly establishes an open bypass path to permit the fluid at the inlet port 104 to pass through the main body 102 and out the outlet port 106 . Although not shown, the outlet port 106 is adapted to be coupled to downstream conduit piping to divert the overpressurized fluid to a safe location, such as a storage tank, a drain, etc.
The three-piece construction of the housing main body 102 facilitates efficient disassembly and cleaning of the valve 100 prior to return of the valve to service after an overpressure event. Details regarding these and other features will be discussed below.
FIGS. 2A-2B depict another clean service pressure relief valve 200 generally similar to the valve 100 of FIG. 1 . FIG. 2A shows the valve 200 in the normally closed position, and FIG. 2B shows the valve 200 in an open position. As with the valve 100 of FIG. 1 , the valve 200 of FIG. 2 includes a main body 202 , inlet port 204 , bypass path outlet port 206 , and a collapsible pin assembly 208 including a mechanically collapsible pin 210 , standoffs 212 , piston stops 214 , top support plate 215 and retention nut 216 . It will be noted that, depending on spacing, there may be additional standoffs such as behind the pin 210 , but such has been omitted from FIGS. 2A-2B for clarity of illustration.
The main body 202 is formed from separate lower, intermediate and upper housing members 218 , 220 and 222 . These respective members are secured together using upper and lower coupling rings 224 , 226 . The coupling rings are secured using respective fasteners (not shown in FIGS. 2A-2B ). A cylindrical insert 228 is housed within the upper housing member 222 .
A reciprocal valve assembly 230 is disposed within the main body 202 . The valve assembly 230 includes a cylindrical piston member 232 attached to an upper plate 234 . The upper plate 234 engages a lower end of the collapsible pin 210 . The piston 232 is shown to have a cup-shaped configuration, but other configurations including a solid configuration can be used.
The piston member 230 has a cylindrical outer wall 236 that is contactingly engaged by upper and lower annular sealing members 238 , 240 . The upper sealing member 238 is compressingly disposed between the housing members 220 , 222 by the coupling ring 224 . The lower sealing member 240 is compressingly disposed between the housing members 218 , 220 by the coupling ring 226 .
As shown in the normally closed position of FIG. 2A , the lower sealing member 240 provides a fluid-tight seal against the outer wall 236 of the piston member 232 to isolate the inlet port 204 from the outlet port 206 while the valve 200 is in the normally closed position.
Once the pressure of the pressurized fluid at the inlet port 204 provides sufficient upwardly directed force upon a lower surface 242 of the piston member 230 , the pin 210 mechanically collapses and the valve assembly 230 moves upwardly to the open position depicted in FIG. 2B . More specifically, the pin 210 collapses into a captured, bent configuration as shown in FIG. 2B responsive to the upwardly directed force upon the surface 242 exceeding the yield limit of the pin 210 . The upwardly directed force is generally a function of the exposed surface area of the surface 242 and the pressure of the inlet fluid.
While a collapsible pin is shown, such is merely exemplary and not required. Other mechanisms can be used to maintain the valve 200 in the normally closed position and transition the valve to the open position, including but not limited to a spring mechanism, a rupture disc, etc. Moreover, while the valve is contemplated as constituting a normally closed valve, other configurations for a valve incorporating various aspects disclosed herein are also contemplated such as a normally open emergency shutdown valve, a flow regulating valve, etc.
The open position depicted in FIG. 2B establishes a bypass path for the pressurized fluid to pass from the inlet port 204 to the outlet port 206 . The valve assembly 230 is balanced so that the force upon the piston 232 from the inlet pressurized fluid at inlet port 204 will operate to open the valve irrespective of downstream pressure (if any) at the outlet port 206 . The upward movement of the valve assembly 230 is arrested by contacting engagement between the upper plate 234 and the piston stops 214 . The actual amount of movement can vary as required. The valve can be alternatively configured as a pressure differential valve so that the valve transitions to the open position in response to the pressure differential between the inlet and outlet ports 204 , 206 .
FIG. 3 shows the lower sealing member 240 from FIGS. 2A-2B in greater detail. The upper sealing member 238 may be nominally identical to the lower sealing member 240 , or may have different dimensions and/or shape characteristics. The sealing member 240 is formed of a suitable elastomeric material compatible with the clean service application and includes an annular body portion 244 with a substantially rectangular cross-section.
Upper and lower radiused projections 246 , 248 extend from the annular body portion 244 , as represented in FIG. 4A . The radiused projections 246 , 248 each have a half-circle hemispheric cross-sectional shape, although other shapes can be used. The upper and lower radiused projections 246 , 248 are axially aligned as shown. Axially aligned projections can help ensure proper alignment of the seal since it will not matter which side is up during installation.
An interior sidewall 250 of the sealing member 240 is configured to contactingly engage the outer cylindrical sidewall 236 of the piston 232 . An exterior sidewall 252 of the sealing member 240 may similarly engage an interior surface of the clamp ring 226 .
The respective distances from the inner sidewall 236 to the projections 246 , 248 is denoted in FIG. 4A as distance L 1 . The respective distances from the outer sidewall 252 to the projections 246 , 248 is denoted as distance L 2 . L 2 is shown to be nominally equal to L 1 (e.g., L 1 =L 2 ), but such is merely exemplary and not required; for example, the sealing member is alternatively shown in FIGS. 2A-2B such that L 1 >L 2 .
Similarly, the radius R 2 is shown in FIG. 4A to be nominally equal to R 1 (e.g. R 1 =R 2 ), but this is also merely exemplary and not required. For example, R 1 may be greater than or smaller than R 2 . Moreover, one side may have a first shape (e.g., circular as shown) and the other side may have a projection with some other shape (e.g., rectilinear, etc.). While the interior and exterior sidewalls 250 , 252 are shown to be flat, other shapes, such as radiused (circular) shapes, can be used as desired.
FIG. 4B illustrates an alternative sealing ring 240 A. The sealing ring 240 is similar to the ring 240 in FIG. 4A except that upper and lower projections 246 A, 248 A are axially offset. As noted above, it is contemplated that axially aligning the projections as in FIG. 4A will tend to allow the seal to be reversible, provided that the projections each share a common size and/or shape. An offset configuration as in FIG. 4B presents a seal that only fits “one-way,” which can be useful in applications where different sizes, shapes, diameters, etc. of the projections and/or the associated housing members are used.
It is contemplated that the sealing members 238 , 240 will be reusable, so that the sealing members can be reinstalled and reused in a given application after disassembly and cleaning operations have been performed. Alternatively, the seals can be configured as one-time use items so that after an overpressure event, the main housing components can be subjected to appropriate cleaning operations and new, sterile sealing members can be installed.
FIG. 5 depicts the lower sealing member 240 in its installed position. It can be seen that an inner distal end portion 254 of the sealing member 240 projects from the housing members 218 , 220 and into the interior of the main body 202 . The relative distance of projection of the end portion 254 may be sized in relation to the thickness of the sealing member 240 to ensure durability and sealing effectiveness. For example, it can be seen that the axial thickness of the sealing member 240 (vertical dimension) is greater than the length of the end portion 254 (horizontal dimension). Again, this is merely exemplary and not necessarily limiting.
FIG. 6 shows aspects of FIG. 5 in a partially exploded representation. The mating housing members, in this case the upper end of the lower housing member 218 and the lower end of the intermediate housing member 220 , are provided with flat seating surfaces 260 , 262 and associated annular grooves 264 , 266 . The flat seating surfaces 260 , 262 are configured to contactingly engage and seal against the main body portion 244 of the sealing member 240 . The grooves 264 , 266 are configured to contactingly receive the radiused projections 246 , 248 . Other shapes for both the seating surfaces and the grooves can be used, and the seal configuration can be conformed thereto as required.
FIG. 7 is a schematic representation of the clamping ring 226 from FIG. 5 . Generally, the clamping ring 226 includes two clamp segments 270 , 272 which are respectively rotatable via an intervening hinge 274 . Once the sealing member 240 is properly located between the respective housing members 218 , 220 (See FIGS. 5-6 ), the segments 270 , 272 are opened, slipped around the circumference of the sealing member 240 and closed so as to bring distal ends 276 , 278 into alignment.
A fastener such as 280 can thereafter be used to secure the distal ends 276 , 278 and apply a suitable compressive force upon the sealing member 240 by engaging internal threads 282 in the respective clamp segments 270 , 272 . The particular configurations of the clamp segments 270 , 272 , the distal ends 276 , 278 and the fastener 280 can vary as required. In some cases, a finger-operated fastener may be used as depicted in FIG. 1 . It is contemplated albeit not necessarily required that the clamp 226 contactingly engages the outermost surface (e.g., surface 252 ) of the sealing member 240 (and similarly for sealing member 238 ).
Accordingly, the exemplary clean service pressure relief valves 100 , 200 disclosed herein can operate in a sterile or other clean environment. The elastomer sealing members 238 , 240 provide a novel, efficient construction that provides improved sealing due to the increased surface area contact between the sealing member and the respective housing members. The additional surface area provided by projections 246 , 248 provides a tortuous path for the fluid to pass from one end of the sealing member to the other end. No o-ring type grooves are supplied to trap bacteria or contaminants.
The various housing and valve components can be formed of a suitable material such as 304 or 316 stainless steel. The valve can be downstream balanced and thus senses only upstream pressures, and downstream containment pressures will not change the set pressure at which the valve opens. It has been found that the disclosed valves can have an accurate setpoint of about +/−5% or less, and set pressures as low as about 2 pounds per square inch (psi) can be achieved.
The collapsible pin 110 , 210 provides accurate and consistent opening performance. The pin is external to the interior flow of the pressurized clean service fluid and therefore the valve does not need to be opened in order to change the pin. Installation of a new replacement pin can be accomplished in seconds.
Other benefits of the valve include a visual indication of open position (e.g., a bent pin as in FIG. 2B ). A fast opening time (usually within milliseconds) can be provided, and the valve is substantially unaffected by pulsating pressures or changes in ambient temperatures. Very precise set points can be established.
The radiused projections 246 , 248 on the sealing members 238 , 240 help to ensure proper alignment of the sealing member relative to the housing members, and vice versa, as well as to ensure centering of the sealing member with respect to the piston. This can be particularly useful in a clean service application where disassembly and reassembly of the valve may be required from time to time to meet regulatory requirements. It will be appreciated, however, that the various valve configurations can also be used in “non-clean” environments, due to the ease of disassembly. For example, valves can be easily disassembled and reassembled with different internal and/or external components to meet a variety of different operational environments.
It is contemplated that the seals may be reused after a disassembly and cleaning/sanitizing operation, or new seals may be provided for use each time. The seals facilitate precise overpressure control and subsequent maintenance operations to reset a triggered relief valve. The three-piece construction of the illustrative embodiments allows for quick disassembly, sterilization/sanitizing and reassembly.
While three-piece housings have been illustrated, any number of housing components can be used, including housings that use two mating housing components and a single intervening seal, housings with more than three housing components and additional seals, etc. In some cases, N housing components can be used with N−1 intervening sealing members of common or different configurations.
As used herein, the term “clean service” and the like will be understood consistent with the foregoing discussion to describe an operational environment with specified regulatory requirements concerning contaminant levels, such as but not limited to the food service, dairy, pharmaceutical, medical, chemical and other industries. While the transport of pressurized liquids has been contemplated, other forms of fluids such as gasses and mixtures of gas and liquid can be transported. Any number of operational temperatures are envisioned, including relatively cold (e.g., liquid nitrogen) and relatively hot (e.g., steam) applications are envisioned.
It is to be understood that even though numerous characteristics and advantages of various embodiments of the present disclosure have been set forth in the foregoing description, together with details of the structure and function of various embodiments, this detailed description is illustrative only, and changes may be made in detail, especially in matters of structure and arrangements of parts within the principles of the present disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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Apparatus for forming a fluidic seal such as in a clean service relief valve. In accordance with some embodiments, a ring-shaped sealing member has an annular main body portion with an innermost surface at an innermost diameter, an outermost surface at an outermost diameter and opposing top and bottom flat surfaces which respectively extend between the innermost surface and the outermost surface. An annular first projection extends away from the top flat surface in a first direction, and an annular second projection extends away from the bottom flat surface in an opposing second direction.
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RELATED APPLICATION
[0001] This application is related to and claims the benefit of priority from French Patent Application No. 05 52461, filed on Aug. 8, 2005, the entirety of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a composition for a material capable of withstanding extreme temperature conditions.
[0003] A particularly advantageous but non-exclusive application of the invention lies in the field of power and/or telecommunications cables that are to remain operational for a defined length of time when subjected to high temperatures and/or directly to flames.
BACKGROUND OF THE INVENTION
[0004] At present, one of the major concerns in the cable industry is improving the behavior and the performance of cables under extreme temperature conditions, particularly those encountered during a fire. Essentially for safety reasons it is necessary to maximize the ability of a cable both to retard flame propagation and also to resist fire. Any significant slowing down of flame propagation leads to a corresponding increase in time for evacuating premises and/or for using suitable fire-extinguisher means. Better resistance to fire makes it possible for a cable to operate for longer since it is damaged more slowly.
[0005] Regardless of whether a cable is electrical or optical, for transporting energy or for transmitting data, it can be said, in outline, to be constituted by at least one conductor element extending inside at least one insulator element. It should be observed that at least one of the insulator elements may also act as protection means and/or that the cable may also have at least one specific protection element constituting a sheath. Unfortunately, it is known that amongst the best insulating and/or protection materials used in cable making, many are also materials that are highly flammable. This applies in particular to polyolefins and copolymers thereof, such as, for example: polyethylene, polypropylene, copolymers of ethylene and vinyl acetate, and copolymers of ethylene and propylene. In any event, in practice, this excessive flammability is completely incompatible with requirements to withstand fire as mentioned above.
[0006] In the field of cable-making, there exist numerous methods of improving the fire behavior of polymers employed as insulating and/or sheathing materials.
[0007] The solution that has been most widely used until now consists in employing halogen compounds in the form of a halogenated by-product dispersed in a polymer matrix, or directly in the form of a halogenated polymer as with polyvinylchloride (PVC) for example. However present regulations are tending to ban future use of substances of that type, essentially because of their potential toxicity and corrosiveness, whether at the time the material is fabricated, or in the event of it being decomposed by fire. This is particularly true when the decomposition in question can occur accidentally during a fire, or also deliberately during incineration. In any event, the recycling of halogenated materials continues to be particularly problematic.
[0008] That is why recourse is being had more and more to fire-retardant fillers that are not halogenated, and in particular to metal hydroxides such as aluminum hydroxide or magnesium hydroxide. Nevertheless, that type of technical solution presents the drawback of requiring large quantities of filler in order to achieve a satisfactory level of effectiveness, whether in terms of ability to retard flame propagation or in terms of resistance to fire. By way of example, the metal hydroxide content may typically reach 100 to 150 parts by weight per 100 parts by weight of polymer resin.
[0009] Any massive incorporation of filler leads to a considerable increase in the viscosity of the composite material. This leads inevitably to a significant reduction in extrusion speed, and consequently to a significant drop in productivity. In the end, that has a negative impact on the cost of the composite material, which is already badly encumbered by the cost price of the non-halogenated fire-retardant filler which is intrinsically high, particularly since the filler needs to be used in large quantity.
[0010] However, independently of this purely economic aspect, the fire-withstanding performance of materials having non-halogenated fire-retardant fillers continue at present to be still insufficient for satisfying all of the conditions of fire tests.
[0011] Phyllosilicates are also known for being usable as non-halogenated fire-retardant fillers. Those inorganic compounds are remarkable in that they are capable of forming nanocomposites with the polymer matrices in which they are dispersed.
[0012] Nevertheless, that type of solution presents the drawback of being particularly expensive, essentially because of the cost of the unavoidable prior treatment that needs to be applied to each phyllosilicate in order to give it a characteristic that is sufficiently organophilic. Such composite materials also present mediocre electrical properties, viscosity that is penalizing for extrusion speeds, and an ability to withstand fire that is in any event always insufficient.
OBJECT AND SUMMARY OF THE INVENTION
[0013] Thus, the technical problem to be solved by the subject matter of the present invention is to propose a fire-resistant composition, in particular as a material for a power and/or a telecommunications cable, which composition makes it possible to avoid the problems of the prior art, while being inexpensive, and while providing significantly improved properties in terms of withstanding fire.
[0014] According to the present invention, the solution to the technical problem posed consists in that the composition comprises a polymer and aluminum oxide in the form of particles having a mean diameter that is less than one micrometer (μm).
[0015] The term aluminum oxide is used to mean non-hydrated alumina having the formula Al 2 O 3 .
[0016] In other words, the composition of the invention comprises a polymer matrix in which sub-micron alumina is dispersed to act as a fire-retardant filler.
[0017] It should be observed that the term “fire-resistant composition” is used herein very broadly to cover any composition that is for constituting a material capable of slowing down fire propagation and/or of resisting fire.
[0018] In any event, the mean size of the aluminum oxide particles constitutes the essential parameter of the invention in that the ability of the polymer material to withstand fire is directly associated with the grain size of the fire-retardant filler. A particularly pronounced fire-retardant effect is observed once the alumina used presents grain size that is very fine, and in particular when the particles making it up present a mean diameter that is less than one micrometer. It should also be observed that the smaller the size of the alumina oxide particles, the more the fire-retardant effect is remarkable.
[0019] The invention as defined in this way presents the advantage of being capable of providing a polymer material that benefits from improved ability to withstand fire and good mechanical properties, compared with corresponding prior art materials. Such a material is well suited for use in making sheaths for power and/or telecommunications cables. This applies equally well to an insulating covering and to a protective sheath or a layer of cable-filler or “padding” material.
[0020] In a presently preferred embodiment of the invention, the aluminum oxide is constituted by particles presenting a mean diameter that is less than 20 nanometers (nm).
[0021] In particularly advantageous manner, the composition comprises 1% to 80% by weight aluminum oxide, and preferably 2% to 20%.
[0022] According to a feature of the invention, the polymer is selected from a polyethylene, a polypropylene, a copolymer of ethylene and propylene (EPR), an ethylene-propylene-diene terpolymer (EPDM), a copolymer of ethylene and vinyl acetate (EVA), a copolymer of ethylene and methyl acrylate (EMA), a copolymer of ethylene and ethyl acrylate (EEA), a copolymer of ethylene and butyl acrylate (EBA), a copolymer of ethylene and octene, an ethylene-based polymer, a polypropylene-based polymer, an imide polyether, a thermoplastic polyurethane, a polyester, a polyamide, a halogenated polymer, or any mixture thereof.
[0023] According to another feature of the invention, the composition is also provided with at least one associated fire-retardant filler.
[0024] In particularly advantageous manner, each associated fire-retardant filler is selected from compounds containing phosphorous such as organic or inorganic phosphates, compounds containing antimony such as antimony oxide, metallic hydroxides such as aluminum hydroxide and magnesium hydroxide, compounds based on boron such as borates, carbonates of alkaline metals in groups IA and IIA such as the carbonates of calcium, sodium, potassium, or magnesium, and the corresponding hydroxide carbonates, compounds based on tin such as stannates and hydrostannates, melamine and its derivatives such as melamine phosphates, formophenolic resins, phyllosilicates such as sepiolite, attapulgite, montmorilonite, illite, chlorite, kaolinite, micas, and talcs.
[0025] Preferably, the composition includes 1% to 80% by weight of associated fire-retardant filler.
[0026] According to another feature of the invention, the composition is also provided with at least one additive selected from the group comprising lubricants, plasticizers, temperature stabilizers, pigments, antioxidants, and ultraviolet stabilizers.
[0027] The invention also provides any power and/or telecommunications cable having at least one insulating sheath made from a fire-resistant composition as described above. It should naturally be understood that each insulating sheath in question may also perform a protection and/or padding function.
[0028] The invention also provides any power and/or telecommunications cable provided with at least one protective sheath made from a fire-resistant composition as described above. It should be observed at this point that each protective sheath may also perform an insulating and/or padding function.
[0029] Finally, the invention provides any power and/or telecommunications cable provided with at least one padding layer made from a fire-resistant composition as described above. It should be observed that each layer of padding material may also perform an insulating and/or protective function.
[0030] It is important to specify that although such cables are for conveying power and/or transmitting data, they could equally well be electrical and/or optical, depending on whether the conductor elements with which they are provided are of the electrical and/or optical type.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Other characteristics and advantages of the present invention appear from the following comparative example, said example being given by way of non-limiting illustration.
COMPARATIVE EXAMPLE
[0032] Five samples of material were prepared using five different compositions in order to compare their respective performances in terms of withstanding fire. It is specified that the compositions in question were all suitable for being used for making insulating and/or sheathing and/or padding materials for energy and/or telecommunications cables.
[0033] In any event, the polymer was common to all five samples. Specifically it was a copolymer of ethylene and vinyl acetate (EVA). Only the nature and the composition of the mixture of fire-retardant fillers varied from one sample to another. Table 1 gives the differences.
TABLE 1 Sample number 1 2 3 4 5 EVA 28 40% 40% 40% 40% 40% Magnesium hydroxide 60% 50% 50% 50% 50% Treated montmorillonite — 10% — 5% 5% Aluminum oxide d50 = 13 nm — — 10% 5% — Aluminum oxide d50 = 0.5 μm — — — — 5%
Procedure
[0034] The compositions were prepared by mixing each fire-retardant filler with an identical quantity of polymer on each occasion, in order to avoid falsifying subsequent comparative analyses; the filler content of the resulting composite remained constant.
[0035] Whatever the precise nature of the composition prepared, the steps of mixing the polymer matrix with the fire-retardant filler were always the same:
temperature setpoint of 160° C. throughout the entire duration of mixing; introducing the polymer into the internal mixer set to rotate at 30 revolutions per minute (rpm); melting the synthetic polymer at 160° C. for 2 minutes (min) at 30 rpm; melting at 60 rpm for 2 min; introducing filler at 30 rpm; and mixing at 30 rpm for about 10 min.
Preparing Samples
[0042] Reference sample 1 was prepared specifically by mixing 100 grams (g) of ethylene and vinyl acetate (EVA) copolymer containing 28% vinyl acetate, a product sold under the trademark Evatane 28-03 by the supplier Arkema, with 150 g of magnesium hydroxide sold under the name Magnifin H10 by the supplier Albemarle. That operation was naturally performed in application of the above-described procedure. Sample 1 is illustrative of a conventional first system providing good ability to withstand fire.
[0043] The same applied for preparing reference sample 2, which specifically comprised a mixture of 100 g of ethylene and vinyl acetate (EVA) copolymer containing 28% vinyl acetate, 125 g of Magnifin H10 magnesium hydroxide, and 25 g of montmorillonite treated with an ammonium alkyl as sold under the name Nanofil by the supplier Sud Chemie. Sample 2 relates to a second system that is well known in the prior art, and that is described in particular in patent document EP 1 033 724.
[0044] Sample 3 comprised a mixture of 100 g of ethylene and vinyl acetate (EVA) copolymer containing 28% vinyl acetate, 125 g of Magnifin H10 magnesium hydroxide, and 25 g of aluminum oxide having a mean diameter d50=13 nm, as sold under the name Aeroxide Alu C by the supplier Degussa. Sample 3 served to evaluate the fire-withstanding performance of a material containing a conventional fire retardant, magnesium hydroxide, and aluminum oxide constituted by particles of very small size.
[0045] Samples 4 and 5 both comprised a mixture of 100 g of ethylene and vinyl acetate (EVA) copolymer containing 28% vinyl acetate, 125 g of Magnifin H10 magnesium hydroxide, and 12.5 g of montmorillonite treated with an ammonium alkyl, and respectively 12.5 g of aluminum oxide having a mean diameter of d50=13 nm, and 12.5 g of aluminum oxide having a mean diameter of d50=0.5 μm, sold under the name Nabalox NO713-10 by the supplier Nabaltec.
[0000] Withstanding Fire
[0046] Fire behavior was evaluated on each occasion using the “épiradiateur” test as specified in French standard NF-P-92-505. To do this the corresponding material needs to be shaped into square plates having a side of 7 centimeters (cm) and a thickness of 3 millimeters (mm). That operation was performed using a hot hydraulic press, in application of the following procedure:
melting at 150° C. for 3 min; applying pressure of 150 bar for 2 min, still at 150° C.; and cooling in water at 150 bar for 5 min.
[0050] Table 2 summarizes fire performance as determined using the “épiradiateur”. Each test had a duration of 5 min during which the time to flaming was evaluated, which time must be as long as possible, and the mean time to self-combustion was also evaluated, which time should be as short as possible.
TABLE 2 Mean time to Sample number Flaming time (s) self-combustion (s) 1 110 8.9 2 120 7.7 3 131 8.2 4 161 6.2 5 136 7.3
[0051] It can be seen firstly that reference sample 2 provides better performance than reference sample 1. The flaming time is longer by 10 seconds and the self-combustion time is shorter by more than one second.
[0052] Sample 3 may be compared to sample 2 since they both contain the same conventional fire-retardant filler at identical concentrations, associated with another filler for improving performance in terms of withstanding fire. It can be seen that the time to flaming for sample 3 is longer by more than 11 seconds compared with sample 2. The use of sub-micron aluminum oxide thus achieves a considerable improvement in time to flaming without significantly affecting the self-combustion time.
[0053] The association of sub-micron aluminum oxide with treated montmorillonite and with magnesium hydroxide enables even better performance to be achieved. Samples 4 and 5 show that the time of flaming can be lengthened by 5 seconds to by as many as 30 seconds, while also significantly shortening the self-combustion time, compared with samples 2 and 3.
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The present invention relates to a fire-resistance composition in particular as a material for a power and/or telecommunications cable. The invention is remarkable in that the composition comprises a polymer together with aluminum oxide in the form of particles having a mean diameter of less than one micrometer.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 08/450,593 filed May 25, 1995, now U.S. Pat. No. 5,591,702.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to compositions and processes for removing organic coatings, particularly paints and the like, from metal surfaces bearing such organic coatings, especially when the metal surfaces have been conversion coated, as with phosphate or chromate coatings, before being given an organic coating. Compositions that are effective in removing organic coatings in this way are often called "stripping compositions" or simply "strippers" and may be so denoted hereinafter. The compositions are at least partially aqueous and alkaline but also contain organic solvents, which may or may not be completely soluble in the aqueous part of the compositions. Additional details may be found in U.S. Pat. No. 3,308,066 of Mar. 7, 1967 to Murphy et al., the entire disclosure of which, except to the extent that it may be inconsistent with any explicit statement herein, is hereby incorporated herein by reference.
More particularly, this invention is concerned with compositions which include at least two chemically distinct types of organic solvents that act synergistically to achieve more rapid stripping than would be expected from the weighted average of stripping times of their individual components. In some of its embodiments, this invention is concerned with alkaline stripping compositions that eliminate or at least substantially reduce the potential for air pollution by excluding or substantially reducing any content of organic solvents recognized as significant contributors to air pollution when evaporated into the air, for example, any solvents listed as Hazardous Air Pollutants under the U.S. Clean Air Act.
2. Discussion of Related Art
Previously known alkaline stripping compositions are diverse, but the most effective previously known ones generally include ethylene glycol, one of the materials often known as "poly- or oligo-!ethylene glycols" because the molecules thereof can be at least formally derived from two or more molecules of ethylene glycol by loss of one water molecule between each pair of ethylene glycol molecules to form an ether bond between the two molecules that replaces the --OH group formerly present in each molecule, and/or monoethers of ethylene glycol and/or its oligomers as defined above. Most if not all such materials have been implicated as significant sources of air pollution and are likely to be legally banned or severely restricted in use in the United States within the next few years.
DESCRIPTION OF THE INVENTION
Objects of the Invention
One major object of the invention is to provide compositions and processes that avoid using significant sources of air pollution while achieving adequate stripping capability compared with the established strippers using derivatives of ethylene glycol as noted above. Another alternative or concurrent object is to provide compositions containing at least two chemically distinct types of organic solvents that are more effective in stripping together than alone.
General Principles of Description
Except in the claims and the operating examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material or conditions of reaction and/or use are to be understood as modified by the word "about" in describing the broadest scope of the invention. Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary: percent, fraction of, "parts of", and ratio values are by weight; the term "polymer" includes "oligomer", "copolymer", "terpolymer", and the like; the description of a group or class of materials as suitable or preferred for a given purpose in connection with the invention implies that mixtures of any two or more of the members of the group or class are equally suitable or preferred; description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description, and does not necessarily preclude chemical interactions among the constituents of a mixture once mixed; specification of materials in ionic form implies the presence of sufficient counterions to produce electrical neutrality for the composition as a whole (any counterions thus implicitly specified should preferably be selected from among other constituents explicitly specified in ionic form, to the extent possible; otherwise such counterions may be freely selected, except for avoiding counterions that act adversely to the stated objects of the invention); and the term "mole" and its variations may be applied to elemental, ionic, and any other chemical species defined by number and type of atoms present, as well as to compounds with well defined molecules.
SUMMARY OF THE INVENTION
Compositions according to the invention may be working compositions suitable for direct use in stripping processes or concentrates, which contain some or all of the active ingredients of working compositions and are suitable for preparing working compositions thereof by dilution with water and/or mixing with other concentrates. Working compositions according to the invention comprise, preferably consist essentially of, or more preferably consist of, water and the following components:
(A) at least one dissolved alkali or alkaline earth metal hydroxide;
(B) at least one compound that is liquid at 25° C. under normal atmospheric pressure and is selected from the group consisting of monoethers of (i) ethylene glycol, (ii) propylene glycol, (iii) butylene glycol, and (iv) "oligomers" as defined above of ethylene glycol, propylene glycol, and butylene glycol; and
(C) at least one compound that is liquid at 25° C. under normal atmospheric pressure and is selected from the group consisting of (i) ethylene glycol, (ii) propylene glycol, (iii) butylene glycol, (iv) "oligomers" as defined above of ethylene glycol, propylene glycol, and butylene glycol, and (v) mono-, di-, and tri-alkanol amines; and, optionally, one or more of the following components:
(D) a component selected from the group consisting of gluconic acid, water soluble and water dispersible salts of gluconic acid, heptogluconic acid and its water soluble and water dispersible salts, and glucono-delta-lactone;
(E) surfactant (alternatively described as "wetting agent"); and
(F) alkaline salts exclusive of alkali metal and alkaline earth metal hydroxides.
Processes of utilizing working compositions according to the invention as defined above for stripping paint and like materials from metal surfaces are another embodiment of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
It is normally preferred that compositions according to the invention as defined above should be substantially free from various ingredients. Specifically, it is increasingly preferred in the order given, independently for each preferably minimized component listed below, that primary compositions according to the invention, when directly contacted with coatings on metal in a process according to this invention, contain no more than 10, 5, 3, 2.0,1.0, 0.35, 0.10, 0.08, 0.04, 0.02, 0.01, 0.001, or 0.0002 percent of any of (i) hydrocarbons; (ii) any other compounds identified as carcinogenic; and (iii) any compound other than water that is not a hydrocarbon with a vapor pressure at 100° C. that exceeds, with increasing preference in the order given, 500, 300, 200, 100, 70, 50, 30, 15, 10, 7, 5, 3, 1.5, or 0.7 millibars.
The alkali metal or alkaline earth metal hydroxide component (A) according to the invention preferably is selected from sodium and potassium hydroxide for a combination of economic and technical reasons. Sodium hydroxide is generally the least expensive among all the suitable hydroxides, and would normally be favored for that reason. However, potassium cations are compatible with larger concentrations of organic solvents in an aqueous phase than are sodium cations, and potassium hydroxide is not prohibitively expensive, so that when speed of stripping is more important than minimum cost of the stripping compositions, potassium is preferred because it can be used in higher concentrations that favor faster stripping. Lithium and alkaline earth cations are even less compatible with organic cosolutes than sodium and usually are not preferred for that reason, although workable at low concentrations. Rubidium and cesium hydroxides are expected to be highly effective in compositions according to the invention but are too expensive for ordinary use.
The concentration of component (A) in a working composition according to the invention may vary over quite wide limits. Generally, faster stripping will be achieved with higher concentrations of component (A), with all other factors equal. Thus, concentrations up to the solubility limit of the particular hydroxide used could be workable in various circumstances. However, very high concentrations of hydroxides may reduce the solubility of components (B) and (C) in the aqueous phase so much that stripping will actually be impeded. Generally, the concentration of component (A) preferably is, with increasing preference in the order given, at least 0.1, 0.3, 0.5, or 0.8 gram moles per kilogram (hereinafter usually abbreviated "M/kg"), and for removing difficult paints or similar coatings on alkali resistant metal surfaces still more preferably is, with increasing preference in the order given, at least 1.1, 1.4, 1.7, 2.0, 2.2, 2.4, 2.6, 2.7, 2.8, 2.9, or 3.0 M/kg of total working composition. Independently, in most circumstances the concentration of component (A) in a working composition according to the invention preferably is, with increasing preference in the order given, not more than 10, 8, 6, or 5 M/kg of total working composition and for one preferred embodiment still more preferably is not more than 4.5, 4.1, 3.8, 3.6, 3.5, 3.3, 3.2, or 3.1 M/kg of total working composition.
The total of components (B) and (C) in working compositions according to this invention preferably is, with increasing preference in the order given, at least 1, 3, 5, 7, 9, 10, 11, 12, 13, 14, or 15.0 percent and independently preferably is, with increasing preference in the order given, less than or equal to 50, 40, 30, 25, 22, 20, 19, 18, 17, 16.0, or 15.5 percent.
The glycol unit residues in components (B) and (C) as described above preferably are those of ethylene or propylene glycol. Propylene glycols and oligomers thereof with either or both of 1,2- or 1,3-propanediol structure or residues therefrom may be used, but molecules with the 1,2 substituted structure are usually preferred because they are usually less expensive. Independently, the molecules of component (B) preferably: either contain at least two glycol residues each or contain one glycol residue and a total of at least 5 carbon and oxygen atoms in their etherifying moiety; independently preferably contain, with increasing preference in the order given, at least 4, 5, 6, or 7 carbon atoms each, and independently preferably contain, with increasing preference in the order given, not more than 14, 12, 11, or 10 carbon atoms each. The glycols, glycol residues, and/or etherifying moieties in the molecules of components (B) and (C) may be straight or branched aliphatic, cycloaliphatic, aromatic, or heterocyclic and may include unsaturation and substituent groups such as ether groups and halogens that do not substantially dish paint stripping ability. Normally, however, primarily for reasons of economy, unsubstituted aliphatic glycols, glycol ethers, and etherifying moieties are preferred.
An important characteristic of many preferred embodiments of the invention is the existence of a synergistic effect, as defined below, between components (B) and (C). A synergistic effect for the purposes of this description is defined to exist whenever a composition according to this invention is found to strip paint more rapidly than would be expected from the weighted average of the stripping times of comparison compositions in which only component (B) or component (C) alone is used, with other constituents and physical conditions being kept constant. In mathematical terms, if (i) component (B) is present in the composition in a fraction "b" parts by weight of the total "t" pans by weight of components (B) and (C), (ii) the stripping time for a constant type and thickness of organic coating to be stripped from a constant metal substrate at a constant temperature by a composition containing t parts of component (B) and no component (C) is denoted as "S b " and the stripping time under the same conditions, except for using a composition containing t parts of component (C) and no component (B) is denoted as "S c ", then the weighted average expected stripping time, "W", for the composition containing both components (B) and (C) is defined as follows:
W=b·S.sub.b +(1-b)·S.sub.c.
The "percent synergy" of the actual stripping time "S.sub.(b+c) " is defined to equal 100(W-S b+c )))W!. If this value is negative, the percentage is defined to represent "anti-synergy", because the mixture strips more slowly than would be expected from its individual constituents. Compositions according to this invention that have types and amounts of components (B) and (C) that have a positive percent synergy for stripping at least one type of organic coating from metal under at least one set of physical conditions are preferred embodiments of this invention, with compositions including combinations with higher positive percent synergy values increasingly more preferred.
Several specific preferred combinations for components (B) and (C) have been discovered for specific examples of components (B) and (C) identified by the following abbreviations: DEGMPE=diethylene glycol monopropyI ether; PG=propylene glycol; DPG=dipropylene glycol; TPG=tripropylene glycol; MEA=monoethanolamine; DEGMnBE=diethylene glycol monon-butyl ether; TEGMME=triethylene glycol monomethyl ether; TEGMEE=triethylene glycol monoethyl ether; TEGMnBE=triethylene glycol monon-butyl ether; DPGMPE=dipropylene glycol monopropyl ether; DPGMnBE=dipropylene glycol monon-butyl ether; TPGMnBE=tripropylene glycol monon-butyl ether; DPGMtBE=dipropylene glycol monot-butyl ether; EGMFE=ethylene glycol monofurfuryl ether; DEGMHE=diethylene glycol monohexyl ether; TPGMME=tripropylene glycol monomethyl ether; DPGMME=dipropylene glycol monomethyl ether. Some preferred combinations are:
EGMFE and TPG, with a fraction of TPG that preferably is at least, with increasing preference in the order given, 0.40, 0.50, 0.60, 0.70, or 0.80 and independently preferably is, with increasing preference in the order given, less than or equal to 0.95.0.90, 0.85, or 0.81;
DEGMPE and MEA, with a fraction of MEA that preferably is at least, with increasing preference in the order given, 0.10, 0.20, 0.30, 0.40, 0.50, or 0.55 and that independently preferably is less than or equal to, with increasing preference in the order given, 0.90, 0.80, 0.70, or 0.65;
DEGMPE and PG, with a fraction of PG that preferably is, with increasing preference in the order given, at least 0.50, 0.55, or 0.59 and independently preferably is, with increasing preference in the order given, less than or equal to, with increasing preference in the order given, 0.75, 0.65, or 0.61;
DEGMPE and DPG, with a fraction of DPG that preferably is, with increasing preference in the order given, at least 0.10, 0.19, and 0.39 and independently preferably is, with increasing preference in the order given, less than or equal to 0.90, 0.85, or 0.81;
TEGMME and MEA, with a fraction of MEA that preferably is, with increasing preference in the order given, at least 0.40, 0.45, 0.50, 0.55, or 0.60 and independently preferably is, with increasing preference in the order given, less than or equal to 0.80, 0.70, 0.65, or 0.61;
TEGMME and PG, with a fraction of PG that preferably is, with increasing preference in the order given, at least 0.15, 0.20, 0.30, or 0.39 and independently preferably is, with increasing preference in the order given, less than or equal to 0.80, 0.70, 0.65, or 0.60;
TEGMME and DPG, with a fraction of DPG that preferably is, with increasing preference in the order given, at least 0.35, 0.55, or 0.60 and independently preferably is, with increasing preference in the order given, less than or equal to 0.95, 0.90, 0.85, or 0.81;
DPGMME and PC, with a fraction of DPG that preferably is at least, with increasing preference in the order given, 0.05, 0.10, 0.15, or 0.20 and independently preferably is less than or equal to, with increasing preference in the order given, 0.90, 0.85, or 0.81 and in more weakly alkaline solutions still more preferably is, with increasing preference in the order given, less than or equal to 0.55, 0.41, 0.35, 0.30, 0.25, or 0.21;
DPGMME and DPG, with a fraction of DPG that preferably is, with increasing preference in the order given, at least 0.10, 0.15, or 0.20 and for removing paint less than or equal to 50 microns thick more preferably is, with increasing preference in the order given, less than or equal to 0.30, 0.40, 0.50, 0.60, 0.70, or 0.79 and independently preferably is, with increasing preference in the order given, less than or equal to 0.90, 0.85, or 0.81;
DPGMME and TPG, with a fraction of TPG that preferably is, with increasing preference in the order given, at least 0.25, 0.35, or 0.40 and in relatively weakly alkaline compositions at least 0.55 or 0.60 and independently preferably is, with increasing preference in the order given, less than or equal to 0.90, 0.85, or 0.81;
DEGMnBE and MEA, with a fraction of MEA that preferably is, with increasing preference in the order given, at least 0.15, 0.20, or 0.58 and independently preferably is, with increasing preference in the order given, less than or equal to 0.90, 0.85, 0.80, 0.70, or 0.61;
DEGMnBE and PC, with a fraction of PC that preferably is, with increasing preference in the order given, at least 0.20, 0.30, 0.35, or 0.40 and independently preferably is, with increasing preference in the order given, less than or equal to 0.90, 0.80, 0.70, or 0.62;
DEGMnBE and DPG, with a fraction of DPG that preferably is, with increasing preference in the order given, at least 0.50, 0.55, or 0.60 and independently preferably is, with increasing preference in the order given, less than or equal to 0.95, 0.90, 0.85, or 0.81;
TEGMEE and MEA, with a fraction of MEA that preferably is, with increasing preference in the order given, at least 0.12, 0.18, or 0.38 and independently preferably is, with increasing preference in the order given, less than or equal to 0.80, 0.60, 0.55, 0.50, 0.45, or 0.41;
TEGMEE and PC, with a fraction of PG that preferably either (i) is at least, with increasing preference in the order given, 0.10, 0.15, or 0.20 and independently preferably is, with increasing preference in the order given, not more than 0.45, 0.40, 0.35, 0.30, or 0.25 or (ii) is at least, with increasing preference in the order given, 0.50, 0.55, or 0.60 and independently preferably is, with increasing preference in the order given, less than or equal to 0.90, 0.85, 0.80, 0.75, 0.70, or 0.65;
TEGMEE and DPG, with a fraction of DPG that preferably is, with increasing preference in the order given, at least 0.10, 0.15, or 0.20 and independently preferably is, with increasing preference in the order given, less than or equal to 0.95, 0.90, 0.85, 0.80, 0.75, 0.70, 0.65, or 0.61;
TEGMEE and TPG, with a fraction of TPG that preferably is, with increasing preference in the order given, at least 0.10, 0.15, 0.18, or 0.19 and independently preferably is, with increasing preference in the order given, less than or equal to 0.90, 0.85, 0.81, 0.71, 0.55, 0.40, or 0.21;
DEGMHE and DPG, with a fraction of DPG that preferably is, with increasing preference in the order given, at least 0.20, 0.30, 0.35, or 0.39 and independently preferably is, with increasing preference in the order given, less than or equal to 0.81, 0.61, 0.50, 0.46, or 0.41;
TEGMnBE and MEA, with a fraction of MEA that preferably is, with increasing preference in the order given, at least 0.45, 0.50, 0.55, or 0.59 and independently preferably is, with increasing preference in the order given, less than or equal to 0.90, 0.81, 0.71, 0.66, or 0.61;
TEGMnBE and PG, with a fraction of PG that preferably is, with increasing preference in the order given, at least 0.45, 0.50, 0.55, or 0.59 and independently preferably is, with increasing preference in the order given, less than or equal to 0.90, 0.85, or 0.81;
TEGMnBE and DPG, with a fraction of DPG that preferably is, with increasing preference in the order given, at least 0.10, 0.15, 0.20, 0.30, or 0.40 and independently preferably is, with increasing preference in the order given, less than or equal to 0.81, 0.70, or 0.61;
TPGMME and DPG, with a fraction of DPG that preferably is, with increasing preference in the order given, at least 0.20, 0.40, 0.50, 0.60, 0.70, or 0.80 and independently preferably is, with increasing preference in the order given, less than or equal to 0.95, 0.90, 0.85, or 0.81; and
TPGMME and TPG, preferably with a fraction of TPG that is, with increasing preference in the order given, at least 0.50, 0.60, 0.70, or 0.80 and independently preferably is, with increasing preference in the order given, less than or equal to 0.95, 0.90, 0.85, or 0.81.
The above-noted preferred combinations of components (B) and (C) preferably are used as such, and not in mixtures among themselves. These preferred combinations may be formulated as concentrates according to the invention, in compositions containing no other essential ingredients, suitable for adding to any of the well established alkaline stripping agents for paint and the like. These combinations, with the same relative proportions among components (B) and (C), may also advantageously be used in complete concentrates, also containing water and component (A), which are suitable for use as working compositions after dilution with water only, or in working compositions according to the invention and processes of stripping coatings from metals therewith.
When both of components (B) and (C) contain at least six carbon atoms per molecule, there may be phase separation problems in complete concentrates if only the most preferred constituents as outlined above are used in the complete concentrates. If such phase separation problems are encountered, they may often be overcome by adding a third component, usually ethylene glycol or propylene glycol. For example, when the above noted preferred combination of TPGMME for component (B) and DPG for component (B) is used, a ratio of dipropylene glycol to propylene glycol in a working composition that preferably is, with increasing preference in the order given, not less than or equal to 1.0, 1.5, 2.0, 2.3, 2.6, 2.8, 2.9, 3.0, 3.1, or 3.15 and independently preferably is, with increasing preference in the order given, not more than 50, 25, 15, 10, 7.5, 5.0, 4.5, 4.2, 3.9, 3.7, 3.6, 3.5, 3.4, 3.3, or 3.25 has been found to yield exceptionally favorable results in a preferred complete concentrate according to the invention that contains potassium hydroxide as component (A).
Optional component (D) is believed to have at least two possibly favorable effects on working compositions according to the invention: mutual solubilization of hydroxide and the organic components and an ability to attack phosphate conversion coatings which often underlie the paint or similar coating to be stripped and thereby to speed the stripping process by undermining the bond between the paint film to be removed and the underlying metal. It is accordingly preferred in most such working compositions that the concentration of component (D) in a working composition according to this invention is, with increasing preference in the order given, not less than or equal to 0.01, 0.03, 0.05, 0.07, 0.09, 0.11, 0.13, 0.15, 0.16, 0.17, 0.18, 0.19, or 0.20 M/kg of total composition and independently preferably is, with increasing preference in the order given, not more than 2.0, 1.5, 1.0, 0.8, 0.6, 0.50, 0.45, 0.40, 0.37, 0.34, 0.31, 0.29, 0.27, 0.25, 0.24, 0.23, 0.22, or 0.21 M/kg of total composition. The most preferred chemical compound for use in preparing compositions according to the invention to provide component (D) is gluconic acid, although it is expected to be present in salt form in the highly alkaline working compositions.
Component (E) of surfactant or wetting agent is not generally needed, but may be useful in some cases for removing coatings that have an extraordinarily hydrophobic surface. Component (F) of alkaline salts other than hydroxides also is generally not needed, but may be advantageous in cases where the amount of component (A) is lower than is normally preferred, in order to protect the underlying metal surface from alkaline attack.
Speed of stripping is normally substantially increased at higher temperatures. Therefore, it is normally preferred that the temperature of working compositions when in actual contact with coatings to be stripped be maintained at a temperature of at least, with increasing preference in the order given, 75, 80, 85, 90, 92, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, or 104° C., or at the boiling temperature of the working composition if that is higher. It is preferred that the working composition separate into two liquid phases at working temperatures, as this has been found to promote stripping action. However, the solubility of organic compounds in alkaline aqueous ionic solutions is often greater at lower temperatures, so that a preferred composition may form a single phase at normal ambient temperatures, i.e., 15°-25° C.
The invention may be further appreciated by consideration of the following examples and comparative examples.
Preparation of Test Substrates
Cold rolled steel sheets were first normally cleaned and activated and then either (i) phosphate conversion coated with BONDERITE® 1000 iron phosphate conversion coating forming composition and then painted with a thickness of about 20 micrometers (hereinafter usually abbreviated "μm") of DURACRON™ 200 acrylic appliance paint (denoted type "A" below) or (ii) phosphate conversion coated with BONDERITE® 952 zinc-manganese-nickel phosphate conversion coating forming composition and then painted with a thickness of about 56 μm of DURACRON™ 200 paint (denoted type "B" below).
Preparation of Working Compositions for Testing--Group 1
The working stripping compositions (not all of which are necessarily according to the invention) were prepared from two concentrates: An aqueous alkaline concentrate consisting of 46% potassium hydroxide, 8% of a solution of 50% of gluconic acid in water, and 46% of water and an organic additive concentrate with component(s) as shown in Table 1 below. The mount of the organic additive was 15% of each working composition in Table 1, the amount of the alkaline concentrate is listed in Table 1, and the balance of the working compositions was tap water. The working compositions were maintained at boiling temperature and normal ambient atmospheric pressure during the testing, with water replenishment as needed to maintain the original volume. (The boiling temperature is about 104° C. for compositions that contained 30% of the alkaline concentrate and is about 109° C. for compositions that contained 50% of the alkaline concentrate. All of the organic additives tested have boiling points so much higher than water that replenishing them was not needed to maintain substantially constant composition.)
Painted, pre-phosphated test panels prepared as described above were immersed in the working compositions and observed until the paint had been completely stripped, or, in a few cases, until a preset time limit had been exceeded. The time required for stripping was then taken from a timing device that had been started at the time of immersion; if stripping was not achieved, the time limit is shown instead, following a ">" sign in the tables below.
Results are shown in Table 1 below, along with some comparative tests with numbers beginning with "C" in which a single organic compound is used in the working composition and a few comparative examples in which two types of (oligo-)glycol ethers are mixed.
TABLE 1__________________________________________________________________________Test % AC Panel Type A Panel Type BNo. Organic Additive Composition in WC ST % S ST % S__________________________________________________________________________C-12 100% EGMFE 30 4.0 -- 6.0 --129 80% EGMFE + 20% TPG 30 6.5 -35 10.9 -49130 60% EGMFE + 40% TPG 30 4.2 25 8.7 -1131 40% EGMFE + 60% TPG 30 4.0 38 7.5 24132 20% EGMFE + 80% TPG 30 3.5 51 7.2 36C-4 100% TPG 30 8.0 -- 12.5 --C-1 100% DEGMPE 30 4.8 -- 9 -- 13 80% DEGMPE + 20% MEA 30 4.0 59 6.5 51 14 60% DEGMPE + 40% MEA 30 3.5 76 6.2 64 15 40% DEGMPE + 60% MEA 30 3.2 84 5.8 73 16 20% DEGMPE + 80% MEA 30 4.5 82 10 61C-5 100% MEA 30 >30* -- >30* --C-1.1 100% DEGMPE 30 4.8 -- 9.0 -- 1 80% DEGMPE + 20% PG 30 nm nm 7.0 22 2 60% DEGMPE + 40% PG 30 5.2 65 7.5 57 3.140% DEGMPE + 60% PG 30 4.0 80 6.2 71 4.120% DEGMPE + 80% PG 30 19 24 nm nmC-2.1 100% PG 30 >30* -- >30* --C-1.2 100% DEGMPE 50 4.0 -- 6.0 -- 3.240% DEGMPE + 60% PG 50 nm nm 3.0 85 4.220% DEGMPE + 80% PG 50 7.0 72 nm nmC-2.2 100% PG 50 >30 -- >30 -- 4.320% DEGMPE + 80% PG 70 4.0 nm 8.8 nmC-1.1 100% DEGMPE 30 4.8 -- 9.0 -- 5 80% DEGMPE + 20% DPG 30 3.0 52 7.5 29 6.160% DEGMPE + 40% DPG 30 nm nm 5.8 52 7.140% DEGMPE + 60% DPG 30 nm nm 6.5 52 8.120% DEGMPE + 80% DPG 30 3.5 66 6.3 58C-3.1 100% DPG 30 11.8 -- 16.5 --C-1.2 100% DEGMPE 50 4.0 -- 6.0 -- 6.260% DEGMPE + 40% DPG 50 nm nm 5.7 65 7.240% DEGMPE + 60% DPG 50 nm nm 4.7 62 8.220% DEGMPE + 80% DPG 50 nm nm 5 65C-3.2 100% DPG 50 8.0 -- 10.0 --C-1 100% DEGMPE 30 4.8 -- 9 -- 9 80% DEGMPE + 20% TPG 30 5.5 -1 9.2 5 10 60% DEGMPE + 40% TPG 30 5.8 5 9.5 9 11 40% DEGMPE + 60% TPG 30 5.5 18 9.8 12 12 20% DEGMPE + 80% TPG 30 6.2 16 11.5 3C-4 100% TPG 30 8.0 -- 12.5 --C-7.1 100% TEGMME 30 5.5 -- 9.4 -- 45 80% TEGMME + 20% MEA 30 6.5 38 13.0 4 46.160% TEGMME + 40% MEA 30 >18 nm 14.2 20 47.140% TEGMME + 60% MEA 30 >10 nm 16 26 48.120% TEGMME + 80% MEA 30 >10 nm 21 19C-5.1 100% MEA 30 >30* -- >30* --C-7.2 100% TEGMME 50 4.2 -- 6.2 -- 46.260% TEGMME + 40% MEA 50 4.0 72 5.2 67 47.240% TEGMME + 60% MEA 50 3.0 85 6.0 71 48.220% TEGMME + 80% MEA 50 4.2 83 9.0 64C-5.2 100% MEA 50 >30 -- >30 --C-7.1 100% TEGMME 30 5.5 -- 9.4 -- 41.180% TEGMME + 20% PG 30 10.0 -96 14.8 -74 42.160% TEGMME + 40% PG 30 10.0 35 21 -19 43.140% TEGMME + 60% PG 30 15 26 21.2 3 44.120% TEGMME + 80% PG 30 >15 nm 40 -55C-2.1 100% PG 30 >30* -- >30* --C-7.2 100% TEGMME 50 4.2 -- 6.2 -- 41.280% TEGMME + 20% PG 50 4.0 57 5.2 53 42.260% TEGMME + 40% PG 50 3.5 76 5.0 68 43.240% TEGMME + 60% PG 50 3.2 84 5.8 72 44.220% TEGMME + 80% PG 50 7.0 72 7.2 71C-2.2 100% PG 50 >30 -- >30 --C-7.1 100% TEGMME 30 5.5 -- 9.4 -- 37 80% TEGMME + 20% DPG 30 5.2 23 11 -2 38 60% TEGMME + 40% DPG 30 8.8 -10 12.8 -5 39.140% TEGMME + 60% DPG 30 >15 <-62 nm nm 40.120% TEGMME + 80% DPG 30 13.1 -24 16.8 -11C-3.1 100% DPG 30 11.8 -- 16.5 --C-7.2 100% TEGMME 50 4.2 -- 6.2 -- 39.240% TEGMME + 60% DPG 50 3.8 41 5.4 36 40.220% TEGMME + 80% DPG 50 4.2 42 6 35C-3.2 100% DPG 50 8 -- 10 --C-5 100% TEGMME 30 5.5 -- 9.4 -- 33 80% TEGMME + 20% TPG 30 7.0 -17 12 -20 34 60% TEGMME + 40% TPG 30 10 -54 14 -32 35 40% TEGMME + 60% TPG 30 6.8 3 12.6 -12 36 20% TEGMME + 80% TPG 30 5.0 33 12 -1C-4 100% TPG 30 8.0 -- 12.5 --C-15.1 100% DPGMME 30 30 -- 45.7 --159.180% DPGMME + 20% PG 30 8.8 66 60 -49160.160% DPGMME + 40% PG 30 9.3 69 60 -52161.140% DPGMME + 60% PG 30 35 -17 60 -65162.120% DPGMME + 80% PG 30 >60 -100 >60 -81C-2.1 100% PG 30 >30* -- >30* --C-15.2 100% DPGMME 50 13.3 -- 20.7 --159.280% DPGMME + 20% PG 50 7.8 53 11 51160.260% DPGMME + 40% PG 50 7.8 61 18.5 24161.240% DPGMME + 60% PG 50 6.0 74 12.7 52162.220% DPGMME + 80% PG 50 6.2 77 20 29C-2.2 100% PG 50 >30 -- >30 --C-15.1 100% DPGMME 30 30 -- 45.7 --163.180% DPGMME + 20% DPG 30 10 60 13.1 65164.160% DPGMME + 40% DPG 30 6.0 74 8.5 75165.140% DPGMME + 60% DPG 30 6.2 68 9.0 68166.120% DPGMME + 80% DPG 30 5.8 62 11.5 49C-3.1 100% DPG 30 11.8 -- 16.5 --C-15.2 100% DPGMME 50 13.3 -- 20.7 --163.280% DPGMME + 20% DPG 50 6.9 44 8.8 53164.260% DPGMME + 40% DPG 50 5.0 55 5.8 65165.240% DPGMME + 60% DPG 50 4.2 58 5.5 61166.220% DPGMME + 80% DPG 50 3.7 59 5.7 53C-3.2 100% DPG 50 8.0 -- 10.0 --C-15.1 100% DPGMME 30 30 -- 45.7 --167.180% DPGMME + 20% TPG 30 10.7 58 16.5 57168.160% DPGMME + 40% TPG 30 9.2 57 14 57169.140% DPGMME + 60% TPG 30 6.5 61 9.0 65170.120% DPGMME + 80% TPG 30 6.2 50 8.5 56C-4.1 100% TPG 30 8.0 -- 12.5 --C-15.2 100% DPGMME 50 13.3 -- 20.7 --167.280% DPGMME + 20% TPG 50 7.5 38 10.6 43168.260% DPGMME + 40% TPG 50 6.2 42 9.0 46169.240% DPGMME + 60% TPG 50 9.0 5 14 6170.220% DPGMME + 80% TPG 50 8.8 -7 12.1 6C-4.2 100% TPG 50 70 -- 11.0 --C-6 100% DEGMnBE 30 6.5 -- 11.6 -- 17 80% DEGMnBE + 20% MEA 30 5.5 51 11.5 25 18 60% DEGMnBE + 40% MEA 30 5.8 64 12 37 19 40% DEGMnBE + 60% MEA 30 4.8 77 9.8 57 20 20% DEGMnBE + 80% MEA 30 6 76 12.2 54C-5 100% MEA 30 >30* -- >30* --C-6 100% DEGMnBE 30 6.5 -- 11.6 -- 21 80% DEGMnBE + 20% PG 30 6.0 46 10.5 31 22 60% DEGMnBE + 40% PG 30 5.0 69 9.8 48 23 40% DEGMnBE + 60% PG 30 5.0 76 10.0 56 24 20% DEGMnBE + 80% PG 30 7.8 69 10.0 62C-2 100% PG 30 >30* -- >30* --C-6 100% DEGMnBE 30 6.5 -- 11.6 -- 25 80% DEGMnBE + 20% DPG 30 7.2 5 13.5 -7 26 60% DEGMnBE + 40% DPG 30 8.8 -2 11.0 19 27 40% DEGMnBE + 60% DPG 30 5.5 43 10.2 30 28 20% DEGMnBE + 80% DPG 30 5.5 49 7.5 52C-3 100% DPG 30 11.8 -- 16.5 --C-6 100% DEGMnBE 30 6.5 -- 11.6 -- 29 80% DEGMnBE + 20% TPG 30 8.0 -18 14.5 -23 30 60% DEGMnBE + 40% TPG 30 11.0 -55 15.8 -32 31 40% DEGMnBE + 60% TPG 30 6.2 16 12.5 -3 32 20% DEGMnBE + 80% TPG 30 9.0 -17 11.8 4C-4 100% TPG 30 80 -- 12.5 --C-7.1 100% TEGMEE 30 5.5 -- 9.4 -- 61 80% TEGMEE + 20% MEA 30 4.0 62 7.8 42 62 60% TEGMEE + 40% MEA 30 4.0 74 7.5 57 63.140% TEGMEE + 60% MEA 30 6.5 68 14.9 32 64.120% TEGMEE + 80% MEA 30 6.5 74 18 30C-5.1 100% MFA 30 >30* -- >30* --C-7.2 100% TEGMEE 50 4.2 -- 6.2 -- 63.240% TEGMEE + 60% MEA 50 3.5 82 6.7 67 64.220% TEGMEE + 80% MEA 50 4.2 83 6 76C-52 100% MEA 50 >30 -- >30 --C-7.1 100% TEGMEE 30 5.1 -- 9.1 -- 49 80% TEGMEE + 20% PG 30 4.0 60 9.0 32 50 60% TEGMEE + 40% PG 30 5.0 67 9.3 47 51.140% TEGMEE + 60% PG 30 >10 nm 15 31 52.120% TEGMEE + 80% PG 30 10.0 60 20 23C-2.1 100% PG 30 >30* -- >30* --C-7.2 100% TEGMEE 50 3.9 -- 6.0. -- 51.240% TEGMEE + 60% PG 50 2.8 86 6.0 71 52.220% TEGMEE + 80% PG 50 3.0 88 6.4 75C-2.2 100% PG 50 >30 -- >30 --C-7.1 100% TEGMEE 30 5.1 -- 9.1. -- 53 80% TEGMEE + 20% DPG 30 3.8 41 10.5 1 54 60% TEGMEE + 40% DPG 30 3.8 51 7.8 35 55.140% TEGMEE + 60% DPG 30 9.0 1 7.3 46 56.120% TEGMEE + 80% DPG 30 9.2 12 15.5 -3C-3.1 100% DPG 30 11.8 -- 16.5 --C-7.2 100% TEGMEE 50 3.9 -- 6.0 -- 55.240% TEGMEE + 60% DPG 50 6.0 6 5.2 38 56.220% TEGMEE + 80% DPG 50 4.8 33 5.7 38C-32 100% DPG 50 8.0 -- 10.0 --C-7 100% TEGMEE 30 5.1 -- 9.1 -- 57 80% TEGMEE + 20% TPG 30 4.2 26 8.5 13 58 60% TEGMEE + 40% TPG 30 5.0 20 8.8 16 59 40% TEGMEE + 60% TPG 30 5.5 20 12.3 -10 60 20% TEGMEE + 80% TPG 30 5.2 30 12.2 -3C-4 100% TPG 30 8.0 -- 12.5 --C-13 100% DEGMHE 30 9.0 -- 16.5 --141 80% DEGMHE + 20% PG 30 6.1 54 18.1 6142 60% DEGMHE + 40% PG 30 9.2 47 19.1 13143 40% DEGMHE + 60% PG 30 11.5 47 18.5 25144 20% DEGMHE + 80% PG 30 9.0 65 13 52C-2 100% PG 30 >30* -- >30* --C-13 100% DEGMHE 30 9.0 -- 16.5 --137 80% DEGMHE + 20% DPG 30 8.8 8 16.6 -1138 60% DEGMHE + 40% DPG 30 5.2 49 10.8 35139 40% DEGMHE + 60% DPG 30 6.0 44 11.7 29140 20% DEGMHE + 80% DPG 30 6.2 45 12.6 24C-3 100% DPG 30 11.8 -- 16.5 --C-13 100% DEGMHE 30 9.0 -- 16.5 --133 80% DEGMHE + 20% TPG 30 8.3 6 19 -21134 60% DEGMHE + 40% TPG 30 8.5 1 13.7 8135 40% DEGMHE + 60% TPG 30 8.8 -5 14 1136 20% DEGMHE + 80% TPG 30 9.2 -12 14.6 -10C-4 100% TPG 30 8.0 -- 12.5 --C-8 100% TEGMnBE 30 7.0 -- 12.2 -- 65 80% TEGMnBE + 20% MEA 30 7.0 40 14.3 9 66 60% TEGMnBE + 40% MEA 30 7.0 57 14.3 26 67 40% TEGMnBE + 60% MEA 30 4.7 77 9.2 60 68 20% TEGMnBE + 80% MEA 30 6.0 76 10.0 62C-5 100% MEA 30 >30* -- >30* --C-8 100% TEGMnBE 30 7.0 -- 12.2 -- 69 80% TEGMnBE + 20% PG 30 7.0 40 13 18 70 60% TEGMnBE + 40% PG 30 7.0 57 12.8 34 71 40% TEGMnBE + 60% PG 30 6.2 70 12.2 47 72 20% TEGMnBE + 80% PG 30 6.2 76 12.2 54C-2 100% PG 30 >30* -- >30* --C-8 100% TEGMnBE 30 7.0 -- 12.2 -- 73 80% TEGMnBE + 20% DPG 30 5.0 37 13.2 -1 74 60% TEGMnBE + 40% DPG 30 5.2 42 9.9 29 75 40% TEGMnBE + 60% DPG 30 5.0 49 9.8 34 76 20% TEGMnBE + 80% DPG 30 5.5 49 10.5 33C-3 100% DPG 30 11.8 -- 16.5 --C-8 100% TEGMnBE 30 7.0 -- 12.2 -- 77 80% TEGMnBE + 20% TPG 30 9.8 -36 11.3 8 78 60% TEGMnBE + 40% TPG 30 9.8 -32 11.5 7 79 40% TEGMnBE + 60% TPG 30 10.0 -32 12 3 80 20% TEGMnBE + 80% TPG 30 10.0 -28 12 4C-4 100% TPG 30 8.0 -- 12.5 --C-9 100% DPGMnBE 30 43 -- 52 -- 93 80% DPGMnBE + 20% MEA 30 30 26 34 29 94 60% DPGMnBE + 40% MEA 30 20 47 26 40 95 40% DPGMnBE + 60% MEA 30 18 49 24 38 96 20% DPGMnBE + 80% MEA 30 10.8 67 20 42C-5 100% MEA 30 >30* -- >30* --C-9.1 100% DPGMnBE 30 43 -- 52 -- 81.180% DPGMnBE + 20% PG 30 >10 nm 70 -31 82.160% DPGMnBE + 40% PG 30 >10 nm 71 -64 83.140% DPGMnBE + 60% PG 30 >10 nm 65 -68 84.120% DPGMnBE + 80% PG 30 >10 nm 125 -263C-2.1 100% PG 30 >30* -- >30* --C-9.2 100% DPGMnBE 50 37 -- 36 -- 81.280% DPGMnBE + 20% PG 50 >10 nm 60 -72 82.260% DPGMnBE + 40% PG 50 >10 nm 60 -79 83.240% DPGMnBE + 60% PG 50 >10 nm 45 -39 84.220% DPGMnBE + 80% PG 50 >10 nm 70 -124C-2.2 100% PG 50 >30 -- >30 --C-9 100% DPGMnBE 30 43 -- 52 -- 85 80% DPGMnBE + 20% DPG 30 17 54 45 0 86 60% DPGMnBE + 40% DPG 30 45 -47 57 -51 87 40% DPGMnBE + 60% DPG 30 20 18 25 19 88 20% DPGMnBE + 80% DPG 30 12 33 16 32C-3 100% DPG 30 11.8 -- 16.5 --C-9 100% DPGMnBE 30 43 -- 52 -- 89 80% DPGMnBE + 20% TPG 30 30 17 45 -2 90 60% DPGMnBE + 40% TPG 30 16.5 43 22 39 91 40% DPGMnBE + 60% TPG 30 9.8 55 20 29 92 20% DPGMnBE + 80% TPG 30 8.0 47 15.2 25C-4 100% TPG 30 8.0 -- 12.5 --C-11 100% DPGMtBE 30 46 -- 55 --125 80% DPGMtBE + 20% MEA 30 31 28 34 32126 60% DPGMtBE + 40% MEA 30 28 29 30 33127 40% DPGMtBE + 60% MEA 30 15 59 17 58128 20% DPGMtBE + 80% MEA 30 23 31 34 3C-5 100% MEA 30 >30* -- >30* --C-11 100% DPGMtBE 30 46 -- 55 --121 80% DPGMtBE + 20% PG 30 38 11 66 -32122 60% DPGMtBE + 40% PG 30 24 39 55 -22123 40% DPGMtBE + 60% PG 30 39 -7 45 -13124 20% DPGMtBE + 80% PG 30 49 -48 99 -183C-2 100% PG 30 >30* -- >30* --C-11 100% DPGMtBE 30 46 -- 55 --117 80% DPGMtBE + 20% DPG 30 38 3 49 -4118 60% DPGMtBE + 40% DPG 30 20 38 32 19119 40% DPGMtBE + 60% DPG 30 15 41 26 18120 20% DPGMtBE + 80% DPG 30 13 30 19 21C-3 100% DPG 30 11.8 -- 16.5 --C-11 100% DPGMtBE 30 46 -- 55 --113 80% DPGMtBE + 20% TPG 30 47 -22 54 -16114 60% DPGMtBE + 40% TPG 30 24 22 33 13115 40% DPGMtBE + 60% TPG 30 16 31 28 5116 20% DPGMtBE + 80% TPG 30 10.4 33 22 -5C-4 100% TPG 30 8.0 -- 12.5 --C-14.1 100% TPGMME 30 32.5 -- 45** --147.180% TPGMME + 26% PG 30 26 12 38.7 8148.160% TPGMME + 40% PG 36 18.4 42 29.6 24149.140% TPGMME + 60% PG 30 18.3 41 27.1 25150.120% TPGMME + 80% PG 30 17.3 43 24.2 27C-2.1 100% PG 30 >30* -- >30* --C-14.2 100% TPGMME 50 9.0 -- 19.3 --147.280% TPGMME + 20% PG 50 25 -89 39.3 -83148.260% TPGMME + 40% PG 50 17.5 -1 30.7 -30149.240% TPGMME + 60% PG 50 17 21 26.5 -3150.220% TPGMME + 80% PG 50 15.5 40 22.1 21C-2.2 100% PG 50 >30 -- >30 --C-14.1 100% TPGMME 30 32.5 -- 45** --151.180% TPGMME + 20% DPG 30 11.7 57 21.5 44152.160% TPGMME + 40% DPG 30 9.2 62 17 49153.140% TPGMME + 60% DPG 30 8.7 57 12.1 57154.120% TPGMME + 80% DPG 30 7.5 53 9.2 59C-3.1 100% DPG 30 11.8 -- 16.5 --C-14.2 100% TPGMME 50 9.0 -- 19.3 --151.280% TPGMME + 20% DPG 50 10.1 -15 16.6 5152.260% TPGMME + 40% DPG 50 6.5 24 12.5 20153.240% TPGMME + 60% DPG 50 6.0 29 8.1 41154.220% TPGMME + 80% DPG 50 4.5 45 5.0 58C-3.2 100% DPG 50 8 -- 10 --C-14.1 100% TPGMME 30 32.5 -- 45** --155.180% TPGMME + 20% TPG 30 20 28 41 -5156.160% TPGMME + 40% TPG 30 12.8 44 22.7 29157.140% TPGMME + 60% TPG 30 11.4 36 18.8 26158.120% TPGMME + 80% TPG 30 10.5 19 12.7 33C-4.1 100% TPG 30 8.0 -- 12.5 --C-14.2 100% TPGMME 50 9.0 -- 19.3 --155.280% TPGMME + 20% TPG 50 14 -63 19.5 -11156.260% TPGMME + 40% TPG 50 9.2 -12 15.5 3157.240% TPGMME + 60% TPG 50 6.5 17 11 23158.220% TPGMME + 80% TPG 50 6.0 19 8.0 37C-4.2 100% TPG 50 7.0 -- 11.0 --C-10 100% TPGMnBE 30 70 -- 150 -- 97 80% TPGMnBE + 20% MEA 30 40 35 70 44 98 60% TPGMnBE + 40% MEA 30 27 50 55 46 99 40% TPGMnBE + 60% MEA 30 19.6 57 41 47100 20% TPGMnBE + 80% MEA 30 14.1 63 29 46C-5 100% MEA 30 >30* -- >30* --C-10 100% TPGMnBE 30 70 -- 150 --101 80% TPGMriBE + 20% PG 30 56 10 65 48102 60% TPGMnBE + 40% PG 30 70 -30 80 22103 40% TPGMnBE + 60% PG 30 51 -11 60 23104 20% TPGMnBE + 80% PG 30 30 21 37 31C-2 100% PG 30 >30* -- >30* --C-10 100% TPGMnBE 30 70 -- 150 --105 80% TPGMnBE + 20% DPG 30 40 31 60 51106 60% TPGMnBE + 40% DPG 30 20 57 37 62107 40% TPGMnBE + 60% DPG 30 14 60 29.5 58108 20% TPGMnBE + 80% DPG 30 10.2 56 14.3 67C-3 100% DPG 30 11.8 -- 16.5 --C-10 100% TPGMnBE 30 70 -- 150 --109 80% TPGMnBE + 20% TPG 30 46 20 50 59110 60% TPGMnBE + 40% TPG 30 31 31 48 49111 40% TPGMnBE + 60% TPG 30 12 63 23 66112 20% TPGMnBE + 80% TPG 30 10.0 51 16 60C-4 100% TPG 30 80 -- 12.5 --C-13 100% DEGMHE 30 9.0 -- 16.5 --145 50% DEGMHE + 50% EGMFE 30 4.5 31 9.0 20146 65% DEGMHE + 35% EGMFE 30 5.0 31 10.0 22C-12 100% EGMFE 30 4.0 -- 6.0 -__________________________________________________________________________ Footnotes for Table 1 *This lower limit was not directly measured, but was inferred from the value measured with 50 % of alkaline concentrate and the inevitable observation that stripping times are longer for strippers with only 30% o alkaline concentrate, with all other active ingredients maintained the same. **About 5% of the coating remained after this time, but the test was nevertheless discontinued. Abbreviations for Table 1 "AC" = "Alkaline Concentrate"; "WC" = "Working Composition"; "ST" = "Stripping Time"; "% S" = "Percent Synergy" or if the value is negative, "Percent Antisynergy"; "Min" = "Minutes"; "nm" = "not measured", or, in columns where the values are calculated rather than directly measured, "not meaningful" (because at least one directly measured value required for the calcuIation was not measured at all or was merely given a lower limit rather than a complete measurement).
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Solvent assisted alkaline paint stripping can be speeded by using mixtures of (i) glycol and/or oligoglycol monoethers with (ii) unetherified glycols and oligoglycols and/or alkanolamines.
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This application is a continuation of 08/325,845, filed Oct. 19, 1994, now U.S. Pat. No. 5,595,875, which is a division of application Ser. No. 08/032,231, filed Mar. 17, 1993, now U.S. Pat. No. 5,449,556, which is a division of Ser. No. 07/826,186, filed Jan. 22, 1992, now U.S. Pat. No. 5,227,489, which is a continuation of Ser. No. 07/226,639, filed Aug. 1, 1988, now abandoned.
FIELD OF THE INVENTION
The present invention relates to a novel method for the detection of an analyte in a fluid sample. More particularly, the present invention relates to a method for the detection of an analyte in a fluid sample using acridinium esters encapsulated within the walls of liposomes (lumisomes). This invention also relates to novel acridinium esters useful as chemiluminescent markers which can be encapsulated within liposome vesicles without significant leakage of the esters from the vesicles.
BACKGROUND OF THE INVENTION
The use of liposomes as carriers of marker molecules for nonisotopic immunoassays is known. See, e.g., U.S. Pats. Nos. 4,704,355; 4,695,554; 4,656,129 and 4,193,983. An important advantage of using liposomes in immunoassays is the ability of liposomes to carry a large number of marker molecules per liposome vesicle, and thereby provide an amplified signal to immunoassays. Immunoassays utilizing liposomes with encapsulated macromolecular markers such as enzymes or small organic marker molecules such as fluorescent or absorbing dyes, spin-labels, metal chelators, and enzyme activators or inhibitors, have been described. See, e.g., Kricka, L. and Carter T., Clinical and Biochemical Luminescence, pp. 153-178 (Marcel Dekker, Inc., New York and Basel, 1982).
Prior to the present invention, chemiluminescent markers such as the acridinium esters described in Ann. Clin. Biochem. 25, p. 27 (1988), Clin. Chem. 31, p. 664 (1985), European Patent Application No. EP 82,636, and U.S. Pat. No. 4,745,181, have only been used as labels for immunoassays by conjugating them directly to biological molecules, such as antigens or antibodies. The lipophilic nature of the prior art acridinium esters and other chemiluminescent compounds render them unsuitable for encapsulation within liposomes because of their rapid leakage through the liposome wall. Additionally, the limited water solubility of prior art acridinium esters and other chemiluminescent compounds only allow the encapsulation of a few marker molecules per liposome vesicle, resulting in relatively low signal amplification.
Accordingly, it is the purpose of the present invention to provide a novel method for detecting an analyte using acridinium esters. It is also a purpose of the present invention to provide novel hydrophilic acridinium esters useful for encapsulation within liposomes for use as chemiluminescent markers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a standard curve for a Total T 4 Assay using lumisomes of this invention.
FIG. 2 is a standard curve for a Free T 4 Assay using lumisomes of this invention
FIG. 3 is a standard curve for a CKMB Assay using lumisomes of this invention.
FIG. 4 is a comparison of two standard curves for a TSH Assay, the top curve respresenting a TSH assay using lumisomes of this invention and the bottom curve representing a TSH assay using antibody directly labeled with acridinium ester.
FIG. 5 is a comparison of two standard curves for a TSH Assay, the top curve representing a TSH assay using lumisomes of this invention and shortened incubation times and the bottom curve representing a TSH assay using antibody directly labelled with acridinium ester and normal incubation times.
DESCRIPTION OF THE INVENTION
The following terms as used in the specification and claims shall have the following meanings:
Analyte--the compound or composition to be measured which can be a ligand that is mono- or polyepitopic, antigenic, or haptenic. The analyte can be a piece of DNA or RNA.
Antigen--any substance capable of provoking an immune response in vertebrates, particularly with the production of specific antibodies.
Hapten--an incomplete antigen, incapable by itself to provoke an immune response but when suitably attached to another molecule becomes capable of producing antibodies which will specifically recognize the hapten.
Epitope--a specific chemical and spatial configuration which is specifically recognized by an antibody.
Ligand--any compound for which a receptor naturally exists or can be prepared.
Ligand analog--a modified ligand which can compete with the analogous ligand for a receptor, the modification providing means to join a modified ligand to another molecule.
Receptor--any compound capable of recognizing a particular spatial and polar organization of a molecule, i.e., epitopic site. Illustrative receptors include antibodies, enzymes, antibody fragments, such as Fab fragments, DNA or RNA fragments, lectins, complement components, conglutin, rheumatoid factors, hormones, avidin, staphylococcal protein A, and the like.
Antiligand--a receptor for a ligand.
DNA probe--piece of DNA that recognizes specific DNA or RNA sequences by hydridizing to complementary DNA or RNA.
RNA probe--piece of RNA that recognizes specific DNA or RNA sequences by hydridizing to complementary DNA or RNA.
Liposomes--single or multicompartmented bodies obtained when lipids, particularily lipid mixtures, are dispersed in aqueous suspension. The walls or membranes are composed of a continuous lipid bilayer.
Lumisomes--liposomes comprising an encapsulated acridinium ester.
The acridinium esters useful in the method of the present invention can be any acridinium ester which can be encapsulated within a liposome and which can generate a chemiluminescent signal. Preferred acridinium esters include acridinium esters of the following formula: ##STR1## wherein R 1 is alkyl, alkenyl, alkynyl, aryl, or aralkyl, containing from 0 to 20 heteroatoms, preferably nitrogen, oxygen, phosphorous or sulfur;
R 2 , R 3 , R 5 , and R 7 are hydrogen, amino, alkoxyl, hydroxyl, --COOH, halide, nitro, ##STR2## wherein
R is alkyl, alkenyl, alkynyl, aryl, or aralkyl, containing from 0-20 heteratoms;
R 4 and R 8 are alkyl, alkenyl, alkynyl, aralkyl, or alkoxyl;
X is an anion, preferably CH 3 SO 4 - , OSO 2 F - , halide, ##STR3## wherein R is as defined above; Q is ##STR4## diazo, ##STR5## I is an ionizable group; and n is at least 1.
Preferably R 1 is alkyl, alkenyl, alkynyl, aryl or aralkyl of from 1 to 24 carbon atoms;
R 2 , R 3 , R 5 and R 7 are hydrogen, amino, --COOH, cyano, hydroxyl, alkoxyl of from 1 to 4 carbon atoms, nitro, halide, --SO 3 , or --SCN;
R 4 and R 8 are preferably or alkyl, alkenyl, alkynyl, or alkoxyl, of from 1 to 8 carbon atoms; X is halide; R 6 is --Q--R--I.sub.(n) ; Q is ##STR6## diazo, ##STR7## and R is alkyl, alkenyl, alkynyl, aryl, or aralkyl, of from 1 to 24 carbon atoms, containing from 0 to 20 heteratoms selected from the group consisting of nitrogen, oxygen, phosphorous, and sulfur.
An ionizable group for the purposes of this invention is any functional group which retains a net positive or negative charge within a specific pH range. Preferably the functional group will retain a net positive or negative charge within the range of pH2-10 and, more preferably, within the range of pH5-9. I can be any ionizable group provided that the ionizable group is not deleterious to the encapsulation of the acridinium ester of this invention within the liposome. I is preferably --SO 3 H, --OSO 3 H, --POCOH) 2 or --OPO 3 (OH), and n is preferably about 1 to about 20 and, more preferably, less than about 10.
More preferably, R 1 is alkyl of from 1 to 10 carbon atoms; R 2 , R 3 , R 5 , and R 7 are hydrogen, nitro, --CN, halide, alkoxyl of from 1 to 4 carbon atoms, amino, or --SO 3 H; and R 4 and R 8 are alkyl of from 1 to 4 carbon atoms.
Most preferably, R 1 , R 4 , and R 8 are methyl; R 2 , R 3 , R 5 , and R 7 are hydrogen; X is bromide; R 6 is --Q--R--I.sub.(n), Q is a ##STR8## and --R--I.sub.(n) is selected from the group consisting of aminomethanesulfonic acid, 7-amino-1,3-naphthalenedisulfonic acid, S-(3-sulfopropyl)cysteine, 2-aminoethyl hydrogen sulfate, 2-aminoethylphosphonic acid, and 2-aminoethyl dihydrogen phosphate.
The R 5 and R 6 position can be interchanged in the acridinium esters of this invention. Accordingly, the preferred acridinium esters of this invention include acridinium esters of the following formula: ##STR9## wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , and X are as defined above.
The novel acridinium esters of the present invention are highly soluble in water and can be encapsulated in liposomes at high concentrations. Once inside liposomes, the novel acridinium esters remain encapsulated for extended periods of time and do not leak appreciably.
It will be appreciated that although the novel acridinium esters of the present invention have been described with respect to their usefulness with liposomes, the novel acridinium esters of the present invention are also useful in other applications where acridinium esters are utilized, such as labeling ligands or analytes (such as antigens); labeling the specific binding partners of ligands or analytes (such as the corresponding antibodies); or labelling nucleic acids and molecules comprising nucleic acids.
Lumisomes useful in this invention can be prepared by any of the various known methods for producing either unilamellar liposome vesicles or multilamellar liposome vesicles. Lumisomes are single or multicompartmented bodies obtained when lipids or lipid mixtures are dispersed in an aqueous suspension containing the acridinium esters useful in this invention.
As an example of one method for producing lumisomes, lipids are dissolved in a suitable organic solvent, such as chloroform, and placed into a suitable vessel. A dry film of lipids is formed on the interior surface of the vessel by evaporation of the organic solvent. The aqueous solution containing the acridinium esters to be entrapped within the lumisomes is then placed in the vessel in contact with the lipid film. The lipid film is then dispersed in the aqueous solution by vigorous agitation or sonication.
Numerous other methods exist for forming liposomes which are useful for producing the lumisomes useful in this invention and it is left to the artisan to choose the method best suited for a desired use. A preferred method for manufacturing liposomes is disclosed in copending U.S. application Ser. No. 940,519, filed on Dec. 10, 1986, now U.S. Pat. No. 4,933,121 herein incorporated by reference.
The lnmisome can be derivatized with a ligand, ligand analog, or anti-ligand using known procedures in the art. Depending on the intended use of the lumisome, the ligand, ligand analog, or anti-ligand can be an antigen, hapten, antibody, nucleic acid, DNA, RNA, avidin or other receptor.
The lumisomes so formed can be used as tracers in assays in which an analyte in a sample fluid is to be detected. The type of assay utilized and/or the analyte to be detected will determine the ligand, ligand analog or anti-ligand used to form the lumisome. For example, if a competitive assay is used for determining an antigen or hapten, the ligand or ligand analog employed will be either the analyte or its analog.
If a sandwich assay is to be used the ligand, ligand analog or anti-ligand employed would be specific for the analyte to be assayed. For example, an antibody, such as a monoclonal antibody, elicited in response to the analyte to be assayed, could be used to derivatize the lumisome.
An example of an assay for detecting a DNA or RNA probe using the lumisomes of this invention is as follows: The DNA or RNA probe is tagged with a ligand such as a hapten or a biotinylated modified nucleotide. The DNA or RNA probe is allowed to hybridize with complementary DNA or RNA and immobilized on a solid support. The immobilized probe is then reacted with lumisomes comprising a receptor for the ligand, such as an antibody or if the probe is biotinylated, avidin. The lumisomes are ruptured and the amount of signal generated by the encapsulated acridinium ester is measured.
Alternatively, a receptor can be utilized which recognizes and binds to the probe/complementary DNA or RNA hybrid, in the absence of a tag, such as an anti-hybrid antibody.
The following Examples are presented to illustrate the present invention.
EXAMPLE 1
Preparation of 2',6'-Dimethyl-4'-carboxyphenyl 10-methyl-acridinium-9-carboxylate bromide (DMAE-COOH)
A mixture of 2',6'-dimethyl-4'-benzyloxycarbonylphenyl 10-methyl-acridinium-9-carboxylate methosulfate (7.9, 13.4 mmole) (prepared as described in U.S. Pat. No. 4,745,181), 150 ml of glacial acetic acid and 46 ml of 48% hydrogen bromide was heated at 100°-105° C. for 3 hours and then left at room temperature overnight. 400 ml of anhydrous ethyl ether was added to the mixture to form a second mixture which was then refrigerated 3 days. The second mixture was then filtered to produce a yellow crystalline residue. The residue was washed with anhydrous ethyl ether and air dried.
EXAMPLE 2
Preparation of 2',6'-Dimethyl-4'-(sulfomethylcarbamoyl)phenyl 10-methyl-acridinium-9-carboxylate bromide (DMAE-AMS)
A solution of 2',6'-dimethyl-4'-carboxylphenyl 10-methyl-acridinium-9-carboxylate bromide (DMAE-COOH, 20 mg, 0.043 mmole) in 2 ml of dimethylformamide (DMF)/CHCl 3 (1:1) was cooled in an ice bath, treated with triethylamine (31 ul, 0.215 mmole) and ethyl chloroformate (6.1 ul, 0.065 mmole) to form a reaction mixture. After 30 min. the reaction mixture was evaporated. The residue of the evaporation was reconstituted in 2 ml of DMF, treated with triethylamine (31 ul, 0.215 mmole) and aminomethanesulfonic acid (9.5 mg, 0.086 mmole) to form a second reaction mixture. The second reaction mixture was stirred at room temperature overnight, and evaporated. The crude product so formed was purified on one analytical TLC plate (Silica gel 60, F254, Merck & Co., Inc., Rahway, N.J.), and developed with chloroform/methanol/water (65:25:4). The yellow band which developed on the plate (Rf=0.38) (which could also be detected under both long and short UV light) was stripped from the plate and eluted with the same solvent system. The eluent so produced was evaporated and the residue of the evaporation triturated with methanol to form a mixture. This mixture was then filtered through a polycarbonate membrane (13 mm diameter, 0.2 um pore size) (Nucleopore Corp., Pleasanton, Calif.) mounted on a syringe filter holder, and the filtrate so produced was evaporated to give DMAE-AMS (15 mg, 62%).
EXAMPLE 3
Preparation of 2',6'-Dimethyl-4'-[N-7-(1,3-disulfonaphthalenyl)carbamoyl]phenyl 10-methyl-acridinium-9-carboxylate Bromide (DMAE-ANDS)
A solution of 2',6'-dimethyl-4'-carboxylphenyl 10-methyl-acridinium-9-carboxylate bromide (DMAE-COOH, 18 mg, 0.038 mmole) in 3.6 ml of a dioxane/water (1:1) mixture was treated with 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (37 mg, 0.193 mmole, Aldrich Chemical Co., Inc., Milwaukee, Win.) at room temperature for 5 minutes to form a reaction mixture. A solution of 7-amino-1,3-naphthalenedisulfonic acid (ANDS, 26 mg, 0.076 mmole, Aldrich Chemical Co., Inc.) in 0.9 ml of water was added to the reaction mixture which was then stirred at room temperature overnight and evaporated.
The residue of the evaporation was dissolved in a minimal amount of 0.1M sodium carbonate to obtain a solution at neutral pH. This solution was mixed with an equal amount of methanol and purified on a 20×20cm preparative TLC plate (Silica gel 60, F254, Merck & Co., Inc.), and developed with chloroform/methanol/water (55:40:5). The yellow band which developed (Rf=0.4) was treated in the same manner as the yellow band described in Example 1 to give DMAE-ANDS (15 mg, 50%). Fast Atom Bombardment (FAB) Mass Spectral Analysis (by Oneida Research Services, Whitesboro, N.Y.) in the positive ion mode gave a M+ peak of 671, a M+Na peak of 693, and a M+2Na peak of 715. A bromide peak of 80 was detected in the negative ion mode.
EXAMPLE 4
Preparation of 2',6'-Dimethyl-4'-{N-[1-carboxyl-2-(3-sulfopropylthio)ethyl]carbamoyl}phenyl 10-methyl-acridinium-9-carboxylate bromide (DMAE-SCYS)
A solution of 2',6'-dimethyl-4'-carboxylphenyl 10-methyl-acridinium-9-carboxylate bromide (DMAE-COOH, 50 mg, 0.107 mmole) in 10 ml of DMF/CHCl 3 (1:1) was cooled in an ice bath, treated with triethylamine (77 u., 0.535 mmole) and ethyl chloroformate (20 ul, 0.214 mmole) to form a reaction mixture. After 30 min. the reaction mixture was evaporated. The residue of the evaporation was reconstituted in 10 ml of DMF/CHCl 3 (1:1), treated with triethylamine (77 u., 0.535 mmole), and S-3-sulfopropyl-L-cysteine (51 mg, 0.214 mmole) (prepared by the method of U.T. Ruegg and J. Rudinger, J. Peptide Protein Res. 6, 447, 1974) to form a second reaction mixture. The second reaction mixture was heated at 60° C.-70° C. overnight, and evaporated.
The residue of the evaporation was purified on one 20×20 cm preparative TLC plate (Silica gel 60, F254, Merck & Co., Inc.), developed with chloroform/methanol/water (55:40:5). The yellow band which developed (Rf=0.4) (which could also be detected under both long and short UV light) was treated in the same manner as the yellow band described in Example 1 to give the DMAE-SCys (37 mg, 36%).
FAB Mass Spectral Analysis in the positive ion mode gave a M+ peak of 611, a M+Na peak of 633, and a M+Na,K peak of 673.
EXAMPLE 5
Preparation of 2',6'-Dimethyl-4'-[N-(2-sulfonyloxyethyl)carbamoyl]phenyl 10-methyl-acridinium-9-carboxylate bromide (DMAE-AEOS)
A solution of 2',6'-dimethyl-4'-carboxylphenyl 10-methyl-acridinium-9-carboxylate bromide (DMAE-COOH, 35 mg, 0,075 mmole) in 5 ml of DMF was cooled in an ice bath, treated with triethylamine (44 ul, 0.31 mmole) and ethyl chloroformate (8.5 ul, 0.090 mmole). After 20 minutes, aminoethyl hydrogen sulfate (Aldrich, 30 mg, 0.21 mmole) was added to form a reaction mixture, and the ice bath removed. The reaction mixture was stirred at room temperature overnight and evaporated. The residue of the evaporation was triturated with 5 ml of a chloroform/methanol/water (73:24:3) mixture, and filtered to remove the insoluble materials. The filtrate so produced was concentrated, purified on a 20×20 cm preparative TLC plate (Silica gel 60, F254, Merck & Co., Inc.) and developed with chloroform/methanol/water (65:25:4). The yellow band which developed (Rf=0.48) (which could also be detected under both long and short UV light) was treated in the same manner as the yellow band described in Example 1 to give DMAE-AEOS (14 mg, 32%).
EXAMPLE 6
Preparation of 2',6'-Dimethel-4'-[N-(2-phosphonoethyl)carbamoyl]phenyl 10-methyl-acridiniUm-9-carboxylate bromide (DMAE-AEP)
A solution of 2',6'-dimethyl-4'-carboxylphenyl 10-methyl-acridinium-9-carboxylate bromide (DMAE-COOH, 100 mg, 0.215 mmole) in 20 ml of 25% DMF in chloroform was cooled in an ice bath, treated with triethylamine (180 ul, 1.30 mmole) and ethyl chloroformate (62 ul, 0.65 mmole) to form a reaction mixture. After 30 minutes, the reaction mixture was evaporated. The residue of the evaporation was reconstituted in 12 ml of DMF. To this solution so formed was added triethylamine (300 ul, 2.15 mmole) and 2-aminoethylphosphonic acid (80 mg, 0.64 mmole, Aldrich Chemical Co., Inc.) in 5 ml of water to form a second reaction mixture. The second reaction mixture was stirred at room temperature overnight and evaporated. The residue of the evaporation was taken up in 2-3 ml of chloroform/methanol/water (73:24:3), purified on one 20×20 cm preparative TLC plate (Silica gel 60, F254, Merck & Co., Inc.) and developed with chloroform/methanol/water (65:25:4). The yellow band which developed on the plate (Rf=0.45) (which can be detected also under long and short UV light) was treated in the same manner as the yellow band described in Example 1 to give DMAE-AEP (72 mg, 58%).
FAB Mass Spectral analysis in the positive ion mode gave a M+ peak of 493 and a M+Na peak of 515.
EXAMPLE 7
Preparation of 2',6'-Dimethyl-4'[N-(2-phosphonooxyethyl)carbamoyl]phenyl 10-methyl-acridinium-9-carboxylate bromide (DMAE-AEOP)
A solution of 2',6'-dimethyl-4'-carboxylphenyl 10-methyl-acridinium-9-carboxylate bromide (DMAE-COOH, 100 mg., 0.215 mmole) in 20 ml of 25% DMF in chloroform was cooled in an ice bath, treated with triethylamine (180 ul, 1.30 mole) and ethyl chloroformate (62 ul, 0.65 mmole) to form a reaction mixture. After 30 minutes, the reaction mixture was evaporated. The residue of the evaporation was reconstituted in 12 ml of DMF. To this solution so formed was added triethylamine (300 ul, 2.15 mmole) and 2-aminoethyl dihydrogen phosphate (91 mg, 0.64 mmole, Aldrich Chemical Co., Inc.) in 5 ml of water to form a second reaction mixture. The second reaction mixture was stirred at room temperature overnight and evaporated. The residue of this evaporation was taken up in 2-3 ml of chloroform/methanol/water (73:24:3), purified on one 20×20 cm preparative TLC plate (Silica gel 60, F254, Merck & Co., Inc.) and developed with chloroform/methanol/water (65:25:4). The yellow band which developed (Rf=0.45) (which could also be detected also under long and short UV light) was treated in the same manner as the yellow band described in Example 1 to give DMAE-AEOP. (100 mg: 79%). FAB Mass Spectral analysis in the positive ion mode gave a M+ peak of 509.
EXAMPLE 8
Rate of Leakage of Acridinium Esters From Lumisomes
Lumisomes were prepared as follows:
Chloroform solutions containing 25 mg dipalmitoyl phosphatidylcholine, 13.5 mg cholesterol, and 2.2 mg dipalmitoyl phosphatidylglycerol were air-dried on a round flat glass dish, 7 cm in diameter, and were placed for 16 hours in a vacuum to produce dry lipid films. Acridinium esters DMAE-COOH, DMAE-AMS, and DMAE-ANDS, were each dissolved in a solution of 0.215M sucrose, 0.25 mM EDTA, pH 7 (0.1-0.26 mg/ml). Acridinium esters DMAE-SCYS, DMAE-AEOS, DMAE-AEP, and DMAE-AEOP, were each dissolved in a solution of 50 mM sodium phosphate, pH 7.4 (0.1-0.26 mg/ml). A three ml aliquot of each acridinium ester solution so formed was added to a separate dry lipid film and gently mixed at 45° C. for 10 min. to produce a lumisome suspension. Each suspension so formed containing DMAE-COOH, DMAE-AMS, and DMAE-ANDS, was extruded through polycarbonate membranes with a pore size of 0.4 and 0.2 microns and then washed 4 times by ultracentrifugations at 45,000 rpm for 30 min. in TRIS Buffer (0.1M TRIS, 0.03M NaCl, 0.01% NaN 3 , 0.5 mM EDTA, pH 7.8) to produce a lumisome pellet. The lumisome pellets so formed were each resuspended in 10 ml of TRIS Buffer. Each lumisome suspension containing DMAE-SCYS, DMAE-AEOS, DMAE-AEP, and DMAE-AEOP, was extruded through polycarbonate membranes with a pore size of 0.4 and 0.2, microns and then washed 4 times by ultracentrifugation at 45,000 rpm for 30 min. in 50 mM sodium phosphate, pH 7.4, to produce a lumisome pellet. The lumisome pellets so formed were each resuspended in 10 ml of 50 mM sodium phosphate, pH 7.4. A sample of each resuspended lumisome pellet was mixed with 0.1% TRITON X-100 detergent (weight/volume) for determination of the total amount of encapsulated acridinium ester. Aliquots of each of the resuspended lumisome pellets were incubated for 7 days at 4° C. and 37° C. The aliquots were then centrifuged at 45,000 rpm for 2 hours. After centrifugation, a sample was taken from each supernatant and mixed with 0.1% TRITON X-100. The concentration of acridinium ester in each supernatant was then measured using the Ciba Corning Magic® LITE Analyzer (Ciba Corning Diagnostics Corp., Medfield, Mass.). The percent leakage of acridinium ester was then calculated by comparing the amount of acridinium ester in the supernatant to the total amount of acridinium ester originally encapsulated within the lumisomes.
TABLE 1______________________________________Acridinium % Leakage at % Leakage atEster 4° C./7 Days 37° C./7 Days______________________________________DMAE-COOH 25.0% 36.0%DMAE-AMS 0.8% 26.0%DMAE-ANDS 1.3% 1.9%DMAE-SCYS 0.5% 4.9%DMAE-AEOS 1.4% 52.8%DMAE-AEP 0.3% 1.0%DMAE-AEOP 1.8% 1.7%______________________________________
EXAMPLE 9
Effect of Different Buffers on Acridinium Ester Leakage From Lumisomes
Lumisomes encapsulating DMAE-ANDS were prepared according to the procedure described in Example 8 except that the DMAE-ANDS was dissolved in the four buffers listed in Table 2, prior to addition to the dry lipid film. The buffers were then used to wash, resuspend and store, respectively, the four lumisome prepartions in Table 2. The lumisomes so prepared were stored in their respective buffers for 35 days at either 4° C. or 37° C. and then centrifuged at 45,000 rpm for 2 hours. The concentration of DMAE-ANDS in each supernatant was then measured using a Ciba Corning Magic® LITE Analyzer. The percent leakage of DMAE-ANDS was then calculated by comparing the amount of DMAE-ANDS in the supernatant versus the amount of DMAE-ANDS originally encapsulated within the lumisomes.
TABLE 2______________________________________Effect of Different Buffers on the Leakage of DMAE-ANDS fromLumisomes After 35 Days at 4° C. and at 37° C.Buffer (50 mM) % Leakage at 4° C. % Leakage at 37° C.______________________________________Sodium phosphate 0.35% 0.85%pH 7.4Sodium acetate 0.33 1.39pH 7.4Sodium tartarate 0.62 1.30pH 7.4Sodium HEPES 0.79 1.71pH 7.4______________________________________
EXAMPLE 10
Total T 4 Assay
A. Reagent Preparation
Thyroxine (T 4 ) lumisomes encapsulating DMAE-AMS were prepared as described in Example 8 except that 0.16 mg of dipalmitoyl-phosphatidylethanolamine-succinyl-thyroxine (prepared as described in U.S. application Ser. No. 094,667, filed on Sep. 9, 1987, herein incorporated by reference) was added to the lipid mixture. DMAE-AMS at 0.2 mg/ml in phosphate buffer was used for hydration of the lipid film. The lumisome thus formed with the attachment of a hapten, thyoxine, is hereby referred to as a luminescent conjugate. The final lumisome preparation was diluted in Buffer A (0.02M Tris, 0.1M NaCl, 0,001M EDTA, 0.1% bovine serum albumin (BSA), 0.1% sodium azide, pH 7.8).
Monoclonal anti-T 4 antibody was produced in mice (A/J) by immunization with a BSA-T 4 conjugate and subsequent fusion of the splenocytes with Sp2/0-Ag 14 myeloma cells by the procedure described byKohler and Milstein in Nature (London), Vol. 256, pp. 495-497 (1975). Hybridoma cells secreting anti-T 4 antibody were detected by radioimmunoassay using the following procedure: Supernatant from the cells were diluted 1:5 in phosphate buffered saline containing 0.1% (weight/volume) bovine gamma globulin. 100 ul of each diluted supernatant and 100 ul of 125 I-labelled T 4 were added to a test tube and were incubated. for one (1) hour at room temperature. Goat anti-mouse IgG coupled to paramagnetic particles were added to each tube for ten (10) minutes at room temperature. The particles were magnetically separated and counted. The cells that tested positive (i.e., produced counts over background) were plated at 0.1 cell/well and then retested after growth.
Cells resulting from this regrowth which tested positive were then injected introperitoneally into pristane-primed mice (CAF). Ascitic fluid from these mice was collected after 3-5 weeks. The anti-T 4 antibody was purified from the ascitic fluid by Protein A column chromatography using the Affi-Gel Protein A MAPS II Kit (Bio-Rad Laboratories, Richmond, Calif.) according to the written protocol provided by the kit. The anti-T 4 antibody was immobilized on paramagnetic particles as described by Groman et al, BioTechniques 3:156-160 (1985). The antibody-derivatized particles were diluted to a concentration of 50 ug of particles per 0.1 ml of Buffer B (0.03M phosphate, 0.1M NaCl, 2.9 mg/ml merthiolate, and 0.1% BSA, 0.1% sodium azide, pH 7.4).
B. Assay procedure
A series of standards (0.05 ml) with known increasing amounts of T 4 were added to 12×75mm plastic tubes. 0.1 ml of the T 4 -lumisomes prepared in A containing 10×10 6 RLU (relative light units) in Buffer A were then added, followed by the addition of 0.5 ml of the paramagnetic-particles immobilized with monoclonal anti-T 4 antibody as prepared in A. The tubes were incubated for 1 hour at room temperature and then placed in a magnetic field of a specially designed rack useful for magnetic separation of paramagnetic particles in test tubes (available from Ciba Corning Diagnostics Corp., Medfield, Mass.). The magnetic field separated the particles from the supernatant and the supernatant was then decanted. The particles were washed once in 1 ml of phosphate-buffered saline, vortexed, and magnetically separated. The particles were resuspended in 0.1 ml of TRITON X-100, 0.1% (w/v) in deionized water.
The tubes were then placed in a luminometer (MAGIC® LITE Analyzer, Ciba Corning Diagnostics Corp., Medfield, Mass.). 0.3 ml of a solution of 0.1% hydrogen peroxide in 0.1N HNO 3 was added to each tube by the luminometer and the light emission was triggered by the addition of 0.3 ml of 0.25N NaOH containing ARQUAD surfactant (Armark Chemicals, Chicago, Ill.). The measured RLU for each tube was plotted against its respective T 4 concentration as shown in FIG. 1.
EXAMPLE 11
Free T 4 Assay
A series of serum-based standards containing known increasing concentrations of free T 4 were added to 12×75 mm plastic tubes. 0.1 ml of the T 4 -lumisomes prepared in Example 10A containing 10×10 6 RLU was added, followed by the addition of 0.5 ml of the paramagnetic-particles immobilized anti-T 4 antibody as prepared in Example 10A, in Buffer B minus merthiolate. The reaction was carried out for 1 hour at room temperature and the tubes were further processed and read as in Example 10. FIG. 2 shows the standard curve obtained by plotting the measured RLU for each tube against its respective free T 4 concentration.
EXAMPLE 12
Creatine kinase MB (CKMB) Assay
A. Reagent preparation
Monoclonal antibodies to creatine kinase MB (CKMB) and creatine kinase BB (CKBB) were prepared as described by Piran et al, Clinical Chemistry 33:1517-1520 (1987).
Lumisomes were prepared as described in Example 8, except that 1 mg dithiopyridyl dipalmitoyl phosphatidylethanolamine (DTP-DPPE), prepared according to Barbet et al, J. Supramolecular Structure 16:243-258 (1981), was added to the lipid mixture. The dry lipid film was hydrated with DMAE-ANDS, 2 mg/ml, and the final lumisome preparation was diluted in 0.1M sodium phosphate, 0.15M NaCl, and 0.005M EDTA, pH 7.5.
The anti-CKMB monoclonal antibody was coupled to the DTP-DPPE containing lumisomes by the method of Barbet et al J. Supromolecular Structure 16:243-258 (1981). The anti-CKMB antibody bearing lumisomes were diluted in Buffer C (0.1M 1,4-piperazinediethanesulfonic acid, 0.15M NaCl, 0.001M EDTA, 0.1% NAN 3 , 0.1% BSA, pH 6.5). "The "anti-CKMB antibody bearing lumisomes" which is described in this paragraph is called a luminescent conjugate."
The anti-CKBB monoclonal antibody was immobilized on paramagnetic particles as described in Example 10 for the anti-T 4 antibody and diluted in Buffer C to a final concentration of 100 ug of particles per ml of Buffer C.
B. Assay procedure
A series of serum-based standards (0.1 ml) with known increasing concentrations of human cardiac CKMB were added to 12×75 mm plastic tubes. 0.1 ml of the anti-CKMB antibody bearing lumisomes prepared in A containing 10×10 6 RLU was added to each tube and the tubes were then incubated for 30 minutes at room temperature. To each tube was then added 50 ug of the anti-CKBB antibody bearing paramagnetic-particles prepared in A and the the tubes were incubated for another 30 minutes at room temperature. The tubes were then processed and read as in Example 10, except that Buffer C minus BSA was used in the wash step instead of phosphate-buffered saline. The measured RLU for each tube was plotted against its respective CKMB concentration as shown in FIG. 3.
C. Four samples of human sera were assayed using the procedure described in B and concentrations of <1, 21, 24 and 68 ng/ml CKMB respectively, were determined. When these four samples were assayed using the CKMB Magic® LITE Assay (Ciba Corning Diagnostics Corp., Medfield, Mass. 02052), CKMB values of <1, 18, 24 and 72 ng/ml, respectively were determined, indicating good agreement between the two assays.
EXAMPLE 13
Thyroid Stimulating Hormone (TSH) Assay
A. Reagent preparation
Anti-TSH monoclonal antibodies were produced from TSH-immunized mice as described in Example 10 for the preparation of anti-T 4 antibodies. Preparation of DTP-DPPE containing lumisomes loaded with DMAE-ANDS and paramagnetic particles-immobilized anti-TSH was done as described in Example 12. These reagents were diluted in Buffer C.
B. Assay procedure
A series of serum-based standards (0.1 ml) with known increasing concentrations of TSH were added to 12×75 mm plastic tubes. 0.1 ml of the anti-TSH antibody bearing lumisomes prepared in A containing 8×10 6 RLU were added and the tubes were then incubated for 2 hours at room temperature. Paramagnetic-particles immobilized anti-TSH antibody as prepared in A was then added (0.5 ml) and the tubes were then incubated for an additional 30 minutes at room temperature. The tubes were then processed and read as described in Example 11.
C. The TSH assay was performed by the same procedure as described in B, except that the anti-TSH antibody bearing lumisomes were replaced by the anti-TSH antibody prepared in A labeled directly with 2',6'-dimethyl-4'-(N-succinimidyloxycarbonyl)phenyl 10-methyl-acridinium-9-carboxylate methosulfate (DMAE-NHS).
D. The standard curves obtained by the procedures described in B and C using the two types of labels are shown in FIG. 4. The results indicate that by using lumisomes encapsulating the hydrophilic acridinium ester analogue as the label, the signal to noise ratio at the low end of the assay is significantly increased. This increase in signal to noise ratio is advantageous because it allows better assay sensitivity, precision and speed.
E. The assay described in B was conducted using shorter incubation times (see FIG. 5). It was found that even when the first incubation time was 2.5 minutes and the second incubation time was also 2.5 minutes the sensitivity of the assay was satisfactory. It was not possible to obtain a sufficiently sensitive standard curve using the anti-TSH antibody which had been labeled directly with DMAE-NHS using the short incubation times. Surprisingly, the signal to noise ratio of the short lumisome assay was higher than that of the 2.0 hour/0.5 hour conventional assay (FIG. 5).
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Vesicular luminescent conjugates comprising liposomes coupled to molecules with biological activity, such as antigens, antibodies, and nucleic acids, for use in luminescent assays, are described herein. These conjugates encapsulate hydrophilic polysubstituted aryl acridinium esters and are useful as chemiluminescent tracers in immunoassays and other binding assays.
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BACKGROUND OF THE INVENTION
The invention concerns a sealing arrangement for shafts with small diameters within or bordering on housings containing mediums, where a lip seal is loaded by an axially acting spring.
The general prior art includes axial face seals for centrifugal pumps. The characteristic of this type of seal is that the moving sealing surface which is subject to wear has been relocated away from the shaft surface into a surface perpendicular to the shaft axis. The actual seal is established between the surfaces of a fixed ring and a rotating sliding ring. The latter is axially acted upon by a spring force. A fixed-body contact exists during operation between the sliding surfaces, so that a gap is no longer present (refer to Dubbel, pp. 197, 198 "Gleitringdichtungen" [axial face seals]).
Also known from the prior art is loading the seal by means of a worm spring in order to thereby obtain the necessary contact pressure for the desired seal. But it has been demonstrated that inserting such a worm spring is for space reasons not possible with very small shaft diameters.
Exactly with very small shaft diameters and high shaft peripheral speeds along with high liquid or gas pressures it was heretofore considered as impossible that with high peripheral speeds of the shaft to be sealed and with high pressures an effective sealing arrangement could be employed. The illustrated operating conditions regularly led to a relatively quick aging of the seals employed, whereby their resilience was lost, particularly at the seal lips. The result was leakages and liquid penetration at the transmission parts and engines connected to the shafts.
The problem underlying the invention is to provide a sealing arrangement for shafts with small diameters of the initially named type, which arrangement is simple in its entire structure, additionally allows a simple assembly and assures an optimum effect also over a long period of time while avoiding the disadvantages of the said prior art.
SUMMARY OF THE INVENTION
This problem is inventionally solved in that the seal lips of the lip seal are separated by wedge-shaped working surfaces of axially effective thrust parts and, independently from one another, are radially spread in such a way that at least the radially inner seal lip bears tightly on the shaft under pressure. Essential is that the working surfaces bear in line fashion on the end sections of the inside edges of the sealing lips of the lip seal.
With this form of a sealing arrangement, the two opposed sealing lips of the U-shaped lip seal are through the action of a thrust part spread in a fashion such that at least the one sealing lip bears in sealing fashion, tightly, on the shaft rotating at high peripheral speeds. The opposite sealing lip is selectively tightly forced on the housing wall. The contact force of the thrust part is achieved essentially by the helical compression spring used and a possibly pressurized liquid or air, respectively a gas. To keep the friction losses stemming from the contact of the wedge-shaped working surfaces as low as possible, the working surfaces of the thrust part bear essentially in line fashion on the inside edges of the sealing lips of the lip seal.
To obtain the line contact of the working surfaces on the inside edges of the sealing lips, the working surfaces may be inclined to the longitudinal axis of the shaft at a greater angle than the end areas of the inside edges of the sealing lips of the lip seal which bear on the working surfaces. These latter may be inclined at an angle of about 45° to the longitudinal axis of the shaft, while the end areas are inclined at an angle of about 30° to the longitudinal axis of the shaft. This assures that the seal is established only by the outermost edge of the sealing lip, whereby a greater friction on the shaft is avoided.
The line contact between the working surfaces of the thrust part and the sealing lips of the lip seal may be established also by two or more springs arranged successively and extending annularly around the inside edges of the sealing lips of the lip seal.
An essential characteristic of the invention is that the outer and inner sealing lips are pushed down separately from each other. Experiments have shown that forcing the two sealing lips down simultaneously by a single thrust part is practically impossible, since the necessary close tolerances cannot be maintained with the very small shaft diameters, if an economical production in series is presupposed. In the tests it was shown that, when using a single thrust part, for instance the one sealing lip was forced down, whereas the second sealing lip allowed liquid to pass, since the pressure was insufficient.
The experiences gathered in the sealing system relate primarily to teflon as sealing material, which has no elasticity.
A considerable difference between the radially outer and inner sealing lips is constituted also in that the outer sealing lip can be forced firmly on the inside wall of the bore (of the housing), whereas the inner sealing lip is forced down moderately, for instance at a pressure of 100 grams, in order to keep the friction with the rapidly rotating shaft low and thus also reduce the necessary energy, respectively the power consumption of the drive motor.
In the embodiment of the invention, the headside working surfaces may be formed on a single thrust part acted upon by a helical spring. On the other hand, the working surfaces acting on the radially outer sealing lip of the lip seal may be formed by a housing shoulder while the second working surface, on the head side, is provided on a thrust part loaded by a compression spring.
In yet another embodiment of the invention, the working surface acting on the radially outer sealing lip of the lip seal may be formed by a cylinder ring on the housing wall, while the second working surface, on the head side, is provided on a compression spring-loaded thrust part.
These aforementioned embodiments mean that selectively a single thrust part may be provided as a ring which extends around the shaft and features on the head side the wedge-shaped working surfaces which spread the sealing lips of the lip seal apart. On the other hand, though, it is also possible to fashion a thrust part, e.g., as a cylinder ring which bears on the inside wall of the housing, or bore, and features on the head side a working surface which forces the radially outer sealing lip on the housing wall. The radially inner sealing lip is forced on the shaft by a thrust part, under spring load. This means that only the inner thrust part is axially movable, whereas the cylinder ring stands firmly on the bottom of the housing shoulder. As an alternative to it, the radially outer cylinder ring itself may be fashioned also by the housing wall, in that a working surface of wedge shape is machined there, which forces the radially outer sealing lip of the lip seal on the housing wall.
The sealing ring may favorably be made of a PTFE material. But it may also be made of Viton, neoprene, Buna or polyamide. The housing may consist of both metal and plastic.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention is illustrated in the drawing, showing in
FIG. 1, the sealing arrangement in half section on the example of a gear pump powered by an electric motor;
FIG. 2, the sealing arrangement according to FIG. 1, in half section, in a modified design;
FIG. 3, the sealing arrangement according to FIG. 2, in half section and modified design;
FIG. 4, a section IV in FIG. 1, in cross section.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the example of FIG. 1, an electric motor 1 drives a shaft 2. The shaft 2 has a very small diameter, for instance of 2.5 mm, and a high speed of rotation, respectively peripheral speed. The shaft 2 is mounted in a plain bearing 3, which on the motor side butts axially on the motor flange 4. Of course, also antifriction bearings are usable. The outer shell surface of the bearing 3 is in contact with the inside wall of the housing 5, or bore. Contained in the axial extension of the bearing 3 is a sealing ring 6 representing a lip seal of plastic, preferably of PTFE. The lip seal 6 is essentially U-shaped and bears with its radially inner sealing lip 6.1 on the outer circumference of the shaft 2. The radially outer sealing lip 6.2 bears on the inside wall of the housing 5. The end section of the inside edges 6.3 of the sealing lips 6.1 and 6.2 is at an angle 7 of about 30° so inclined that the two opposed inside edges 6.3 inscribe an angle of about 60°.
U-shaped in cross section, the lip seal 6 is engaged at its open U, axially, by a thrust part 8 which is of ring-shaped design and arranged around the shaft 2. On the head side, the thrust part 8 features working surfaces 8.1 extending wedge-shaped at an angle of about 45°. The thrust part 8 is acted upon by a helical compression spring 9 which, for one, bears on the housing bottom 10 and, for another, on an annular shoulder 11 beneath the working surfaces 8.1 of the thrust part 8. Thus, the thrust part is subjected to a force acting axially in the direction on the lip seal 6, whereby the working surface 8.1 of the thrust part 8 bears on the inside edges 6.3 of the sealing lips 6.1. Due to the different angles of the working surfaces 8.1 and the inside edges 6.3 of the lip seal 6, an essentially line-shaped contact is brought about between the seal 6 and the thrust part 8. Inclined at an angle, the working surfaces force the sealing lip 6.1 firmly and tightly on the outside circumference of the shaft. The tight contact of the lip seal 6 is assured nearly without limitation by the thrust part 8. The outer sealing lip 6.2 is forced on the inside wall of the housing 5, for instance by the liquid pressure or by gas pressure.
Provided on the end 12 of the shaft 2 is a gear 13 meshing with a not illustrated second gear and forming thereby, e.g., a gear pump. Filled with a liquid medium in the case of a gear pump, the space 14 is pressurized by the liquid, which through the annular gap 15 of the housing 5 prevails also on the thrust part 8 and acts in the direction toward the lip seal 6. The liquid pressure can quite possible amplify also the axial force of the helical spring 9, so that the working surfaces 8.1 of the thrust part 8 will always remain in firm contact with the inside edges 6.3 of the lip seal 6. This type of sealing arrangement prevents in a technically simple manner and with an optimum design a penetration of the liquid from the liquid space 14 to the bearing 3, or motor 1.
Instead of the presented example of a motor-powered gear pump for liquid mediums, of course, it is also conceivable to use this sealing arrangement in spaces carrying gas or air pressure.
The housing 5 can selectively be fashioned of plastic or metal. Using a metal housing 5 provides the option of using according to FIG. 2 a cylinder ring 16 which firmly stands on the housing bottom 10 while on the head side it possesses a working surface 16.1 extending at an angle of about 45°. This working surface 16.1 is in connection with the inside edge 6.3 of the radially outer sealing lip 6.2 of the lip seal 6, forcing the sealing lip 6.2 on the inside wall of the housing 5. The thrust part 8, subjected again to the force of a helical compression spring 9 acting axially, features working surfaces 8.1 on the head side. In this case of the example illustrated in FIG. 2 though, only the radially inner working surface 8.1 bears on the inside edge 6.3 of the radially inner sealing lip 6.1 of the lip seal 6, forcing this sealing lip 6.1 tightly on the outer circumference of the shaft 2.
Otherwise, this illustration according to FIG. 2 corresponds to the design features of FIG. 1. Here, too, a gear pump driven by an electric motor is to be shown, from the pump housing pressure side 17 of which liquid flows through the annular gap 15 of the housing 5 in the direction of the lip seal 6.
Another version of the sealing arrangement, proven in tests, is illustrated in FIG. 3. In this embodiment, the cylinder ring 16 according to FIG. 2 has been replaced by a corresponding recess 18 in the housing. This recess 18 is constituted in that at the level of the inside edge 6.3 of the radially outer sealing lip 6.2 of the lip seal 6 there is a ring-shaped housing shoulder 19 integrally molded in place, the working surface 19.1 of which bears outwardly on the inside edge 6.3 of the lip seal 6. Here too, the working surface 19.1 is slanted at an angle of about 45° while the inside edge 6.3 is inclined at an angle of about 30° to the longitudinal axis of the shaft, so that the line contact occurs again.
The thrust part 8 with the working surface 8.1 and helical compression spring 9 corresponds to the design according to FIG. 2.
Illustrated in FIG. 4, scaled up, is the circular section 4 according to FIG. 1. The working surface 8.1 of the thrust part 8 extends again at an angle of about 45° while the inside edge 6.3 in the end section of the radially outer sealing lip 6.2 of the lip seal 6 is shaped with an angle of 30° to the longitudinal axis of the shaft.
In a preferred embodiment of the invention, the lip seal 6 consists of plastic and may be made selectively of PTFE, Buna, neoprene, Viton or polyamide. The housing 5 may selectively consist of metal or plastic.
The lip seal 6 of PTFE can be produced by machining on an automatic lathe and features sealing lips 6.1 and 6.2 whose inside edges 6.3 inscribe an angle of 60°.
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Proposed is a sealing arrangement for shafts with very small diameters, with an essentially U-shaped lip seal (6) subjected to the force of an axially acting helical compression spring (9). The two sealing lips (6.1 and 6.2) of the lip seal (6) are by thrust parts (8) with working surfaces (8.1) of wedge-shaped arrangement spread apart in such a way that the radially inner sealing lip (6.1) is pressed tightly on the shaft outside circumference and the radially outer sealing lip (6.2), independently thereof, tightly on a housing wall (5).
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BACKGROUND OF THE INVENTION
At the present time, roof waterproofing membranes used in flat commercial and industrial roofing applications are secured around the periphery of the roof deck by means of mechanical fasteners through the waterproofing membrane, in combination with adhesives and flashing materials. Such applications result in disengagement, puncturing, tearing or otherwise damaging the waterproofing membrane and flashing when the waterproofing membrane billows as a result of wind-uplift forces, a condition associated with changes in atmospheric pressure. Expansion and contraction of the waterproofing membrane and flashing, due to temperature changes, can result in loosening of the waterproofing membrane and flashing from the periphery of the roof deck. The net result is that the roofing application ultimately fails.
SUMMARY OF THE INVENTION
The present invention involves the combination of a one-piece fabricated coved securement base with resilient compression retainers for positively securing the waterproofing membrane, either alone or in combination with the apertured overlay described in applicant's copending patent application Ser. No. 294,023.
A coved securement base may be metallic or nonmetallic, cast, molded, rolled, drawn, extruded, stamped, or formed. The resilient compression retainers may be metallic or nonmetallic. Preferably two resilient compression retailers are used; one retains the waterproofing membrane in the coved portion of the base member and the other retains the apertured overlay on top of the waterproofing membrane in the coved portion of the base. However, in some applications a single resilient retainer may be used, either to secure the waterproofing membrane or to secure both the waterproofing membrane and the apertured overlay.
It is therefore an object of this invention to provide a perimeter securement assembly for a roof deck covering for securing roof waterproofing membrane without puncturing or damaging the membrane by means of mechanical fasteners or disengagement of adhesives.
It is also an object of this invention to provide roof perimeter securement assembly which may be used to hold a roof waterproofing membrane, or a roof membrane and an apertured overlay, securely on a roof deck.
These, together with other objects and advantages of the invention will become more readily apparent to those skilled in the art when the following general statements and descriptions are read in the light of the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the applicant's invention with portions of the apertured overlay broken away.
FIG. 2 is a modification of applicant's invention showing a different type of resilient compression retainer.
DETAILED DESCRIPTION OF THE INVENTION
Referring now more particularly to FIG. 1, the roof deck is shown at 10 adjacent to a parapet or wall 11. The base member 12 of the applicant's invention comprises a coved section 13 and two complementary elements 14 and 15 extending inwardly. The base member 12 may be cast, molded, rolled, drawn, extruded, stamped, or formed and may be made from a metallic or a nonmetallic material. The base member 12 may be attached to the parapet or wall 11 and the roof deck 10, or a nailing strip on the roof deck, by fasteners 16--16. As shown, the waterproofing membrane 17 lies on the roof deck 10, and is covered with an apertured overlay 18. Resilient compression retainers 19 and 20 are shown with resilient compression retainer 19 holding waterproofing membrane 17 in place in the base member 12 adjacent the elements 14 and 15. Preferably the resilient retainers 19 and 20 are designed so that they engage a substantial portion of the interior surfaces and edges of elements 14 and 15. The waterproofing membrane 17 also extends over and adjacent the elements 14 and 15 and preferably is pdressed against the interior surfaces and the edges of elements 14 and 15. The apertured overlay 18 has been cut away to show the position of the resilient compression retainer 19. An identical resilient compression retainer 20 is shown holding the apertured overlay in place atop waterproofing membrane 17. The resilient compression retainers 19 and 20 preferably are about two inches wide, are placed alternately on approximate one-foot centers, and preferably are constructed of stainless steel. The base member 12 may be any suitable length. The length is only restricted by the means for its transportation. The waterproofing membrane 17 may be fastened to the parapet or wall 11 by any suitable means well-known in the art. If there is no parapet or wall 11, a fascia may be used which will extend over the upper portion of the base member 12 with the waterproofing membrane 17 being enclosed between fascia and base member 12 thereby in a conventional method of terminating the waterproofing membrane. The apertured overlay 18 which covers the waterproofing membrane 17 to prevent billowing is described in detail in applicants copending patent application Ser. No. 294,023.
Referring now more particularly to FIG. 2, there is shown a different type of resilient compression retainer 21. This is a resilient solid or tubular member. In this instance, both the waterproofing membrane 17 and the apertured overlay 18 have been forced into the coved section 13 of the base member 12 behind and adjacent the elements 14 and 15 and the resilient member 21 is pressed into the resulting space which it is designed to fit. Of course, the resilient member 21 may be used with the waterproofing membrane 17 alone, if the apertured overlay 18 is not used. The resilient solid or tubular member 21 may be an extrusion made of any suitable material which is flexible enough so that it may be forced in between and behind the complimentary elements 14 and 15 so as to hold the apertured overlay 18 and the waterproofing membrane 17 in place. Certain forms of rubber and plastic are satisfactory.
The use of this perimeter securement assembly for a roof covering assures a permanent securement of the waterproofing membrane and an apertured overlay, if used, without mechanically puncturing or adhesively securing the waterproofing membrane. This system may be used with conventional ballast or any other existing methods of installing a waterproofing membrane although, of course, the preferred use is with the apertured overlay 20.
While this invention has been described in its preferred embodiment, it is to be appreciated that variations therefrom may be made without departing from the true scope and spirit of the invention.
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A perimeter securement assembly for a roof deck covering involving a one-piece fabricated coved securement base with resilient compression retainers for positively securing said waterproofing membrane roof deck covering therein.
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FIELD OF THE INVENTION
This invention relates to assembly fixtures, and more particularly, to a fixture for laminating electronic circuit modules.
BACKGROUND OF THE INVENTION
In the construction of electronic modules, circuit chips are often assembled in a stack configuration within a cube build fixture with the planar chips positioned one over the other with interleaved deposits, or layers of bonding material. Such fixtures are designed to laterally align the chips, and support and confine them in a stack configuration to facilitate application of light pressure for bonding the layers into a laminated module. In some arrangements, the walls of the cavity are grooved to accommodate the flow of excess adhesive from the chip stack, and a thin foil, of aluminum for example, is interposed between the sides of the chip stack and the sidewalls of the cavity to preclude adhesion to the stack cavity.
Presently available fixtures for assembling circuit chip modules, provide a stack defining configuration, such as a stack cavity, with a removable section designed to facilitate loading of circuit chips in a stack within the fixture, as for example, is shown in U.S. Pat. No. 4,704,319. In this arrangement, a block is formed around a stack of chips to produce an open top cavity, having one or more removable side walls to allow stacking of the circuit chips. The open ended cavity is of a size to accommodate the lateral dimensions of the circuit chips to laterally align them for bonding. The chips are assembled one on the other within the cavity through its top and open wall section. Following stack assembly, the absent sidewalls are replaced, and a low level force applied to the top of the assembled stack, e.g., through a press arrangement, to hold the stacked chips under light pressure as the bonding material is allowed to set. This assembly fixture is constructed of material having a particular specific coefficient of expansion to accommodate the application of heat during bonding, and the sidewalls of the stack cavity are grooved to allow for excess adhesive.
In a slightly different arrangement, a stacking fixture is provided by upright pins, or rods mounted on a flat support surface to produce an outline of the lateral dimensions of the chips for aligning them in a stacked configuration. To facilitate stacking of the chips within the upright rods, one or more of them, may be made removable.
While the above noted fixtures facilitate bonding of the circuit chips in a stack or cube, it should be evident that they do not provide as rapid, or efficient loading of the chips, as is desirable. Moreover, it can also be seen that these fixtures generally require manual steps which do not easily lend themselves to automation of the electronic module assembly.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an improved assembly fixture for laminating circuit chips into a modular configuration.
A further object of the invention is to provide a fixture designed for simple, convenient loading of circuits chips in a stack configuration for bonding as a laminated module.
A still further object of the invention is to provide an assembly fixture having an expandable stack cavity allowing convenient loading of the chips within, and removal of the completed module from, the stack cavity.
Another object of the invention is to provide a fixture having a stack cavity alterable between a stack aligning size for enabling bonding of circuit chips into a laminated module, and an expanded size designed for convenient loading of the chips in, and removal of the laminated module from, the stack cavity.
Still another object of the invention is to provide a electronic module building fixture particularly suited for automated assembly of circuits chips modules.
These desirable results, and other objects of the present invention, are realized and provided by a housing having an open ended housing cavity defined at least in part, by an inwardly facing, inclined wall which defines an inclined surface having one end spaced more closely to the center of the housing than the other. The housing cavity contains at least one moveable segment which defines an open ended stack cavity configured for receiving circuits chips positioned one over another for bonding into a stack configuration. An inwardly facing wall of the moveable segment forms at least a portion of one wall of the stack cavity, and an outwardly facing wall of the segment is inclined at an angle similar to that of the inclined housing surface and arranged in mating relation therewith such that, when the segment is moved along the inclined surface of the housing in a given direction, the segment will be automatically urged inwardly to laterally confine the circuit chips positioned in the stack cavity between its inwardly facing wall and the opposite wall of the stack cavity, and when the segment is moved in an opposite direction, the segment can move outwardly to expand the stack cavity, and thereby facilitate its loading and unloading.
For rectilinear chips, at least two adjacent segments are preferred, and a spring arrangement biases the segments away from each other to automatically alter the cavity to its expanded mode when its moved in a select direction along the inclined surface. In the preferred embodiment, the housing cavity is generally circular in lateral cross section with its inwardly facing wall inclined downwardly and inwardly from the upper surface of the housing to form a truncated, cone-shaped housing cavity. Four moveable segments are supported within the housing cavity by its inclined wall, with each segment having an inwardly facing, substantially upright wall for defining the sidewalls of a stack cavity. Each segment also includes an outwardly facing wall, inclined in a fashion similar to that of the inclined surface of the housing cavity and in mating relation therewith such that when the segments are moved upwardly along the inclined housing surface, they can be urged outwardly from each other to expand the stack cavity for loading and unloading, and as they are moved downwardly along the inclined surface, they will be urged inwardly to align the stacked circuit chips within the stack cavity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in section of a fixture providing moveable segments for assembling a laminated electronic module in accordance with the invention;
FIG. 2 is a plan view of the lower portion of the fixture shown in FIG. 1;
FIG. 3 is a plan view illustrating an expanded cavity configuration of the moveable segments of the fixture illustrated in FIGS. 1 and 2;
FIG. 4 is view in perspective of a lifting bar for raising the moveable segments so as to release the electronic module following its assembly; and
FIG. 5 is a diagrammatic view in section of a stack of circuit chips assembled within a bag for loading in the fixture illustrated in FIGS. 1 to 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Basically, the present invention, as illustrated in FIGS. 1 and 2, provides a jig, or assemble fixture 10 comprising a stacking fixture 12 and a pressure plate assembly 14. The stacking fixture 12 consists of a housing 16 having an open ended housing cavity 20 extending downwardly to a bottom surface 18 of this cavity.
Four moveable segments 22a, 22b, 22c and 22d form an inner assembly 24 within the housing cavity 20, and inwardly facing, upright walls 26a, 26b, 26c, and 26d of each segment define the sidewalls of a centrally located, stack cavity 30. As will be subsequently explained in detail, the stack cavity 30 is designed to laterally position a plurality of circuit chips 36 in a stack 37 (both of which are shown in FIG. 5) for bonding to a laminated electronic circuit cube, or module (not shown).
As can be seen in FIG. 1, the housing cavity 20 is defined by an inwardly facing, inclined wall surface 32 which inclines inwardly, approximately at an angle of 30 degrees, from a top surface 34 of the housing 16 to the bottom surface 18. Consequently, the inclined surface 32, provides a truncated cone shape to the housing cavity 20.
The four segments 22a-d, which make up the inner assembly 24, are aligned within the housing cavity 20 in lateral engagement with each other as illustrated in FIGS. 1 and 2. This is accomplished by virtue of the fact that the segments 22a-d, each have an outwardly facing, inclined wall surfaces of which only surfaces 28b and 28d are shown in FIG. 1. These wall surfaces are inclined at approximately the same angle as the inclined surface 32, and mated thereto so that gravity tends to draws the four segments toward each other as illustrated in FIGS. 1 and 2. To enhance movement of the segments 22a-d along the inclined surface 32, as later explained, all the inclined surfaces are brought to a highly polished finish.
In the preferred embodiment, the four segments 22a-d are machined to provide a truncated cone shape for the inner assembly 24 such that, when the segments are mated together in the housing cavity 20, the outer diameter of the inner assembly 24 at its top surface 38, will be approximately equal to the diameter of the housing cavity 20 where it opens to the top surface 34.
To define a suitable stack cavity 30, the inner assembly 24, formed by the segments 22a-d when assembled in the housing cavity 20, is designed to equal the maximum dimensions of the chips to be assembled into a module. Stated otherwise, for stack construction with chips 36 of a given maximum length and width, the dimensions of the segments 22a-d are designed to define a stack cavity 30 equal to these maximum lateral dimensions plus twice the thickness of an aluminum separation sheet, since the latter is employed on all four sides, as later explained in more detail in regard to FIG. 5.
The segments 22a-d are shown slightly spaced apart in FIG. 3 to depict the expanded condition of the stack cavity 30, as later explained. For clarity, the spacing illustrated for the segments 22a-d is slightly exaggerated, to more adequately depict their structure. As shown in this FIG. 3, segments 22a-d are lightly biased apart at their lateral sides 40 by springs 42 to aid in the loading of the chips 36 and unloading of the assembled module (not shown), once curing has been completed. The springs 42 are carried within appropriate indents 44 in the lateral sidewalls 40 to urge the segments slightly apart when they are released from, or raised from, their confinement within the housing cavity 20.
Once the bonding is complete, the segments 22a-d are forced upward, allowing them to spring away from each other and expand the stack cavity 30. This reduces pressure on the side walls of the assembled module to facilitate its removal. That is, as the segments 22a-d are raised slightly in the stack cavity 30, they separate under the bias of the springs 42 to expand the cavity, as depicted in slightly exaggerated form in FIG. 3, for unloading of the assembled module, as well as acceptance of the next stack of chips for assembly.
As illustrated in FIG. 3, the springs 42 provide means for displacing, or biasing the segments 22a-d apart as the segments are raised from, and released from, confinement within the housing cavity. Other displacing means would also be applicable. For example, the outward edges of the lateral sides of the segments 22a-d could carry a cam surface (not shown), each of which is designed to engage one of four cams (not shown) of the housing cavity 20 so as to drive the segments apart as they are raised.
Advantageously, even slight upward movement of the segments releases them from confinement in the housing cavity and begins the expansion of the stack cavity. Consequently, where excess adhesive has exerted pressure against the sidewalls of the stack cavity 30, they will still easily break away from the module.
A slot 50 is provided within the housing 16 in a plane parallel to the surface 18, to facilitate lifting of the segments 22a-d. The height of the slot 50 is designed to intersect and pass beneath the bottom 48 of the segments when they are located in their module bonding position, shown in FIGS. 1 and 2. For lifting the segments 22a-d, a wedge shaped key or lifting bar 52, as shown in FIG. 4, is provided. The bar 52 is bifurcated to allow passage of its leading ends 54 around a centrally located section 60 (See FIG. 1) of the surface 18, which forms the bottom support for the chips in the stack cavity 30.
Each of the ends 54 of the lifting bar 52 include an inclined or ramped surface 62 which forms an inclined plane. Consequently, as the lifting bar 52 is inserted in the slot 50, its ramped surface will engage the bottom 38 of each of the moveable segments 22a-d to ramp them away from the bottom surface 18 so as to lift them, and thereby open the stack cavity 30.
The ramped surfaces 62 of the lifting bar 52 provides the mechanical advantage of a sliding plane to force the segments upwardly. This combined with rapid cavity expansion provides for efficient release of the module.
Other arrangements for lifting the segments 22a-d to allow opening of the stack cavity 30 can also be utilized. For example, of the housing 16 can have four small openings (not shown), one beneath each of the segments 22a-d to receive upright members or rods (not shown) inserted through the base and into engagement with the segments to raise the latter.
In the method of the preferred embodiment, the chips are not individually placed in the stack cavity 30, but into a shell or other holder such as the bag 46, shown in FIG. 5, for placement in the stack cavity 30 when the latter is in its expanded configuration. Hence, the chips 36 (with interposed adhesive (not shown), such as epoxy, are first stacked within the bag 46, and the filled bag 46 then deposited within the expanded stack cavity 30. The bag 46 is formed of aluminum or other releasable material, or otherwise coated with a suitable release coat.
As is evident, the bag 46 provides an easily loaded carrier for initial stacking of the chips for top loading in the expanded cavity and also precludes bonding of the stack to the stack cavity. To further enhance the latter, the inner walls 26a-d, which make up the stack cavity 30, are fluted or ribbed in a vertical direction, to minimize the surface area in contact with the bag, and to provide room for excess bonding material extruded from the stack.
In the method of assembly, with the bar 52 in place in the slot 50 and the cavity 30 is in its expanded condition, the fixture 10 is ready for loading. The filled bag 46 in placed in the expanded cavity and the lifting bar removed. At this point in the assembly, the force of gravity will draw the segments downward to loosely engage the chip filled aluminum bag 46, and indirectly through it, to the lateral edges of the stacked chips to align and confine them in a proper stack configuration with a high degree of precision.
Once the chip filled bag 46 has been placed within the stack cavity, the pressure plate assembly 14 (illustrated in FIG. 1) is placed on the housing 16 and aligned thereon by any suitable arrangement, such as aligning pins (not shown). As shown, the plate assembly 14 comprises a plate 68, and a piston 70. The plate 68 is designed to bear upon the segments 22a-d and force them flush with the housing top surface 34, at which point, their lateral sides 32 will be in engagement with each other to form a stack cavity 30 having lateral dimensions equal to the maximum dimensions of the chip filled bag 46, and as previously indicated, thereby laterally maintaining the chips in the stack 37 within an acceptable tolerance for module assembly.
Any suitable press arrangement (not shown) can be utilized to urge the segments downwardly and to independently apply a light downward force to the stack so as to permit the bonding material to set. In the illustrated embodiment, vertical pressure will be exerted on the stack of assembled chips by means of the piston 70, loosely carried within the plate 68. The plate 68 and the piston 70 are then forced against the fixture 12 by any press arrangement (not shown), which will hold the plate against the segments 22a-d and the top surface 34 and independently apply a light downward force to the piston 70 thereby providing appropriate pressure for curing of the module. The plate 68 may, of course, be clamped or fixed to the housing 16 by any suitable clamping mechanism (not shown) and its piston 70 separately urged downward.
As noted previously, the segments 22a-d are preferably designed to be substantially flush with the top surface 34 of the housing 16 when the segments are in their stack aligning mode. However, other arrangements will also be useful. For example, since the abutting of the lateral walls of the segments 22a-d is controlling, the top 38 of the segments can be above or below the top surface 34, so long as an appropriate force is exerted upon the segments to hold them in their abutted condition.
As noted earlier, abutting of the lateral sides of the segments defines the minimum size of the stack cavity in the preferred embodiment, however, the latter function could also be served by other arrangements. For example the inwardly facing walls 26a-d of the segments could be designed to abut adjoining ones to determine the stack cavity, or stops could be provided at the base of the walls 26a-d. The latter could also serve to provide a support base for the chip stack. Further, the size of the stack cavity could also be controlled by the bottoming of the segments 22a-d in the housing cavity.
Consequently, as can be seen from the above description of the preferred embodiment, the fixture 10 can provide alignment in the X and Y directions of a chip stack, as well as compression of the stack during curing. Assembly is convenient and straight forward, and the stacking fixture 12 is essentially self-aligning. Once the filled bag 46 is placed in the cavity 30, the bar 52 removed, and the segments urged downwardly into a flush condition with the top surface 34, no further adjustments of the stack cavity are required. All that remains is to apply a light pressure to the top of the stack until the bonding material is set. When the material is set, the segments are raised such that the cavity expands and the completed module is then removed.
Various arrangements of the assembly fixture may be useful in practicing the invention. Where one or two movable segments are employed, the stack housing can provide fixed sides of the stack cavity. Moreover, moveable segments with curved inclined surfaces can be employed, as in the preferred embodiment, or with planar inclined surfaces (not shown). Both can permit alteration from a stack confining cavity to an expanded cavity.
A four segment fixture in which flat inclined surfaces are employed will also operate satisfactorily. Moreover, the inclination of the surfaces can be along an axis other than the downwardly disposed axis of the preferred embodiment. For example, the housing cavity 20 and the segments 22 a-d may be constructed with planar mating surfaces inclined with respect to the lateral axes of the stack cavity 30 such that the segments are moved along directions parallel to the top of the surface 34 of the fixture to alter the cavity condition.
Advantageously, the assembly fixture 10 will lend itself well to automation of the above described lamination of electronic circuit modules. That is, it should be appreciated that the chip bag 46 can be filled with chips 36, placed in the expanded stack cavity 30 and downward pressure applied, all by suitable machine operation. Likewise, the segments 22a-d can be raised and the module removed by machine, in readiness for repetition of the assembly process.
This completes the description of the preferred embodiment of the invention. Since changes may be made in the above process, without departing from the scope of the inventions described herein, it is intended that all the matter contained in the above description or shown in the accompanying drawings shall be interpreted in an illustrated and not in a limiting sense. Thus other alternatives and modifications will now become apparent to those skilled in the art without departing from the spirit and scope of the invention as set forth in the following claims.
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A fixture having an open ended housing cavity defined by an inwardly inclined wall, and including at least one moveable segment having an inwardly facing wall which defines one wall of a stack cavity configured for receiving a plurality of circuits chips positioned one over another for bonding together in a stack configuration, and an outwardly facing wall of the segment is inclined at the angle of the inclined wall of the housing and arranged in mating relation therewith such that when the segment is moved in one direction along the inclined wall of the housing, it will be urged inwardly to align the circuit chips within the stack cavity, and when urged in an opposite direction it can move outwardly to expand the stack cavity for loading and unloading. A truncated cone shaped housing cavity is preferred with four movable segments having outwardly facing walls inclined similar to the inclined wall of the housing cavity and in mating relation therewith such that when the segments are moved upwardly along the inclined housing surface, they can be urged away from each other to expand the stack cavity, and when the segment are moved downwardly along the inclined surface of the housing, they will be urged inwardly to align the circuit chips in the stack cavity.
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FIELD OF THE INVENTION
[0001] The invention is in the field of Engineering relating to a CNG (Complied Natural Gas) cylinder mounting device for a vehicle.
BACKGROUND OF THE INVENTION
[0002] A structure for holding a CNG cylinder mounting device for a vehicle should be strong and able to hold the gas cylinder securely, preventing the movement or the slide ability there of when the vehicle is running. However, the typical mounting device for the CNG cylinder for a vehicle installed on the bed is provided with a structure comprised of angle bars. Such structure exhibits a rather lower strength under the weight of a 98-kg gas cylinder apart from the force from many directions when the vehicle runs. Therefore the disadvantages of such structure include a shorter lifetime and a possible loosened valve installed at the gas cylinder head, causing the leakage of the gas.
SUMMARY AND OBJECTS OF THE INVENTION
[0003] The mounting device tor the CNG cylinder installed on the bed of a vehicle recording to the present invention is characterized in that the structure is mainly made of flat metal plates and molded-to-shape metal whereas there are provided the upper and the lower cylinder fastening belts; a cylinder supporting frame unit comprising a belt supporting plate, a bracket, a cylinder placement frame, a front frame locking bracket, a rear frame locking bracket, an auxiliary bracket as well as other element parts besides metal work pieces including a cylinder placement frame sleeve, a bracket supporting sleeve, a upper cylinder fastening belt supporting rubber, a lower cylinder fastening belt supporting rubber. All of these parts will be assembled together with bolts, nuts or by moans of fixing.
[0004] The object of the present invention is to develop a strong structure of a CNG cylinder mounting device in order to reduce the problem concerning the gas cylinder body frame whereas a strong structure of a CNG cylinder mounting device is invented to eliminate the problem concerning the gas cylinder body frame by making the mounting device for the gas cylinder and the bed frame mounting device strong and secure as if the mounting device for the CNG cylinder is part of the vehicle structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0005] According to FIG. 1 , it illustrates the structure of a bed floor 1 under the bed floor of the vehicle comprising a front transverse frame 12 , a rear transverse frame 13 , a left-side frame 14 , and a right-side frame. All of these parts will be assembled together by means of fixing at the location for installing the mounting device for the CNG cylinder on the bed according to the present invention whereas the front transverse frame 12 is provided at the front of the vehicle near the cab (not shown in the figure); the rear transverse frame 13 is placed next from the front transverse frame 12 to the rear of the vehicle body (not shown in the figure); the left-side frame 14 is placed on the left parallel to the vehicle body (not shown in the figure); and the right-side frame 15 is placed on the right parallel to the vehicle body 15 (not shown in the figure).
[0006] According to FIG. 2 , it illustrates a gas cylinder supporting frame unit 2 comprising a cylinder placement frame bracket 18 having a feature of a plate with folded angle wings whereas on the base of the work piece, there are provided four holes for the bolts 61 to go through. Also provided are two cylinder supporting plates 17 sandwiching the cylinder placement frame bracket 18 vertically to support the gas cylinder 70 (not shown in the figure). On the top, there is provided the lower cylinder fastening belt 16 having a feature of an arched steel bar to relation to the radius of the curve of the gas cylinder 70 whereas both ends thereof will be folded orthogonally and have one bolt through hole 62 on each end. At each of the hole mouths, there is provided a spot nut 51 fixed below the lower cylinder fastening belt 16 . By means of fixing, the cylinder placement frame bracket 18 , the cylinder supporting plate 17 , the lower cylinder fastening belt 16 and spot nuts 51 are assembled together to provide the gas cylinder supporting frame unit 3 whereas two gas cylinder supporting frame units 2 are required to assembled to make the mounting device for the CNG cylinder for a vehicle according to the present invention.
[0007] According to FIG. 3 , it illustrates parts assembled with the bed frame 1 . Prior to the installation of the mounting device for the CNG cylinder for a vehicle according to the present invention, it's required to locate the positions of the fixing holes for the gas cylinder supporting frame unit 2 whereas it is necessary to layout the locations of eight through holes on the bed floor 11 wherein the locations of thereof are divided into four spots, each of which has two holes: two holes on the left side of the front transverse frame 12 and another two holes of the right side thereof, and two holes on the left side of the rear transverse frame 13 and another two holes on the right side thereof. The size of the holes on the bed floor 11 has to be slightly larger than that of the bracket supporting sleeve 21 to allow the said bracket supporting sleeve 21 to be put into the holes. The bolt through holes 61 are made concentrically with the through holes on the bed floor 11 on the front transverse frame 12 and the rear transverse frame 13 in a total of 8 spots.
[0008] To assemble the gas cylinder supporting frame unit 2 with the bed floor frame unit 1 , the eight bracket supporting sleeves 21 are inserted into the holes on the bed floor 11 whereas upon the insertion, the base of the four bracket supporting sleeves 21 is placed into the U shaped groove of the front transverse frame 12 and that of another four sleeves is placed into that of the rear transverse frame 13 whereas the upper edges of the bracket supporting sleeves 21 are slightly above the bed floor 11 . The bed supporting bracket 20 featuring four plates 61 having two bolt through holes each and folded angle wings is placed on the bed floor 11 at the corresponding four fixing spots whereas the positions of the bolt through holes 61 are aligned with that of the bracket supporting sleeves 21 . The bed supporting bracket 20 acts as a cylinder supporting frame sleeves support 19 preventing the weight of the CNG cylinder mounting device unit according to the present invention installed on the bed floor 11 from directly pressing upon the bed floor 11 . The eight cylinder placement frame supporting sleeves 19 are placed on the bed supporting bracket 20 whereas the positions of the bolt through holes 61 of the cylinder placement frame supporting sleeve 19 and the bed supporting bracket 20 are aligned. The two gas cylinder supporting frame unit 2 as assembled in FIG. 2 are placed upon the cylinder placement frame supporting sleeves 19 whereas the positions of the bolt through holes 61 of the cylinder placement frame bracket 18 are aligned with the bolt through holes 61 of the cylinder placement supporting sleeves 19 .
[0009] To assemble the front frame locking bracket 22 featuring a long steel plate folded to form a U shaped groove, on the base of the U shaped groove, there are provided four bolt through holes in the same interval of the through holes on the front transverse frame 12 . Four spot nuts are individually fixed at the four holes under the groove. The frost frame locking bracket is assembled with the bottom of the front transverse frame 12 whereas the positions of the bolt through holes 61 of the front frame locking bracket 22 and the front transverse frame 12 are aligned correspondingly. The four bolts 61 are inserted into the through holes on the cylinder placement frame bracket 18 , the cylinder placement frame supporting sleeves 19 , the bed supporting bracket 20 , the bracket supporting sleeve 21 , the front transverse frame 12 , and the front frame locking bracket 22 . Then the bolts are tightened to the four spot nuts 52 fixed under the front frame bracket 22 . Thereafter, two of the rear frame locking brackets 23 having a similar feature to the front frame locking bracket 22 but shorter and having only two belt through holes 61 are assembled with the bottom of the roar transverse frame 13 on both left and right sides whereas the two bolt through holes 61 on the rear frame locking bracket 23 are aligned with the bolt through holes 61 of the rear frame bracket 13 . The four bolts 61 are inserted into the bolt through holes on the cylinder placement frame bracket 18 , the cylinder placement frame sleeves 19 , the bed supporting bracket 20 , the bracket supporting sleeves 21 , the rear transverse frame 13 and the rear frame locking bracket 23 . Then the bolts are tightened to the four spot nuts 52 fixed under the rear frame bracket 23 .
[0010] According to FIG. 4 , it illustrates the assembly of the gas cylinder 70 with the CNG cylinder mounting device unit for a vehicle according to the present invention including two lower cylinder fastening belt supporting rubber 24 assembled with the lower cylinder fastening belt 16 on both sides. The gas cylinder 70 is placed upon the lower cylinder fastening belt 16 assembled with the lower belt supporting rubber 24 . Then the upper cylinder fastening belt 27 is assembled with the upper belt supporting rubber 25 . Thereafter, the assembled unit is placed over the gas cylinder 70 . The bolts 62 are inserted into the bolt through holes 62 on the upper cylinder fastening belt 27 and the lower cylinder fastening belt 16 and tightened to the spot nuts 51 fixed to the bottom of the lower cylinder fastening belt 16 . The bolt 63 is inserted into the bolt through holes 63 on the auxiliary bracket 26 as a reinforcing unit for the upper cylinder fastening bolt flange 27 . Later the anti-loosening looking nuts 53 ant tightened to the bolts 63 to the highest level and then the bolts 63 are pushed into the through holes on the lower cylinder fastening belt 16 before tightening them with the spot nuts 51 (not shown in the figure) fixed at the bottom of the lower cylinder fastening bolt flange 16 . Upon tightening, the anti-loosening locking nuts 53 are tightened compressively to the upper flange of the lower cylinder fastening belt 16 to prevent the bolts 63 from being loosened.
[0011] According to FIG. 5 , it illustrates the back of the CNG cylinder mounting device for a vehicle according to the present invention upon the installation on the bed floor 11 .
[0012] According to FIG. 6 , it illustrates the front of the CNG cylinder mounting device for a vehicle according to the present invention upon the installation on the bed floor 11 .
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates a specific area of the frame unit and the bed floor for the installation of a CNG cylinder mounting device for a vehicle according to the present invention;
[0014] FIG. 2 illustrates parts of the gas cylinder, supporting frame unit located in the CNG cylinder mounting device for a vehicle according to the present invention;
[0015] FIG. 3 illustrates parts assemble with the bed frame body and the bed floor of the CNG cylinder mounting device for a vehicle according to the present invention;
[0016] FIG. 4 illustrates the side view of the parts used to assemble the gas cylinder with the CNG cylinder mounting device for a vehicle according to the present invention;
[0017] FIG. 5 illustrates the rear view of the complete installation of the CNG cylinder mounting device for a vehicle according to the present invention; and
[0018] FIG. 5 illustrates the front view of the complete installation of the CNG cylinder mounting device for a vehicle according to the present invention.
THE BEST MODE OF THE INVENTION
[0019] As some as aforementioned in the Detailed Description of the Preferred Embodiments topic.
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This is to the search for the way to hold the gas containers on the carrier of vehicles and to create the parts suitable for actual use and meet the auto parts manufacturing standard while emphasizing on the worthiness, strength and safety.
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BACKGROUND OF THE INVENTION
The invention concerns fast-reacting casting resin on the basis of polyurethanes, processes for their production as well as their use as embedding masses.
The previously known casting resin systems involve not only at normal but also at increased temperatures slower, often hours-long reaction or hardening times. The long reaction periods are limited through slowly proceeding addition reactions of the involved chemical raw materials, and therefore allow only a discontinuous working-up.
It is thus known from DE-OS 28 13 197 to obtain such polyurethanes by reacting an aromatic polyisocyanate with a mixture of castor oil and trimethylol propane into an NCO-group-displaying pre-adduct, and polymerizing the pre-adduct with castor oil or a mixture of castor oil and trimethylol propane. The embedding masses described in this reference distinguish by outstanding characteristics such as high hardness, colorlessness, compatibility with blood, and good working-up characteristics. They are particularly suitable for embedding of membranes such as hollow filaments, tube foils, flat foils and the like. These can be used for construction of separatory arrangements such as dialysators, particularly hemodialysators.
Further such polyurethane embedding masses are known from DE-OS 28 55 243, which discloses as aromatic polyisocyanate 4,4'-diphenylmethane-diisocyanate with a content from 18-22 mol-% dimerised and trimerised diisocyanate, and from DE-OS 29 07 501, in which is described an aromatic polyisocyanate with 10-15 mol-% 3-isocyanatomethyl-3,5,5-trimethyl-cyclohexylisocyanate. These embedding masses distinguish through good storage ability and viscosity characteristics (DE-OS 28 55 243) or through high adhesive strength (DE-OS 29 07 501).
Since now a need exists for such casting resins, which allow hardening within shorter time periods or in continuous processes, whereby particularly the time period up to mold release of the embedding masses is significant, attempts have been made to harden these polyurethanes catalytically.
Thus, e.g. in German patent application P 30 10 030.2-44 embedding masses on the basis of polyurethane compositions from the above mentioned DE-OS 28 13 197, 28 55 243, and 29 07 501 are described, which are hardened with dialkyl tin compounds as catalyst. Through these measures it became possible to shorten the time period up to mold release of the embedded membranes to 20 minutes (with a working-up temperature of 50° C.). Thus, these masses, in connection with a favorable chronological viscosity behavior of the masses during the polymerization, are also suitable for the embedding of membranes in automatic casting machines.
Finally, in DE-OS 24 38 197 there are described polyurethanes which are produced through reaction of an aromatic diisocyanate with a hydroxyl group-containing polymer into a NCO-group-displaying pre-adduct, and polymerization of the pre-adduct with a lower molecular diol in the presence of water and a combination of an organo tin compound and a tertiary amine as catalyst. Therewith both of the catalysts are not added directly as mixture to one of the polymerization components, but are provided initially separated in each one of the components. According to the test examples, which are provided for closer illustration in DE-OS 24 38 197, there results thus with dibutyl tin dilaurate and 1,4-diazabicyclo(2,2,2)-octane in weight ratio 3:1 and a portion of this mixture of 0.2% by weight, relative to the total polyurethane, with a preferred hardening temperature of 50° C., a polyurethane which can be released from the mold after a period of about 1 minute. Involved herewith, though, is a polyurethane foam.
In order to be able to work up polyurethanes, particularly compact embedding masses, more economically in automatic casting machines, casting resins are required which, after the mixing of the NCO-group-displaying pre-adduct ("macroisocyanate"; "hardener") and the polyol ("chain-lengthener") reactant can be removed from the mold within still shorter time periods.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to improve a process for the production of polyurethane embedding masses of the above described type with favorable characteristics and more extensive usefulness by still shorter working-up times and particularly to arrange the working-up in automatic casting machines more economically, whereby the catalyst portion should be held as low as possible.
This object is attained according to the present invention by an embedding mass of polyurethanes, composed of a polyurethane which has been obtained through reaction of an aromatic polyisocyanate with a mixture of castor oil and trimethylolpropane into an NCO-group-displaying pre-adduct, and polymerization of the pre-adduct with a polypropyleneglycol or a mixture of polypropyleneglycol and trimethylolpropane, in the presence of catalyst, and which is thereby characterized in that the embedding mass contains as catalyst about 0.005 up to 0.3% by weight, relative to the total weight of the polyurethane resin, of a mixture of a dialkyl tin dicarboxylate and an aliphatic mono- or diamine in weight ratio 1:1 up to 4:1, and that the employed polypropyleneglycol is constructed of 25 up to 50 propylene oxide units.
It was not to be expected with knowledge of the results obtainable according to the above mentioned DE-OS 24 38 197, to obtain polyurethane form masses with mixtures of such catalysts, which can be removed from the mold within still shorter periods or with still smaller portions of catalyst mixture to obtain at least similarly favorable results.
It was thus even more surprising that according to the present invention with such catalysts in substantially smaller portions, under the conditions which will be more closely described below, not only comparable but still substantially shorter removal from the mold times than according to DE-OS 24 38 197 result.
The dialkyl tin dicarboxylate used as catalyst component in the embedding mass according to the present invention is preferably dibutyl tin diacetate, dibutyl tin dilaurate, dibutyl tin dioctoate, dibutyl tin dinonanoate or dioctyl tin dilaurate.
The tertiary aliphatic mono- or diamine used as catalyst component in the embedding mass according to the present invention is preferably trimethylamine, ethyldimethylamine, diethylmethylamine, triethylamine, N,N-dimethyl-2-phenylethylamine, N,N,N',N'-tetramethylmethanediamine, N,N,N',N'-tetramethylbutane-1,3-diamine, N-methylmorpholine, N,N-dimethylcyclohexylamine, N,N-diethylcyclohexylamine, 1,4-diazabicyclo(2,2,2)-octane, 1,8-diazabicyclo(5,4,0)-undecen-(7),1,2,4-trimethylpiperazine or dimethylaminoethylpiperazine.
The catalyst mixture contains the components dialkyl tin dicarboxylate and tertiary aliphatic amine preferably in weight ratio 2:1 up to 3.5:1.
Preferred amounts of the catalyst mixture are portions from 0.02 to 0.15% by weight, relative to the total weight of the polyurethane resin.
The molecular weight of the polypropyleneglycol employed as polymerisation component influences the reaction velocity: lower molecular weights accelerate, higher molecular weights slow down the polyurethane formation reaction. Lower molecular weights lead to harder, elasticity-poor products, higher molecular weights lead to softer, elastic polyurethanes. Preferred are polypropyleneglycol with 33 up to 44 propylene oxide units. Very good results are obtained with polypropylene glycols with about 40 propylene oxide units.
Polyethyleneglycols are less suitable, since the polyurethane casting resin produced therewith leads to relatively high swelling values in water, which is unfavorable for the use of the produced embedded membranes. Polybutylene glycols (polytetrahydrofurans), on account of their melting range (40° to 50° C.), are not available at room temperature as liquid polymerization component.
For production of such embedding masses from polyurethanes, there serves a process for the reaction of an aromatic polyisocyanate with a mixture of castor oil and trimethylolpropane into an NCO-group-displaying pre-adduct, and polymerization of the pre-adduct with a polypropyleneglycol or a mixture of polypropyleneglycol and trimethylolpropane in the presence of catalyst, which is thereby characterized in that one uses as catalyst 0.005 up to 0.3% by weight, relative to the total weight of the polyurethane resin, of a mixture of a dialkyl tin dicarboxylate and a tertiary aliphatic mono- or diamine in weight ratio 1:1 to 4:1, and that as polypropyleneglycol a product constructed from 25 up to 50 propylene oxide units is employed.
The hardening of the polyurethane embedding masses according to the present invention proceeds very quickly at room temperature or higher temperatures, e.g. 50° C.
The production of these embedding masses takes place substantially according to processes as are described in DE-OS 28 13 197, 28 55 243 and 29 07 501, whereby the main difference according to the present invention is the addition of the catalyst mixture and the polypropyleneglycol. The catalyst mixture is always added to the polypropyleneglycol or the mixture of polypropyleneglycol and trimethylolpropane serving as polymerization component. A precise dosaging of the addition is essential. With the embedding masses according to the present invention, practically all desired hardening or removal from mold periods, starting from seconds up to hours, can be adjusted.
The embedding masses according to the present invention are very suitable for embedding processes which work according to the casting principle, above all for the centrifuge casting technique. They are particularly suitable, though, for embedding processes with automatic casting machines.
The embedding masses according to the present invention have clear appearance and display good mechanical characteristics. With customary liquids, with which they come into contact during use, they are not at all or only negligibly corroded, so that no danger exists that undesired substances become extracted, and in the case of a use of these embedding masses for the embedding of separatory membranes, get led into the dialysate or retentate.
The embedding masses according to the present invention are therefore in more outstanding manner suitable as embedding masses for membranes, particularly for the embedding of membranes in artificial organs. They serve mainly for the embedding of membranes such as hollow filaments, tube foils or flat foils. In this manner embedded membranes are advantageously used in selectively working dialysators, particularly in selectively working hemodialysators, as well as in such apparatus serving for the detoxification of blood.
It is moreover favorable that, whether or not the hardening periods with the processes according to the present invention are substantially shorter than with a manner of operation without catalyst addition, a temperature increase occur only to a small extent, which is particularly advantageous for the embedding of delicate membranes. The embedding masses serve accordingly advantageously also for the embedding of temperature-sensitive membranes.
On account of the outstanding viscosity behavior during the embedding, the embedding masses are also very well suitable for embedding processes which operate according to the casting principle, particularly according to the centrifuge casting technique. The embedding masses distribute very quickly about the membranes to be embedded, on account of their outstanding viscosity behavior, filling all of the space and allowing no cavities to arise. The wetting of the membranes with the embedding mass is excellent. An undesirable, too high rise of the embedding mass as a result of capillary forces into the membranes does not occur. The embedding masses do not tend to form bubbles.
More particularly suitable, though, are the embedding masses according to the present invention for the automatic embedding of membranes based upon their amazingly fast hardening and the favorable chrolonogical viscosity behavior. Therewith the membranes to be embedded can be removed from the mold in a matter of seconds, whereby a more economical, continuously running operation is guaranteed.
The novel features which are considered characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Example 1
Production of the pre-adduct without catalyst
1537.3 g (10.75 Val) liquid polyisocyanate based upon 4,4'-diphenylmethanediisocyanate (Commercial product Isonate 143 L; containing 25% by weight dimerized, trimerized and polymerized diisocyanate) are poured into a reactor and under stirring and nitrogen throughput heated at 60°-70° C. until a clear solution is present.
In a second reactor, successively 309.6 g (0.9 Val) castor oil and 58.2 g (1.3 val) trimethylolpropane are added under stirring and nitrogen throughput, and stirred for about 1 hour at 85° C. Then the heating is cut off, whereupon it must be observed that the temperature does not sink below 60° C.
The clear dissolved content of the second reactor is then within one hour allowed to flow into the liquid polyisocyanate preheated to 65° C., under stirring and nitrogen throughput. Through cooling the temperature during the reaction is held to about 70° C.
After the addition of the trimethylolpropane-castor oil solution, the reaction mixture is held for still 2 hours at 70°-75° C. The mixture should then display an isocyanate content of 18.85% by weight.
The prepared pre-adduct is finally cooled down to a temperature of 60° C., degasified through evacuation under slow stirring, and discharged by immersion filling into a dry container, rinsed with nitrogen, and is thus directly suitable for production of the embedding mass.
Example 2
Production of the catalyst-containing polymerizer
4612.5 g (5.27 Val) polypropyleneglycol with a molecular weight of 2500 (commercial product Pluracol TP 2540) and 156.6 g (3.5 val) trimethylolpropane are placed in a reactor and stirred for 1 hour at 70° up to 80° C. interior temperature, until a clear solution appears.
Then the catalyst mixture is dissolved in a beaker glass in 200 g (0.23 Val) polypropyleneglycol under mild heating at about 50° C. and under stirring, and the entire polymerizer solution is added. In order to adjust e.g. a reaction or hardening time upon the later mixing of the pre-adduct with the polymerizer of 2 minutes at 25° C., 47.4 mg dibutyl tin dilaurate (DBSnDL) and 15.8 mg 1,4-diazabicyclo(2,2,2)-octane (DABCO) must be added.
After cooling of the clear, well stirred mixture to temperatures below 50° C., it is degasified through evacuation under slow stirring, and discharged by immersion filling into a dry, nitrogen rinsed container.
The polymerizer is thus directly usable for the polymerization of the pre-adduct.
Examples 3-9
Casting resin production with DBSnDL and DABCO in weight ratio 3:1
For the casting resin production always 1 part by weight of the pre-adduct prepared according to Example 1 and 2 parts by weight of the polymerizer prepared according to Example 2 are mixed.
The measuring of the reaction velocity follows through determination of the gelation period according to DIN-specification 16945 and refers always to 50 g amounts. Gelation period and removal from the mold period are practically the same with short gelation periods (such as e.g. in the case of Examples 3-5).
There were produced casting resin mixtures with different portions of catalyst mixture (DBSnDL and DABCO in weight ratio 3:1) and the individual gelation periods determined at 25° C. and at 50° C. The corresponding results are set forth in Table 1.
TABLE 1______________________________________Gelation periods at 25° C. and 50° C. of castingresin mixtures with different portions ofcatalyst mixture (DBSnDL and DABCO in weightratio 3:1) Portion of catalyst Gelation period (sec)Example mixture* (ppm) 25° C. 50° C.______________________________________3 851 40 ≦30**4 638 90 305 425 120 456 212 240 607 106 360 1208 53 900 3609 44 1200 480______________________________________ *relative to the total casting resin **gelation times under 30 sec are practically no longer measurable
Examples 10-13
Casting resin mixtures were prepared, as described in Examples 1-9, with the distinction that the ratio of DBSnDL and DABCO is varied. The portion of catalyst mixture in the entire casting resin amounts therewith to 0.06% by weight. The obtained gelation times are summarized in Table 2.
TABLE 2______________________________________Gelation periods at 25° C. and 50° C. of castingresin mixtures with different weight ratiosDBSnDL:DABCO (weight portion of the catalystmixture: 0.06%, relative to the casting resin) weight ratio gelation period (sec)Example DBSnDL:DABCO 25° C. 50° C.______________________________________10 1:1 105 3511 2:1 105 3512 3:1 80 313 4:1 120 40______________________________________
Examples 14-16
In the test examples 14-17 the efficiency of other dialkyl tin salts instead of dibutyl tin dilaurate in the catalyst mixture is demonstrated. The portion of catalyst mixture in the total casting resin amounts to 0.06% by weight. The weight ratio of dialkyl tin salt and DABCO is 3:1.
Casting resin and casting resin components are prepared as set forth in Examples 1-3. The results are set forth in Table 3.
TABLE 3______________________________________Gelation periods at 25° C. and 50° C. with differentdialkyl tin salts as catalyst component(weight ratio dialkyl tin salt and DABCO =3:1; portion of catalyst mixture: 0.06%by weight, relative to the casting resin) gelation periods (sec)Example dialkyl tin salt 25° C. 50° C.______________________________________14 dibutyl tin 115 38 diacetate15 di-n-butyl tin 115 38 dinonanoate16 di-n-octyl 155 50 tin dilaurateComparison di-n-butyl tin 80 30(12) dilaurate______________________________________
Examples 17-22
Casting resin mixtures are prepared as described in Examples 1-3. However, with constant portion of the catalyst mixture (0.06% by weight, relative to the casting resin), other cyclical tertiary amines instead of DABCO are employed as catalyst. The weight ratio of DBSnDL and cyclical tertiary amine is therewith always 3:1 and 1:1.
The gelation periods obtained with these casting resins are set forth in Table 4.
TABLE 4______________________________________Gelation periods at 25° C. and 50° C. with differentcyclical tertiary amines as catalystcomponent (weight ratio DBSnDL: cyclicaltertiary amine = 3:1 and 1:1; portion ofcatalyst mixture: 0.06% by weight,relative to the casting resin) gelation weight ratio periodsEx- DBSnDL:Tert. (sec)ample cycl. tert. amine amine 25° C. 50° C.______________________________________17 N,N'--dimethyl- 3:1 100 3518 cyclohexylamine 1:1 120 4019 N--methyl-mor- 3:1 165 5020 pholine 1:1 180 5521 diazabicyclo- 3:1 90 4022 undecene 1:1 110 4511 3:1 80 30 DABCO 9 1:1 105 35______________________________________
Example 23
Continuous embedding of hollow filament membranes with a two-component dosing and mixing apparatus
Description of the apparatus:
On a base plate are mounted two gear pumps, which can be adjusted with the individual drive motors to the previously described mixing ratio of both components. Both of the components are separated from temperable supply containers with the aid of the described gear pumps and led into a mixing chamber. The mixing chamber contains static mixing elements, which provide for a homogeneous mixture of the dosed components. After the finish of the casting operation, the mixing chamber is cleaned with the aid of solvents.
Casting operation:
The pre-adduct prepared according to Example 1, with a viscosity of 22 Pa.s at 20° C. is placed into a supply container for this purpose. Likewise, the polymerizer prepared according to Example 2, with a viscosity of 0.76 Pa.s at 20° C. is placed in the second supply container. With the aid of the gear pumps, the drives of which are adjusted to a mixing ratio of 1:2, pre-adduct and polymerizer are separately led into the tube-shaped, temperable mixing chamber, which contains 19 static mixing elements. The clear, mixed, bubble-free casting resin processes at 25° C. an initial viscosity of 2.2 Pa.s and at 60° C. of 0.7 Pa.s. It is allowed to flow directly into a prepared form, in which the casting resin sets at room temperature within the shortest time period. The reaction velocity can be accelerated through heating of the shape, so that seconds-fast removal from the mold is possible. For the Shore-A-hardness of the casting resin, after 1 hour the value 64 and after 17 hours the value 75 are determined. The freezing range (glass point) of the casting resin mixture lies between -35° C. and -8° C.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of polyurethane masses differing from the types described above.
While the invention has been illustrated and described as embodied in an embedding mass of the basis of fast-reacting polyurethane casting resin, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
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Embedding masses are disclosed on the basis of fast-reacting polyurethane casting resins, which are obtained through reaction of an aromatic polyisocyanate with a mixture of castor oil and trimethylolpropane into an NCO-group-displaying pre-adduct and polymerization of this pre-adduct with a polypropyleneglycol or a mixture of polypropyleneglycol and trimethylolpropane in the presence of small amounts of a catalyst mixture composed of dialkyl tin dicarboxylate and tertiary amine. The polyurethane casting resins can harden in seconds-fast reaction, and are therefore preferably suitable for a continuous embedding of membranes in automatic machines, particularly of membranes for artificial organs.
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BACKGROUND OF THE INVENTION
This invention relates to an exhaust gas purifier for automotive engines and, more particularly, to an exhaust gas purifier for a diesel engine of the class wherein a throttle valve is provided in an intake passage for reducing the flow rate of intake air during engine idling.
The vibration and noise produced by a diesel engine are generally of a higher level than those of gasoline engines due to the diesel engine's high compression ratio. Such vibration and noise are disadvantageous in terms of driver and passenger comfort, particularly during engine idling.
In order to reduce engine vibration and noise during idling, there is known in the prior art a diesel engine in which a throttle valve is provided in an intake passage. During engine idling, the throttle valve is closed in response to the release of the accelerator pedal of the vehicle, thereby reducing the amount of the air drawn into the cylinders. With a reduced amount of intake air being compressed at the compression stroke, engine vibration and noise are suppressed to a considerable extent. However, such a diesel engine suffers from the shortcoming that the total amount of unburned hydrocarbon emission is increased due to air throttling.
SUMMARY OF THE INVENTION
An object of the invention is to provide an exhaust gas purifier for a diesel engine of the class wherein a throttle valve is provided in an intake passage for reducing the flow rate of the intake air during engine idling.
Another object of the invention is to provide an exhaust gas purifier for a diesel engine which is simple in construction and easy to manufacture.
A further object of the invention is to provide an exhaust gas purifier which is capable of automatically treating the exhaust gas when the engine is operating at an idle condition.
A still further object of the invention is to provide an exhaust gas purifier which is operable even during the cold start of the engine.
According to the present invention, there is provided an exhaust gas purifier for a diesel engine of the class wherein a throttle valve is provided in an intake passage for reducing the flow rate of intake air during engine idling, the exhaust gas purifier comprising: a housing having an exhaust gas inlet and outlet, the housing having a main passage extending from the inlet to the outlet and a passage bypassing at least part of the main passage; means disposed in said bypass passage for oxidizing the unburned combustibles in the exhaust gas passed therethrough; a control valve arranged in the main passage to close the main passage such that all of the exhaust gas is forced to flow through the bypass passage; and means for closing the control valve in synchronization with the closing movement of the throttle valve.
Preferably, the afore-mentioned means for closing the control valve in synchronization with the closing movement of the throttle valve comprises: a source of partial vacuum; a conduit extending from the source of partial vacuum and terminating in two branched ends; a first vacuum actuator connected to one of the branched ends and linked to the throttle valve to close the throttle valve when the partial vacuum is applied thereon; a second vacuum actuator connected to the other one of the branched ends and linked to the control valve to close the control valve when the partial vacuum is applied thereon; and means responsive to the idling condition of the engine for overriding the partial vacuum in the conduit during non-idling operation of the engine and for connecting the source of partial vacuum to the branched ends during idling to close the control valve simultaneously with the throttle valve.
Advantageously, the oxidizing means comprises an oxidation catalyst and the exhaust gas purifier further comprises means for preheating the oxidation catalyst when the temperature thereof is below a predetermined level. Preferably, the preheating means comprises an injector responsive to the temperature of the catalyst and arranged at the entrance end of the bypass passage for injecting a fuel therein and means disposed adjacent to and downstream of the injector for igniting the injected fuel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagramatic view, partly in cross-section, of an embodiment of the exhaust gas purifier according to the invention; and
FIG. 2 is a block diagram of the control unit shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows at the right-hand side a section of an intake tube 1 connected between an air cleaner (not shown) and an intake manifold (not shown) of a diesel engine. A throttle valve 2 is mounted in the intake tube 1 for angular rotational movement between a closed position, shown by the solid line, in which the flow rate of the air drawn into the engine is reduced and a full open position, shown by the dotted line, in which the air is drawn without substantial flow resistance. The throttle valve 2 is adapted to be actuated by a vacuum actuator 4 by means of a link 3.
The exhaust gas purifier comprises a roughly tubular housing 5 having a gas inlet 5A and a gas outlet 5B adapted to be connected, respectively, to an exhaust manifold and an exhaust pipe (not shown). The inner cavity of the housing 5 is partially divided by a partition wall 5C into a main passage 5b and a bypass passage 5a. A bypass control valve 6 is provided at the entrance end of the main passage 5b and is adapted to be actuated by a vacuum actuator 8 through a link 7 so that when it is closed all of the exhaust gas flowing into the purifier is forced to pass the bypass passage 5a. The bypass passage 5a is charged with an oxidation catalyst 9, such as platinum coated pellets, known in the art.
Both vacuum actuators 4 and 8 are pneumatically connected by a conduit 11b to a vacuum tank 11 which is in turn connected to a vacuum pump (not shown) of the diesel engine by means of a conduit 11a. The vacuum applied to the vacuum actuators 4 and 8 is controlled by a solenoid-actuated vacuum override valve 10 which selectively connects the vacuum tank 11 to an air bleed port 10a or to vacuum actuators 4 and 8 in response to a signal from a control unit 18.
In order to preheat the oxidation catalyst 9 prior to the operation of the engine, an injector 12 is mounted through the wall of the housing 5 immediately upstream of the entrance aperture of the bypass passage 5a. The injector 12 is connected to a suitable fuel delivery conduit 12a supplying pressurized fuel and is actuated by the control unit 18 to spray a metered amount of fuel toward the gas passing through the bypass passage 5a in response to a control signal from the control unit 18. The sprayed fuel is ignited by a glow plug 13 positioned adjacent to and downstream of the injector 12. A temperature sensor 14 is provided in the bypass passage for sensing the temperature of the catalyst 9 and producing a temperature indicating signal to the control unit 18.
Illustrated schematically by reference numeral 15 are a series of glow plugs for preheating the air in the combustion chambers during cold start of the engine. Each glow plug 15 is mounted operatively in each combustion chamber. The temperature of the glow plugs 15 is sensed by a temperature sensor 23 which outputs a corresponding signal to the control unit 18.
The control unit 18 is supplied with electric power from a source such as a battery 22 and also with various signals from the temperature sensor 14, a switching circuit 19, a vehicle speed sensor 20, an idle sensor 21, and the temperature sensor 23. The control unit 18 issues control signals to glow plugs 13 and 15 through relays 270 and 280 and also controls the vacuum override valve 10 and the injector 12.
Details of the control unit 18 will now be described in conjunction with its associated devices with reference to FIG. 2. Referring first to devices for inputting signals to the control unit 18, the switching circuit 19 comprises a key switch 19a, a charge indicator lamp 19b, and a normally closed relay contact 19c, which are connected in series with each other, and a relay coil 19d which is connected to a neutral point of an alternator of the engine. When the key switch 19a is closed, electric current flows through the charge indicator lamp 19b and the normally closed relay contact 19c to illuminate the lamp 19b. Then, when the engine is put into operation so that the alternator generates an alternating current, a current flows from the neutral point of the alternator to the relay coil 19d to open the contact 19c, turning off the charge indicator lamp 19b.
The vehicle speed sensor 20 is of the reed switch type, as shown, and is adapted to be closed when the vehicle is moving.
The idle sensor 21 is intended to detect the idle position of the accelerator pedal of the vehicle and comprises a switch which is associated with the accelerator pedal and is closed when the pedal is stepped on.
The temperature sensors 14 and 23 are composed of thermisters, the resistance of which varies in response to the temperature of the catalyst 9 and glow plugs 15, respectively.
Referring to the control unit 18 itself, indicated generally at 180 is a vehicle speed detecting circuit for detecting vehicle speeds exceeding a predetermined value. The speed detecting circuit 180 comprises diodes 181a and 181b; resistors 182a, 182b, 185, 186a, 186b, 187a, 187b, 187c, and 187d; capacitors 183, 184, and 188; and a comparator 189. The comparator 189 issues a "0" level signal to an inverter 253 when the vehicle speed is zero and issues a "1" level signal when the vehicle is running.
Indicated generally at 190 is a temperature detecting circuit for detecting the temperature of the catalyst 9. The detecting circuit 190 comprises a comparator 191 and resistors 192, 193, and 194. The comparator 191 issues a "0" level signal to the input terminal of an AND gate 257 when the temperature of the catalyst 9 exceeds a predetermined value.
Reference numeral 200 indicates a temperature detecting circuit for the glow plugs 15 and comprises a comparator 201 and resistors 202, 203, and 204. The comparator 201 issues a "1" level signal to an AND gate 256 and an inverter 252 when the temperature of the glow plugs 15 exceeds a predetermined value.
Reference numeral 210 indicates a detecting circuit for detecting the idle position of the accelerator pedal and comprises a Zener diode 211 and resistors 212, 213, and 214. When the accelerator pedal is stepped on, the idle position detecting circuit 210 inverts a "1" level signal into a "0" level signal which is fed to one of the input terminals of the AND gate 254.
Reference numeral 220 indicates an injector driving circuit for feeding electric current to a solenoid 12b of the injector 12 and comprises a transistor 220a and a resistor 220b.
Reference numeral 230 indicates a driving circuit for the vacuum override valve 10 and comprises a transistor 230a and a resistor 230b. The valve driving circuit 230 supplies an electric current to a solenoid 10b of the vacuum override valve 10.
Reference numeral 240 indicates a driving circuit for controlling the electric current flowing through a coil 280a for actuating a normally open contact 280b of the relay 280. The relay driving circuit 240 comprises a resistor 240b and a transistor 240a, the collector of which is connected to the relay coil 280a. As described hereinafter, the glow plugs 13 and 15 are connected in series to the battery 22 when the normally open contact 280b of the relay 280 is closed, because normally open contacts 270b and 270c of the relay 270 are then open.
Reference numeral 250 indicates a driving circuit for controlling the electric current flowing through a coil 270a for actuating the normally open contacts 270b and 270c of the relay 270. The relay driving circuit 250 comprises a resistor 250b and a transistor 250a, the collector of which is connected to the relay coil 270a. The glow plugs 13 and 15 will be connected in parallel to the battery 22 when the relay contacts 270b and 270c are closed, because the normally open contact 280b is then open.
Indicated by 251, 252, and 253 are inverters, by 254, 255, 256, and 257 AND gates, and by 258 an OR gate.
The operation of the exhaust gas purifier according to the invention is as follows. When the key switch 19a is closed but the engine is not operating, there is no current from the alternator, so that the relay coil 19d is not energized. The electric current from the battery flows through the charge indicator lamp 19b and the normally closed contact 19c to illuminate the charge indicator lamp 19b. The switching circuit 19 produces a "0" level signal which is input into the inverter 251 and the AND gate 254. The signal entered into the inverter 251 is inverted to a "1" level signal and is fed to the AND gates 255 and 256.
As at this stage, the glow plugs 15 are not heated and, thus, the temperature thereof is below the predetermined temperature, the temperature detecting circuit 200 issues a "0" level signal which is applied to the other input terminal of the AND gate 256, so that the output signal of the AND gate 256 is of a "0" level. This "0" level signal is inverted by the inverter 252 into a "1" level signal which is fed to the other input terminal of the AND gate 255, so that the AND gate 255 outputs a "1" level signal to turn on the transistor 250a of the driving circuit 250. As a result, an electric current flows through the relay coil 270a whereby the normally open relay contacts 270b and 270c are closed. As described hereinafter, since the normally open contact 280b of the relay 280 remains open at this stage, the glow plug 13 and the glow plugs 15 are connected in parallel to the battery so that they are heated quickly.
When the engine is not operating with the key switch 19a closed, the accelerator pedal normally will not be stepped on and the vehicle speed will naturally be zero, so that the idle detecting circuit 210 issues a "1" level signal and the speed detecting circuit 180 outputs a "0" level signal. However, as the output signal from the switching circuit 19 is of the "0" level, as described above, the AND gate 254 issues a "0" level signal which is input into the OR gate 258 and the AND gate 257.
As both signals applied to the two input terminals of the OR gate 258 are of the "0" level, the OR gate 258 produces a "0" level signal so that the transistor 240a of the driving circuit 240 is turned off. Thus, no current flows through the relay coil 280a, so that the contact 280b remains open.
The "0" level output signal from the AND gate 254 is also fed to the driving circuit 230 so that the transistor 230a is turned off to de-energize the solenoid coil 10b of the vacuum override valve 10, whereby the latter remains inactivated. As a result, the air is bled from the bleed port 10a into the vacuum chambers of vacuum actuators 4 and 8, so that the throttle valve 2 and the control valve 6 assume the full open position as shown by the dotted line in FIG. 1.
At this moment, the temperature of the catalyst 9 is below the predetermined value, so the temperaure detecting circuit 190 issues a "1" level signal to one of the input terminals of the AND gate 257. However, the signal from the AND gate 254 applied to the other input terminal of the AND gate 257 is of the "0" level, so the AND gate 257 outputs a "0" level signal. Thus, the transistor 220a of the driving circuit 220 is turned off, whereby the injector 12 remains inoperative.
As mentioned above, when the key switch 19 is closed, electric current flows to the glow plug 13 as well as to glow plugs 15. After a lapse of a few seconds, the glow plugs 15 will be heated so that the diesel engine is ready for start. By turning on the starter, the engine then begins running.
After the engine starts, it drives the alternator to generate electric current. As a result, the potential at the neutral point of the alternator is applied on the relay coil 19d causing its contact 19c is open. Thus, the charge indicator lamp 19b is turned off, indicating to the driver that the engine is operating, and the output signal from the switching circuit 19 shifts from the "0" level to the "1" level.
As a result, the output signal from the AND gate 254 changes from the "0" to "1" level, and the transistor 220a of the injector driving circuit 220 and the transistor 230a of the vacuum override valve driving circuit 230 are turned on. Thus, both the solenoid 10b of the vacuum override valve 10 and the solenoid 12b of the injector 12 are energized.
On actuation of the valve 10, the partial vacuum from the vacuum tank is applied to the vacuum actuators 4 and 8 causing them to actuate the throttle valve 2 and control valve 6, respectively, to close as shown by the solid lines in FIG. 1. Thus, the air through the intake passage 1 is throttled and the main passage 5b is closed to force the exhaust gas to flow through the bypass passage 5a, in which the oxidation catalyst is provided.
Simultaneously, the injector 12 sprays a fuel. The fuel is ignited by the then adequately heated glow plug 13 to burn upstream of the catalyst 9 and preheat the same. When the catalyst 9 becomes heated above a predetermined temperature, the output signal from the temperature detecting circuit 190 changes from the "1" to "0" level, so that the transistor 220a of the injector driving circuit 220 is turned off and the injector 12 is closed. This maintains the temperature of the catalyst 9 at a predetermined level.
In this manner, the intake air is throttled during idling operation of the engine, thereby reducing engine vibration and noise, while the exhaust gas is treated by the oxidation catalyst to reduce exhaust emissions.
When the engine is operating and the signal from the switching circuit 19 changes from the "0" to "1" level as described above, the output signal from the AND gate 255 in turn changes from the "1" to "0" level, causing the relay contacts 270b and 270c to return to their normally open position. Since at this moment the output signal from the AND gate 254 is of the "1" level, the OR gate 258 generates a "1" level signal, whereby the normally open contact 280b is closed. As a result, the former parallel connection of the glow plug 13 with the glow plugs 15 is changed to a series connection, so the glow plugs 15 are heated in an after-glow mode.
If the glow plugs 15 are adequately heated prior to engine start, so that their temperature exceeds a predetermined value, the output signal from the detecting circuit 200 will change from the "0" to "1" level, so that the AND gate 255 issues a "0" level signal and the AND gate 256 issues a "1" level signal. This causes the parallel connection of the glow plug 13 with the glow plugs 15 to change to a series connection, thereby ensuring after-glow of the glow plugs 15.
As the vehicle begins to move with the accelerator pedal stepped on, the output signals from the speed detecting circuit 180 and idle detecting circuit 210 will be inverted so that the output signal from the AND gate 254 changes from the "1" to "0" level. Thus, the transistors 220a, 230a, and 240a are turned off, so the engine will be operated as normal with the after-glow of glow plugs 15 stopped, with the throttle valve 2 open, and with the injector 12 closed.
While in the foregoing, the present invention has been described with reference a specific embodiment thereof, it should be understood that the present invention is not limited thereby and that changes and modifications may be made without departing from the spirit or scope of the appended claims.
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An exhaust gas purifier suitable for use in a diesel engine of the type in which the intake air is throttle by a throttle valve provided in an intake passage during engine idling to reduce engine vibration and noise. Unburned combustibles produced by intake air throttling are treated by the exhaust gas purifier having a main passage and a bypass passage in which an oxidation catalyst is received. A bypass control valve, operable in synchronization with the throttle valve, urges the exhaust gas to flow through the bypass passage during engine idling. Preferably, means for preheating the catalyst is provided, which comprises an injector and an igniting glow plug.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation in part of Ser. No. 350,423 filed Feb. 19, 1982, abandoned, and is also related to our application Ser. No. 314,049 filed Oct. 22, 1981.
FIELD OF THE INVENTION
This invention relates to materials essentially consisting of virgin or reclaimed cellulose and other fibres, particularly to paper materials which possess a high degree of self-extinguishing property attained by incorporating thereinto a high-efficiency substance as flame retarder.
BACKGROUND OF THE INVENTION
The abbreviated term "paper materials", whenever used herein, means all of those materials essentially consisting of cellulose fibers and known, e.g. as waste paper pulp, mechanical pulp, unbleached pulp, bleached pulp, etc. whether or not containing additives and coadjuvants such as binders, fillers, dyes and the like. As is known, paper, paperboard and the like, and relevant applicative products, i.e. products made from paper materials, maintain their combustion once it has started, and because of the lack of self-extinguishing properties their use involves serious risks of fire in many applicative fields. Hence the use of paper materials has been restricted or substantially inhibited in such fields. To obviate the lack of self-extinguishing properties of said materials and products--such as Kraft paper, paper-board, etc.--or at least to reduce the inflammability thereof, various inorganic and/or organic chemical compounds--known as flame retarders--such as, for example: aluminum silicates and phosphates; ammonium sulphates and phosphates along with sodium bicarbonate; ammonium phosphates and polyphosphates, in some cases with melamine; borax-sodium silicate mixtures; salts of phosphorated polyalkyltriazines; amido-polyphosphates; tetrakis-(hydroxymethyl)-phosphonium chloride; hexahydro-triazine phosphonates and derivatives; cellulose ammonium-phosphate with melamine; melamine phosphates; guanyl-urea; copolymers with methyl phosphenyl-isocyanate; diazo-phospholidinones; halogenated polymers; and antimonium aminoalkoxides can be used.
However, these compounds exhibit, depending upon the different utilization modes and media, some drawbacks which do not always render them satisfactory for many applicative fields. For example some of the additives are hygroscopic and easily washable out or swellable by water, so that the physical-mechanical properties of the materials are of low stability in the long run, or because they can evolve, during combustion, very irritant and/or toxic gases, or finally because they are not capable of imparting a sufficient flame retarding effect.
We have developed a flame retarder for other classes of materials substantially different from the paper materials, namely a few types of polymeric material. This retarder is red phosphorus in a form which does not induce in the materials to which it is added, undesirable phenomena of hygroscopicity or instability in the long run any of the mechanical characteristics of practical importance. The red phosphorus powder itself may exhibit drawbacks of hygienic-environmental nature in connection with the fact that red phosphorus, when in contact with the air humidity, generates phosphine (notoriously toxic) during the procedures for incorporating it into the materials to be rendered self-extinguishing, besides during the preceding handlings thereof.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide paper materials which exhibit good self-extinguishing properties, and which are free from the defects and drawbacks mentioned hereinbefore.
Another object of the invention is to extend the principles of our above described copending applications.
DESCRIPTION OF THE INVENTION
These and other objects, which will be more clearly apparent to those skilled in the art from the following detailed description, are achieved, according to the present invention, by a paper composition--in the form e.g. of paperboard, Kraft paper and the like--comprising red phosphorus powder in its various allotropic forms, encapsulated with a particular melaminic resin (hereinafter referred to as modified melaminic resin), said powder being obtained as described in co-pending Italian patent application No. 26064 A/80 of Nov. 19, 1980 and the corresponding U.S. patent application Ser. No. 314,049 filed Oct. 22, 1981. More particularly, said powder is obtained by preparing a hydrodispersion of red phosphorus powder (having a particle size below 100 microns) in a solution in water of a cationized melaminic condensate, prepared from melamine, formaldehyde, triethanolamine and a monohydroxyl aliphatic alcohol having less than 5 carbon atoms heating said hydrodispersion while stirring, thus obtaining the encapsulation of the individual red phosphorus particles by precipitation thereonto of the above-said condensate in the form of an insoluble, partially cross-linked melaminic resin, then in completing the cross-linking during a successive drying step, thereby obtaining a red phosphorus powder encapsulated and consequently stabilized against the generation of phosphine.
The starting components of said melaminic condensate comprise formaldehyde, methanol, triethanolamine and melamine in weight %-ratios of 36.04-30.85%, 8.82-21.96%, 29.87-25.57% and 25.27-21.62%, respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred, but not exclusive, embodiment of self-extinguishing paper materials is obtained, according to the present invention, with compositions comprising paper pulp and red phosphorus powder encapsulated with melamine resin, in the quantitative ratios indicated herein-below in % by weight (referred to the "dry" material):
paper pulp--96-85%
red phosphorus powder encapsulated with 3-5% of "modified" melaminic resin--4-15%
The above-indicated compositions are given for indicative but not limitative purposes within the scope of the inventive concept of the present invention.
The preparation of the abovesaid self-extinguishing paper materials is easily feasible by employing the conventional additivation and mixing techniques, which are known in the technique in general and to those skilled in the art in particular.
A preferred, although not unique, embodiment for obtaining said red phosphorus powder encapsulated with modified melaminic resin, consists in preparing the hydrodispersion of red phosphorus in powder having a particle size below 40 microns, in an aqueous solution of a melamine condensate prepared from 25.27% melamine, 36.04% formaldehyde, 8.82% methanol and 29.87% triethanolamine, cationized with hydrochloric acid, in heating said dispersion, under stirring, at about 100° C., so obtaining the encapsulation of the red phosphorus individual particles, due to slow precipitation thereonto, in a continuous and compact layer, of said condensate in the form of a partially cross-linked insoluble melaminic resin, the cross-linking thereof is completed during a successive dehydration step by drying in an inert gas flow, or preferably under vacuum, at about 100° C. until formaldehyde does no longer form, so obtaining a powder of encapsulated red phosphorus.
More particularly, the abovesaid preferred embodiment of the invention comprises the following steps:
(a) preparing the melamine condensate: in a first step, methanol, triethanolamine, formaldehyde (the last substance in an aqueous solution at approximate 45% calculated on dry basis) are reacted for about 2 hours at approx. 85° C. in weight percent ratios, referred to the dry substance, respectively of 8.82%, 29.87% and 36.04%, the remaining 25.27% being the melamine which is to be added in a second step, at the end of the aforesaid reaction, in order to cause the melamine condensate to form by heating the aforesaid composition at about 90° C. for approx. 6 hours--the starting pH value of 9.5-9.8 being adjusted to the value of 7.4--7.8--till a viscosity of 420-470 centipoises at 20° C. is attained, whereupon, after having adjusted the pH to a value of 7-7.6, it is diluted with water, so obtaining a solution at about 38% of dry substance and with a viscosity of 40-50 centipoises at 20° C. pH adjustments are effected by means of hydrochloric acid in an aqueous solution at 18%, thus cationizing the melamine condensate.
(b) Encapsulating red phosphorus powder: a hydrodispersion of micronized red phosphorus powder having a density of 1.38-1.58 is combined with a desired amount of the aqueous solution at 38% of cationized melamine condensate, prepared as per point (a); the so obtained phosphorus dispersion in the melamine condensate solution is heated, under stirring, for about 1 hour at approx. 100° C., keeping substantially unaltered--by means of a condenser--the reaction mixture volume: under such conditions the melamine condensate precipitates slowly and uniformly (evolving formaldehyde) in the form of a resin partially cross-linked, at first in the liquid-viscous, then in the solid state, around the red phosphorus particles, so encapsulating them. Cross-linking is then completed during dehydration by drying of the product, preferably in a thin layer, at about 100° C. and in an inert gas flow or preferably under vacuum, till formaldehyde does not longer evolve. At the end an encapsulated red phosphorus powder is obtained, which is free-flowing, stabilized to phosphine forming and easily dispersible.
The compositions of the self-extinguishing paper materials object of the present invention are indicated more in detail in the examples which are given hereinbelow.
EXAMPLE 1
Self-extinguishing paper compositions (hereinafter indicated with PM/1, PM/2 and PM/3) of the "paperboard" 250 g/m 2 type, in which the paper material consisted of a "waste paper pulp", and the red phosphorus powder encapsulated with "modified" melamine resin--obtained according to the composition and process described in Example 1 of the cited co-pending patent application Ser. No. 314,049--was contained in said pulp respectively according to the following percentages by weight (referred to the dry material):
PM/1--12% encapsulated red phosphorus powder
PM/2--8% encapsulated red phosphorus powder
PM/3--6% encapsulated red phosphorus powder
The aforesaid three paper compositions, along with a fourth comparative paper composition identical with them, except that it did not contain the encapsulated red phosphorus powder (hereinafter referred to as PM/0), were subjected to inflammability tests according to methods ASTM-D 635 (horizontal propagation) and UL 94 (Underwriter Laboratory; vertical propagation)--which, as is known, are specific methods for self-supporting plastic materials--slightly modified, as specified hereinbelow, to adapt them to the paperboard object of the present example:
ASTM-D 635: ignition time was reduced from 20 to 3 seconds; specimens thickness: 0.35 mm;
UL 94: ignition time was reduced from 10 to 3 seconds and the reference index fixed to 139 mm; specimens thickness: 0.35 mm.
For both methods a "microbunsen" burner with flame height of 33 mm was utilized. For each of the four above-mentioned compositions, 10 inflammability tests according to each of the abovesaid methods were carried out, whereby the following experimental data were determined: burning rate in cm/min. (in abbreviated form:burn.r.), flame time in seconds, glowing fire propagation time in seconds, and burning length in mm. The results obtained (groups of 10 data for each composition and for each method) were arithmetically averaged; in Table 1 there are recorded said average values, the highest value out of the ten averaged values being bracketed alongside the average values. In said Table, the abbreviations have the meanings already specified above, and furthermore "bel." means "below . . . ", and P/i means encapsulated red phosphorus powder.
EXAMPLE 2
Self-extinguishing paper compositions (hereinafter referred to as CG/1 and CG/2) of the 250 g/m 2 "paperboard" type, in which the paper material consisted of "unbleached pulp", and the encapsulated red phosphorus powder (identical with the one of Example 1) was contained in said pulp respectively according to the following percentages by weight (referred to the dry material):
CG/1--12% encapsulated red phosphorus powder
CG/2--8% encapsulated red phosphorus powder
The abovesaid compositions, together with a third comparative composition identical with them, except that it did not contain red phosphorus powder (hereinafter referred to as CG/0) were subjected to the same tests of Example 1; the results obtained therefrom are recorded in Table 1.
EXAMPLE 3
Self-extinguishing paper compositions (hereinafter indicated by CS/1, CS/2 and CS/3) of the 250 g/m 2 "paperboard" type, in which the paper material consisted of "bleached pulp" and the encapsulated red phosphorus powder (identical with that of Example 1) was contained in said pulp respectively according to the following percentages by weight (referred to the dry product):
CS/1--15% encapsulated red phosphorus powder
CS/2--12% encapsulated red phosphorus powder
CS/3--8% encapsulated red phosphorus powder
The abovesaid three compositions, along with a fourth comparative composition identical with them except that it did not contain the modified encapsulated red phosphorus powder (hereinafter referred to as CS/0), were subjected to the same tests of Example 1, the results obtained therefrom being recorded in Table 1.
TABLE 1__________________________________________________________________________ burn.r. Flame time Glowing fire time Burning lengthCompos-P/i (cm/min) (000) (000) (mm)itions% UL 94 UL 94 ASTM D635 UL 94 ASTM D635 UL 94 ASTM D635__________________________________________________________________________PM/0 0 80.2 -- -- -- -- total --PM/1 12 -- 3.1 (5.0) 1.4 (2.0) 25.8 (35.0) 8.2 (10.0) 27.2 (48.0) 9.0 (12.6)PM/2 8 -- 2.2 (3.0) 2.3 (3.0) 6.1 (8.0) bel.5(5.0) 7.4 (10.0) 6.4 (9.6)PM/3 6 74.5 9.2 (11.0) 5.1 (7.0) -- bel.5(4.8) total 9.8 (14.6)CC/0 0 87.2 -- -- -- -- total --CC/1 12 -- 8.7 (18.0) 1.9 (2.0) 7.8 (12.0) bel.5(6.0) 21.2 (29.0) 5.6 (7.6)CC/2 8 83.4 8.2 (11.0) 6.3 (11.0) -- bel.5(2.0) total 8.4 (14.6)CS/0 0 72.8 -- -- -- -- total --CS/1 15 71.9 9.6 (12.0) 2.2 (2.5) -- 12.0 (13.0) total 9.4 (11.6)CS/2 12 -- 5.8 (8.0) 2.2 (3.0) 5.1 (7.5) 5.9 (7.0) 10.4 (14.0) 8.6 (10.6)CS/3 8 70.7 9.8 (11.0) 10.6 (16.0) -- bel.5(6.7) total 15.4 (21.6)__________________________________________________________________________
For the paper compositions indicated in the foregoing three Examples it has been furthermore tested and ascertained that the encapsulated red phosphorus powder contained in said compositions is neither washed out by the water, nor is in any way perceptibly affected by same, thus imparting constant characteristics to the abovesaid compositions.
As is inferable from the data contained in cited Table 1, there are apparent the advantages offered by the present invention, such advantages being obtainable at the highest degree when employing specific amounts of encapsulated red phosphorus powder, contained in the various paper materials, as a function of the nature of the latter.
The compositions and the paper materials described and exemplified hereinbefore may be susceptible of modifications and variations, all falling within the scope of the inventive concept of the present invention.
In particular, said compositions and materials may contain additives and/or paper coadjuvants known in the art.
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Self-extinguishing paper materials essentially consisting of paper pulps obtained from virgin chemical or reclaimed cellulose fibers and from red phosphorus powder encapsulated by a modified melaminic resin. These materials find practical industrial appliances especially as paperboard and in papers of various types requiring flame-retarding self-extinguishing characteristics.
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RELATED APPLICATIONS
[0001] The present invention claims priority on patent application Ser. No. 11/397,399, filed on Apr. 5, 2006, entitled “Road Grader/Spreader” and is hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not Applicable
REFERENCE TO A SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING
[0004] Not Applicable
BACKGROUND OF THE INVENTION
[0005] The prior art reveals a considerable number of devices designed to spread materials over the ground or over existing layers of material where it is desirable to obtain a finished grade. All of the known apparatus of this kind are towable behind a tractor or similar vehicle. Such a device is disclosed in U.S. Pat. No. 6,308,785 to Rhoden, issued Oct. 30, 2001.
[0006] Machines similar to the Rhoden grader/spreader are satisfactory for their intended agricultural purposes but have limitations when applying and spreading materials for road and highway construction. The depth or thickness of layers of gravel and other materials that comprise a road or highway are carefully specified by the design engineers. In many cases the depth requirement is a minimum figure and unintended deposition of a greater amount of material is wasteful and overly expensive. For example, many excess cubic yards of material would be consumed if one inch of material in excess of the specification is applied to a multi-mile roadway thirty feet wide. Failure to maintain a minimum depth of gravel can result in expensive rework. Commonly, the minimum depth for a gravel road is maintained by having a surveying crew place blue tops into the base grade every 60 feet or so. A blue top is a survey or grade stake usually made of plastic with a solid cylinder at one end and a plurality of flexible tails on the second end. Then gravel is placed on the base grade so that the blue tops are covered by the gravel. A road grader then grades the gravel so that the top of the gravel is at the beginning point of the blue tops. Often this takes multiple passes by the road grader. In addition, error can occur in the areas of the road between the blue tops. As a result, considerable time and effort is used to obtain a consistent depth of gravel for a road.
[0007] When a grader/spreader is pulled by a vehicle it can be assumed that the towing vehicle is going to traverse surface variations that are going to cause the grader/spreader to undulate in response to the pitching motions of the towing vehicle. Where the work is being done to construct or resurface a road or highway the rising and falling movement of the grader results in an uneven surface on the material being spread, together with significant departures from the design specification. Agricultural endeavors do not require the grader precision that must be present in road and highway work. Previous devices require a survey team to place blue tops along the base grade of a gravel road. The blue tops define the height of the gravel road and have to be accurately placed at spaced intervals requiring an expensive survey crew. The gravel is then placed over the blue tops and a road grader moves the gravel until all of the tail of the blue tops is exposed but not the body. This process takes multiple passes by the grader to be accurate. Also this does not ensure that the depth between the blue tops is accurate. If the level of the gravel between the blue tops is too low, this requires expensive rework. The previous methods of laying a gravel road often place additional gravel on the road to avoid this rework. However, this is wasteful and expensive.
[0008] Thus there exists a need for a road grader/spreader that accurately lays down a layer of gravel in a single pass.
BRIEF SUMMARY OF INVENTION
[0009] The present invention is a road grader attachment that attaches to a bulldozer. The attachment has an elongated blade with mutually parallel side members attached to the lateral ends of the blade where each of the side members comprise a pair of spaced apart walls that house a plate movable in an up and down direction within the side member. Each of the movable plates is attached at its lower edge to a ground contacting skid. A hydraulic piston or similar in reciprocating device interconnects each side member with its respective interior plate for moving the plate up and down within the side housing member in order to raise or lower the skid that is attached to the movable plate. Up and down movement of the skids with respect to the side members that are attached to the blade results in selective positioning of each end of the blade so their respective elevations above the grade on which the skid rests will result in a precise depth and slope of the material that is being spread.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a bulldozer pushing the grader/spreader of the present invention.
[0011] FIG. 2A is a rear perspective view of the grader blade of the present invention showing in cross section a fragmentary view of the bulldozer blade that mounts the grader blade. The illustrated left side skid is shown in the retracted position that allows the left end of the grader blade to be at essentially the same level as the skid.
[0012] FIG. 2B is a fragmentary perspective view of the grader blade with the illustrated left end of the blade raised above the level of the left side skid.
[0013] FIG. 3 is a cross sectional view taken along lines 3 - 3 in FIG. 2A .
[0014] FIG. 4 is a top right perspective view of the front of an expandable grader attachment in accordance with one embodiment of the invention.
[0015] FIG. 5 is a top right perspective view of the back of the expandable grader attachment in accordance with one embodiment of the invention.
[0016] FIG. 6 is a flow chart of the steps of creating a gravel road in accordance with one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The grader/spreader 2 of the present invention is shown in FIG. 1 as mounted on and carried by the front blade 4 of a bulldozer 6 is spreading gravel 8 to a specified layer depth. Prior to spreading the gravel is piled in front of the blade 10 of the grader/spreader 2 . The bulldozer operates on top of the finished grade 12 of the gravel, or other material that is being spread, thereby assuring a level and constantly accurate depth of the layer 14 .
[0018] The depth of the layer 14 above the base grade 16 is controlled by the elevation of the bottom edge of the blade 10 above the base grade. The elevation of each lateral end of the blade 10 may be independently set by hydraulic controls in the cockpit of the bulldozer. This selective adjustment of the height of the blade allows the grade to be sloped from right to left or left to right, or with equal height of each blade end resulting in a level grade.
[0019] The novel apparatus for selective adjustment of the height of the blade ends is illustrated in FIGS. 2A and 2B . To the lateral ends of the grader blade 10 there are attached side members 20 and 22 . Each of the side members includes a pair of spaced apart steel panels 24 and 26 between which is disposed a plate 28 that is slidable in an up and down direction. The bottom edge of the plate 28 is secured to a flat skid 30 that is adapted to run along the base grade 18 of the roadway being worked on. To provide the force necessary to slide the plate 28 between the panels comprising each of the end members and thus raise or lower the skid 30 , a hydraulic piston 32 is provided. One end of the piston is attached to the skid 30 while the other end of the piston is housed within the hydraulic cylinder 34 that is attached to the side of the outside side member panel 24 . The hydraulic piston and cylinder are conventional in their construction and are operated by the pressure of hydraulic fluid controlled by valves. The controls for the hydraulic system are located in the cockpit of the bulldozer (not shown). Appropriate application of the hydraulic controls will cause the piston 32 to extend out of the cylinder 34 and force the movable plate 28 downwardly and partially out of the side member housing 20 . This movement of the plate 28 causes the end member 20 and the left end of the blade 10 to be raised with respect to the skid 30 ( FIG. 2B ). With opposite adjustment of the hydraulic controls the piston 32 is made to retract into the cylinder 34 , thus lowering the elevation of the blade 10 with respect to the skid 30 ( FIG. 2A ). While hydraulic apparatus is the preferred form of motive force, other well known means may be employed that provide sufficient downward pressure on the skids 30 and keep the bottom of the blade at the right height above the base grade 16 .
[0020] While a single hydraulic piston may be sufficient to supply the power to raise and lower the blade end, a single piston may be structurally unstable. To overcome the instability a tubular sleeve 40 is attached to the outside side member panel 24 and the distal end of a slidable insert 42 is attached to the skid 30 . Thus, while the hydraulic piston and cylinder are supplying the necessary force to move the plate 28 within the end member, the sleeve and slidable insert supply the required structural stability between the movable members.
[0021] To ensure that the skid 30 remains in solid contact with the base grade 16 an auxiliary plow 46 is angularly attached to the front of each skid 30 . The plow is angled inwardly toward the blade 10 so that the material being spread will not collect in front of the skid 30 so as to pass beneath the skid and upset the precision of the height adjustment of the blade 10 .
[0022] As seen in FIGS. 2A and 3 the bottom of the bulldozer blade 4 rests on the top surface of a plurality of rearwardly protruding brackets 50 . In one embodiment, a stop 52 carried by the bracket is screwed against the back of the bulldozer blade 4 to hold the bulldozer blade in place against the grader blade 10 . Between the top portion of the bulldozer blade and the top of the back side of the grader blade a jack screw 55 provides a compression connection between the two blades. Adjustment of the jack screw operates to establish the tilt of the grader blade.
[0023] FIG. 4 is a top right perspective view of the front of an expandable grader attachment 100 in accordance with one embodiment of the invention. The expandable grader attachment 100 is similar to that shown in FIGS. 1-3 , but is expandable. This embodiment of the expandable grader attachment 100 , has a blade made of three portions 10 a , 10 b , 10 c . The outer portions 10 a & 10 b have a number of adjustment holes 102 that align with the adjustment holes 104 of the center portion. Bolts and nuts are used to lock the three portions of the expandable blade 10 a , 10 b , 10 c together. Slides or other forms of holding the blade portions 10 a , 10 b , 10 c together are not rigid enough to produce a high quality gravel road surface. This figure also shows that the hydraulic pump 106 is mounted to the backside of the expandable grader blade 100 . The hydraulic pump 106 connects electrically 116 to a bulldozer's electrical system and provides the hydraulic power to hydraulic cylinders and pistons 32 . Each blade portion 10 a , 10 b , 10 c has an adjustable crown plate 106 a , 106 b , 106 c . The crown plates 106 a , 106 b , 106 c have slots 108 a , 108 b , 108 c that align with holes in the blade portion 10 a , 10 b , 10 c . Bolts are loosened to change the position crown plates 106 a , 106 b , 106 c and then tightened to hold them in place. These adjustable crown plates 106 a , 106 b , 106 c allow the expandable grader blade 100 to contour the gravel road to have a custom crown.
[0024] The skids 30 are equipped with replaceable wear pads 110 . Since the skids 30 ride on the base grade they wear out over time. The wear pads 110 are designed to be replaced. The outer portions of the expandable blade 10 a & 10 b have braces 112 that connect the blade portion to plate 24 . This add stability to the system 100 .
[0025] FIG. 5 is a top back perspective view of the front of the expandable grader attachment 100 in accordance with one embodiment of the invention. This view shows that the expandable blade has a rack and pinion system 114 that is used to expand or contract the size of the expandable blade 10 a , 10 b , 10 c . Once the expandable blade 10 a , 10 b , 10 c is in the desired position, then the blade portions are bolted together for stability. This view also shows the electrical cord 116 that connects to the bulldozer's electrical system. The plurality of rearward protruding brackets 50 are shown in this view. A pair of height gages 118 , 120 allows the operator of the bulldozer to view the depth of the gravel 14 . Note the height of each side of the expandable grader blade can be set separately. A pair of stability arms 122 (only one is shown) has a pintle hitch 124 connecting to the grader blade 10 . An expandable arm 126 has a number of preset lengths and a screw for finer adjustments of the length. A second pintle hitch 128 attaches to a bulldozer. The stability arms provide bracing to the side blades when they are extended beyond a certain point, since the structure will have increase leverage loads toward the ends of the side blades when the side blades are extended.
[0026] FIG. 6 is a flow chart of the steps of creating a gravel road in accordance with one embodiment of the invention. The process starts, step 140 , by preparing a base grade at step 142 . A width of the road is determined at step 144 . A grader/spreader system is attached to the front blade of a bulldozer at step 146 . A length of the expandable grader blade is set at step 148 . A height of the expandable grader blade is set hydraulically at step 150 . A plurality of crown plates are set on the expandable grader blade at step 152 . A pair of ground contacting skids of the grader/spreader system are placed on the base grade at step 154 . A mound of gravel is placed in front of the grader/spreader system at step 156 . At step 158 , the bulldozer is driven forward which ends the process at step 160 .
[0027] Using the system described herein an accurate depth of gravel is laid on the base grade in a single pass without any rework being necessary. The system does not require blue tops, associated surveying costs, or multiple passes like previous techniques of laying down an accurate gravel road. Accurate depth of the gravel road is accomplished by the down pressure applied from the bulldozer through the hydraulic cylinders 32 . The front blade of the bulldozer rests on the brackets 50 and applies down pressure on the expandable grader blade. The pitch screws 55 set the pitch of the expandable grader blade. By setting these so that the grader blade is pitched forward, additional down pressure is created as the bulldozer moves forward. It is important that the bulldozer push the grader blade as this creates a down pressure that cannot be created by pulling the grader blade and allows the bulldozer tracks to ride on the finished grade. The finish grade is level, while the base grade may have some non-uniformity. If the bulldozer tracks rode on the base grade these non-uniformities would translate into non-uniformities in the finish grade. In one embodiment, the invention is attached to a tracked skid steer instead of a bulldozer.
[0028] While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alterations, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alterations, modifications, and in variations in the appended claims.
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The present invention is a road grader attachment that attaches to a bulldozer. The attachment has an elongated blade with mutually parallel side members attached to the lateral ends of the blade where each of the side members comprise a pair of spaced apart walls that house a plate movable in an up and down direction within the side member. Each of the movable plates is attached at its lower edge to a ground contacting skid. A hydraulic piston interconnects each side member with its respective interior plate for moving the plate up and down within the side housing member in order to raise or lower the skid that is attached to the movable plate
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BACKGROUND
The present invention relates to testing of radio frequency (RF) wireless signal transceivers, and in particular, to testing such devices without a need for RF signal cables for conveyance of RF test signals.
Many of today's electronic devices use wireless technologies for both connectivity and communications purposes. Because wireless devices transmit and receive electromagnetic energy, and because two or more wireless devices have the potential of interfering with the operations of one another by virtue of their signal frequencies and power spectral densities, these devices and their wireless technologies must adhere to various wireless technology standard specifications.
When designing such devices, engineers take extraordinary care to ensure that such devices will meet or exceed each of their included wireless technology prescribed standard-based specifications. Furthermore, when these devices are later being manufactured in quantity, they are tested to ensure that manufacturing defects will not cause improper operation, including their adherence to the included wireless technology standard-based specifications.
For testing these devices following their manufacture and assembly, current wireless device test systems (“testers”) employ a subsystem for analyzing signals received from each device. Such subsystems typically include at least a vector signal generator (VSG) for providing the source signals to be transmitted to the device, and a vector signal analyzer (VSA) for analyzing signals produced by the device. The production of test signals by the VSG and signal analyses performed by the VSA are generally programmable so as to allow each to be used for testing a variety of devices for adherence to a variety of wireless technology standards with differing frequency ranges, bandwidths and signal modulation characteristics.
Calibration and performance verification testing of a device under test (DUT) are typically done using electrically conductive signal paths, such as RF cables, rather than wireless signal paths, by which a DUT and tester communicate via electromagnetic radiation. Accordingly, the signals between the tester and DUT are conveyed via the conductive signal path rather than being radiated through ambient space. Using such conductive signal paths helps to ensure repeatability and consistency of measurements, and eliminates positioning and orientation of the DUT as a factor in signal conveyance (transmission and reception).
In the case of a multiple input, multiple output (MIMO) DUT, a signal path must be provided, in some form, for each input/output connection of the DUT. For example, for a MIMO device intended to operate with three antennas, three conductive signal paths, e.g., cables and connections, must be provided for testing.
However, using conductive signal paths significantly impacts the time needed for testing each DUT due to the need for physically connecting and disconnecting the cables between the DUT and tester. Further, in the case of a MIMO DUT, multiple such connecting and disconnecting actions must be performed, both at the beginning and termination of testing. Further, since the signals being conveyed during testing are not radiated via the ambient space, as they would be in the normally intended use, and the antenna assemblies for the DUT are not in use during such testing, such testing does not simulate real world operation and any performance characteristics attributable to the antennas are not reflected in the test results.
As an alternative, testing could be done using test signals conveyed via electromagnetic radiation rather than electrical conduction via cables. This would have the benefit of requiring no connecting and disconnecting of test cables, thereby reducing the test time associated with such connections and disconnections. However, the “channel” in which the radiated signals and receiver antennas exist, i.e., the ambient space through which the test signals are radiated and received, is inherently prone to signal interference and errors due to other electromagnetic signals originating elsewhere and permeating the ambient space. Such signals will be received by the DUT antennas and can include multipath signals from each interfering signal source due to signal reflections. Accordingly, the “condition” of the “channel” will typically be poor compared to using individual conductive signal paths, e.g., cables, for each antenna connection.
One way to prevent, or at least significantly reduce, interference from such extraneous signals, is to isolate the radiated signal interface for the DUT and tester using a shielded enclosure. However, such enclosures have typically not produced comparable measurement accuracy and repeatability. This is particularly true for enclosures that are smaller than the smallest anechoic chambers. Additionally, such enclosures tend to be sensitive to the positioning and orientation of the DUT, as well as to constructive and destructive interference of multipath signals produced within such enclosures.
Accordingly, it would be desirable to have systems and methods for testing wireless signal transceivers, and particularly wireless MIMO signal transceivers, in which radiated electromagnetic test signals can be used, thereby simulating real world system operation as well as avoiding test time otherwise necessary for connecting and disconnecting test cabling, while maintaining test repeatability and accuracy by avoiding interfering signals due to externally generated signals and multipath signal effects.
SUMMARY
In accordance with the presently claimed invention, a system and method to facilitate wireless testing of a radio frequency (RF) signal transceiver device under test (DUT). With the DUT operating in a controlled electromagnetic environment, the tester exchanges multiple test signals wirelessly with the DUT. Signal phases of the respective test signals are controlled in accordance with feedback signals from the DUT and test equipment. Magnitudes of the respective test signals can also be controlled in accordance with such feedback signals, thereby enabling minimizing of apparent signal path loss between the tester and DUT to effectively simulate an electrically conductive signal path.
In accordance with one embodiment of the presently claimed invention, a system to facilitate wireless testing of a radio frequency (RF) signal transceiver device under test (DUT) includes a structure, an electrically conductive signal path, a plurality of antennas and RF signal control circuitry. The structure defines interior and exterior regions with the interior region substantially isolated from electromagnetic radiation originating from the exterior region, with the interior region including: a first interior location configured to allow placement of a DUT; a second interior location distal from the first interior location, and one or more RF absorbent materials disposed substantially lateral to a defined volume between the first and second interior locations. The electrically conductive signal path is to couple to the DUT and convey one or more electrical signals between the interior and exterior regions. The plurality of antennas is disposed at least partially at the second interior location to radiate a plurality of phase-controlled RF test signals. The RF signal control circuitry is coupled to the electrically conductive signal path and the plurality of antennas, and responsive to a plurality of signal data from the DUT related to the plurality of phase-controlled RF test signals and conveyed via the one or more electrical signals, and to a RF test signal by: replicating the RF test signal to provide a plurality of replica RF test signals; and controlling, in accordance with the plurality of signal data, respective phases of at least a portion of the plurality of replica RF test signals to provide the plurality of phase-controlled RF test signals.
In accordance with another embodiment of the presently claimed invention, a method of facilitating wireless testing of a radio frequency (RF) multiple-input, multiple-output (MIMO) signal transceiver device under test (DUT) includes providing a structure, an electrically conductive signal path and a plurality of antennas. The structure defines interior and exterior regions with the interior region substantially isolated from electromagnetic radiation originating from the exterior region, with the interior region including: a first interior location configured to allow placement of a DUT; a second interior location distal from the first interior location; and one or more RF absorbent materials disposed substantially lateral to a defined volume between the first and second interior locations. The electrically conductive signal path is to couple to the DUT and convey one or more electrical signals between the interior and exterior regions. The plurality of antennas is disposed at least partially at the second interior location to radiate a plurality of phase-controlled RF test signals. Further included is responding to a plurality of signal data from the DUT related to the plurality of phase-controlled RF test signals and conveyed via the one or more electrical signals, and to a RF test signal by: replicating the RF test signal to provide a plurality of replica RF test signals; and controlling, in accordance with the plurality of signal data, respective phases of at least a portion of the plurality of replica RF test signals to provide the plurality of phase-controlled RF test signals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a typical operating and possible testing environment for a wireless signal transceiver.
FIG. 2 depicts a testing environment for a wireless signal transceiver using a conductive test signal path.
FIG. 3 depicts a testing environment for a MIMO wireless signal transceiver using conductive signal paths and a channel model for such testing environment.
FIG. 4 depicts a testing environment for a MIMO wireless signal transceiver using radiated electromagnetic signals a channel model for such testing environment.
FIG. 5 depicts a testing environment in accordance with exemplary embodiments in which a MIMO DUT can be tested using radiated electromagnetic test signals.
FIG. 6 depicts a testing environment in which a DUT is tested using radiated electromagnetic test signals within a shielded enclosure.
FIGS. 7 and 8 depict exemplary embodiments of testing environments in which a wireless DUT is tested using radiated electromagnetic test signals in a shielded enclosure with reduced multipath signal effects.
FIG. 9 depicts a physical representation of a shielded enclosure in accordance with an exemplary embodiment for use in the testing environments of FIGS. 7 and 8 .
DETAILED DESCRIPTION
The following detailed description is of example embodiments of the presently claimed invention with references to the accompanying drawings. Such description is intended to be illustrative and not limiting with respect to the scope of the present invention. Such embodiments are described in sufficient detail to enable one of ordinary skill in the art to practice the subject invention, and it will be understood that other embodiments may be practiced with some variations without departing from the spirit or scope of the subject invention.
Throughout the present disclosure, absent a clear indication to the contrary from the context, it will be understood that individual circuit elements as described may be singular or plural in number. For example, the terms “circuit” and “circuitry” may include either a single component or a plurality of components, which are either active and/or passive and are connected or otherwise coupled together (e.g., as one or more integrated circuit chips) to provide the described function. Additionally, the term “signal” may refer to one or more currents, one or more voltages, or a data signal. Within the drawings, like or related elements will have like or related alpha, numeric or alphanumeric designators. Further, while the present invention has been discussed in the context of implementations using discrete electronic circuitry (preferably in the form of one or more integrated circuit chips), the functions of any part of such circuitry may alternatively be implemented using one or more appropriately programmed processors, depending upon the signal frequencies or data rates to be processed. Moreover, to the extent that the figures illustrate diagrams of the functional blocks of various embodiments, the functional blocks are not necessarily indicative of the division between hardware circuitry.
Referring to FIG. 1 , a typical operating environment, and ideal testing environment for a wireless signal transceiver (at least in terms of simulating real world operation), would have the tester 100 and DUT 200 communicate wirelessly. Typically, some form of test controller 10 , (e.g., a personal computer) will also be used to exchange testing commands and data via wired signal interfaces 11 a , 11 b with the tester 100 and DUT 200 . The tester 100 and DUT 200 each have one (or more for MIMO devices) respective antennas 102 , 202 , which connect by way of conductive signal connectors 104 , 204 (e.g., coaxial cable connections, many types of which are well known in the art). Test signals (source and response) are conveyed wirelessly between the tester 100 and DUT 200 via the antennas 102 , 202 . For example, during a transmit (TX) test of the DUT 200 , electromagnetic signals 203 are radiated from the DUT antenna 202 . Depending upon the directivity of the antenna emission pattern, this signal 203 will radiate in numerous directions, resulting in an incident signal component 203 i and reflected signal components 203 r being received by the tester antenna 102 . As discussed above, these reflected signal components 203 r , often the products of multipath signal effects as well as other electromagnetic signals originating elsewhere (not shown), result in constructive and destructive signal interference, thereby preventing reliable and repeatable signal reception and testing results.
Referring to FIG. 2 , to avoid such unreliable testing results, a conductive signal path, such as a RF coaxial cable 106 , is used to connect the antenna connectors 104 , 204 of the tester 100 and DUT 200 to provide a consistent, reliable and repeatable electrically conductive signal path for conveyance of the test signals between the tester 100 and DUT 200 . As discussed above, however, this increases the overall test time due to the time needed for connecting and disconnecting the cable 106 before and after testing.
Referring to FIG. 3 , the additional test time for connecting and disconnecting test cabling becomes even longer when testing a MIMO DUT 200 a . In such cases, multiple test cables 106 are needed to connect corresponding tester 104 and DUT 204 connectors to enable conveyance of the RF test signals from the RF signal sources 110 (e.g., VSGs) within the tester 100 a for reception by the RF signal receivers 210 within the DUT 200 a . For example, in a typical testing environment, the tester for testing MIMO devices will have one or more VSGs 110 a , 110 b , . . . , 110 n providing corresponding one or more RF test signals 111 a , 111 b , . . . , 111 n (e.g., packet data signals having variable signal power, packet contents and data rates). Their corresponding test cables 106 a , 106 b , . . . , 106 n , connected via respective tester 104 a , 104 b , . . . , 104 n and DUT 204 a , 204 b , . . . , 204 n connectors, convey these signals to provide the received RF test signals 211 a , 211 b , . . . , 211 n for the corresponding RF signal receivers 210 a , 210 b , . . . , 210 n within the DUT 200 a . Accordingly, the additional test time required for connecting and disconnecting these test cables 106 can be increased by a factor n corresponding to the number of test cables 106 .
As discussed above, using test cables for connecting the tester 100 a and DUT 200 a does have the advantage of providing consistent, reliable, and repeatable test connections. As is well known in the art, these test connections 107 can be modeled as a signal channel H characterized by a diagonal matrix 20 , where the diagonal matrix elements 22 correspond to the coefficients h 11 , h 22 , . . . , h nn , for the respective signal channel characteristics (e.g., signal path conductivities or losses for the respective test cables 106 ).
Referring to FIG. 4 , in accordance with one or more exemplary embodiments, the conductive, or wired, channel 107 ( FIG. 3 ) is replaced by a wireless channel 107 a corresponding to a wireless signal interface 106 a between the tester 100 a and DUT 200 a . As discussed above, the tester 100 a and DUT 200 a communicate test signals 111 , 211 via respective arrays of antennas 102 , 202 . In this type of test environment, the signal channel 107 a is no longer represented by a diagonal matrix 20 , but is instead represented by a matrix 20 a having one or more non-zero coefficients 24 a , 24 b off of the diagonal 22 . As will be readily understood by one skilled in the art, this is due to the multiple wireless signal paths available in the channel 107 a . For example, unlike a cabled signal environment in which, ideally, each DUT connector 204 receives only the signal from its corresponding tester connector 104 . In this wireless channel 107 a , the first DUT antenna 202 a receives test signals radiated by all of the tester antennas 102 a , 102 b , . . . , 102 n , e.g., corresponding to channel H matrix coefficients h 11 , h 12 , . . . , and h 1n .
In accordance with well known principles, the coefficients h of the channel matrix H correspond to characteristics of the channel 107 a affecting transmission and reception of the RF test signals. Collectively, these coefficients h define the channel condition number k(H), which is the product of the norm of the H matrix and the norm of the inverse of the H matrix, as represented by the following equation:
k ( H )=|| H||*||H −1 ||
The factors affecting these coefficients can alter the channel condition number in ways that can create measurement errors. For example, in a poorly conditioned channel, small errors can cause large errors in the testing results. Where the channel number is low, small errors in the channel can produce small measurements at the receive (RX) antenna. However, where the channel number is high, small errors in the channel can cause large measurement errors at the receive antenna. This channel condition number k(H) is also sensitive to the physical positioning and orientation of the DUT within its testing environment (e.g., a shielded enclosure) and the orientation of its various antennas 204 . Accordingly, even if with no extraneous interfering signals originating elsewhere or arriving via reflections and impinging on the receive antennas 204 , the likelihood of repeatable accurate test results will be low.
Referring to FIG. 5 , in accordance with one or more exemplary embodiments, the test signal interface between the tester 100 a and DUT 200 a can be wireless. The DUT 200 a is placed within the interior 301 of a shielded enclosure 300 . Such shielded enclosure 300 can be implemented as a metallic enclosure, e.g., similar in construction or at least in effect to a Faraday cage. This isolates the DUT 200 a from radiated signals originating from the exterior region 302 of the enclosure 300 . In accordance with exemplary embodiments, the geometry of the enclosure 300 is such that it functions as a closed-ended waveguide.
Elsewhere, e.g., disposed within or on an opposing interior surface 302 of the enclosure 300 , are multiple (n) antennas arrays 102 a , 102 b , . . . , 102 n , each of which radiates multiple phase-controlled RF test signals 103 a , 103 b , . . . , 103 n (discussed in more detail below) originating from the test signal sources 110 a , 110 b , . . . , 110 n within the tester 100 a . Each antenna array includes multiple (M) antenna elements. For example, the first antenna array 102 a includes m antenna elements 102 aa , 102 ab , . . . 102 am . Each of these antenna elements 102 aa , 102 ab , . . . , 102 am is driven by a respective phase-controlled RF test signal 131 aa , 131 ab , . . . , 131 am provided by respective RF signal control circuitry 130 a.
As depicted in the example of the first RF signal control circuitry 130 a , the RF test signal 111 a from the first RF test signal source 110 a has its magnitude increased (e.g., amplified) or decreased (e.g., attenuated) by signal magnitude control circuitry 132 . The resulting magnitude-controlled test signal 133 is replicated by signal replication circuitry 134 (e.g., a signal divider). The resulting magnitude-controlled, replicated RF test signals 135 a , 135 b , . . . , 135 m have their respective signal phases controlled (e.g., shifted) by respective phase control circuits 136 a , 136 b , . . . , 136 m to produce magnitude- and phase-controlled signals 131 aa , 131 ab , . . . , 131 am to drive the antenna elements 102 aa , 102 ab , . . . , 102 am of the antenna array 102 a.
The remaining antenna arrays 102 b , . . . , 102 n and their respective antenna elements are driven in a similar manner by corresponding RF signal control circuits 130 b , . . . , 130 m . This produces corresponding numbers of composite radiated signals 103 a , 103 b , . . . , 103 n for conveyance to and reception by the antennas 202 a , 202 b , . . . , 202 n of the DUT 200 a in accordance with the channel H matrix, as discussed above. The DUT 200 a processes its corresponding received test signals 211 a , 211 b , . . . , 211 m and provides one or more feedback signals 201 a indicative of the characteristics (e.g., magnitudes, relative phases, etc.) of these received signals. These feedback signals 201 a are provided to control circuitry 138 within the RF signal control circuits 130 . This control circuitry 138 provides control signals 137 , 139 a , 139 b , . . . , 139 m for the magnitude control circuitry 132 and phase control circuitry 136 . Accordingly, a closed loop control path is provided, thereby enabling gain and phase control of the individual radiated signals from the tester 100 a for reception by the DUT 200 a . (Alternatively, this control circuitry 130 can be included as part of the tester 100 a .)
In accordance with well-known channel optimization techniques, the control circuitry 138 uses this feedback data 201 a from the DUT 200 a to achieve optimal channel conditions by altering the magnitudes and phases of the radiated signals in such a manner as to minimize the channel condition number k(H), and produce received signals, as measured at each DUT antenna 202 , having approximately equal magnitudes. This will create a communication channel through which the radiated signals produce test results substantially comparable to those produced using conductive signal paths (e.g., RF signal cables).
This operation by the control circuitry 138 of the RF signal control circuitry 130 , following successive transmissions and channel condition feedback events, will vary the signal magnitude and phase for each antenna array 102 a , 102 b , . . . , 102 n to iteratively achieve an optimized channel condition number k(H). Once such an optimized channel condition number k(H) has been achieved, the corresponding magnitude and phase settings can be retained and the tester 100 a and DUT 200 a can continue thereafter in a sequence of tests, just as would be done in a cabled testing environment.
In practice, a reference DUT can be placed in a test fixture within the shielded enclosure 300 for use in optimizing the channel conditions through the iterative process discussed above. Thereafter, further DUTs of the same design can be successively tested without having to execute channel optimization in every instance, since differences in path loss experienced in the controlled channel environment of the enclosure 300 should be well within normal testing tolerances.
Referring still to FIG. 5 , for example, an initial transmission was modeled to produce a channel condition number of 13.8 db, and the magnitudes of the h 11 and h 22 coefficients were −28 db and −28.5 db, respectively. The magnitude matrix for the channel H would be represented as follows:
H
dB
=
[
-
28
-
34.2
-
29.8
-
28.5
]
k
(
H
)
=
13.8
dB
After iterative adjustments of magnitude and phase, as discussed above, the channel condition number k(H) was reduced to 2.27 db, and the amplitudes of the h 11 and h 22 coefficients were −0.12 db and −0.18 db, respectively, producing a channel magnitude matrix as follows:
H
dB
=
[
-
0.12
-
13.68
-
15.62
-
0.18
]
k
(
H
)
=
2.27
dB
These results are comparable to those of a cabled testing environment, thereby indicating that such a wireless testing environment can provide test results of comparable accuracy. By eliminating time for connecting and disconnecting cabled signal paths, and factoring in the reduced time for gain and phase adjustments, the overall received signal test time is significantly reduced.
Referring to FIG. 6 , influences of multipath signal effects upon the channel condition can be better understood. As discussed above, once disposed within the interior 301 of the enclosure 300 , the DUT 200 a , during transmit testing, radiates an electromagnetic signal 203 a from each antenna 202 a . This signal 203 a includes components 203 b , 203 c that radiate outwardly and away from the antenna 102 a of the tester 100 a . However, these signal components 203 b , 203 c are reflected off of interior surfaces 304 , 306 of the enclosure 300 and arrive as reflected signal components 203 br , 203 cr to combine, constructively or destructively, depending upon the multipath signal conditions, with the main incident signal component 203 ai . As discussed above, depending upon the constructive and destructive nature of the interference, test results will generally tend to be unreliable and inaccurate for use in proper calibration and performance verification.
Referring to FIG. 7 , in accordance with an exemplary embodiment, RF absorbent materials 320 a , 320 b are disposed at the reflective surfaces 304 , 306 . As a result, the reflected signal components 203 br , 203 cr are attenuated significantly, thereby producing less interference, either constructively or destructively, with the incident primary signal component 203 ai.
Additional RF signal control circuitry 150 can be included for use between the antenna array 102 a mounted within the interior 301 or on the interior surface 302 of the enclosure 300 a and the tester 100 a . (Alternatively, this additional control circuitry 150 can be included as part of the tester 100 a .) The radiated signals impinging upon the antenna elements 102 aa , 102 ab , . . . , 102 am produce received signals 103 aa , 103 ab , . . . , 103 am with respective signal phases controlled (e.g., shifted) by phase control circuitry 152 having phase control elements 152 a , 152 b , . . . , 152 m controlled in accordance with one or more phase control signals 157 a , 157 b , . . . , 157 m provided by a control system 156 . The resulting phase-controlled signals 153 are combined in a signal combiner 154 to provide the received signal 155 a for the tester 100 a and a feedback signal 155 b for the control system 156 . The control system 156 processes this feedback signal 155 b , as part of a closed loop control network, to adjust, as needed, the respective phases of the composite receive signals 103 aa , 103 ab , . . . , 103 am to minimize the apparent signal path loss associated with the interior region 301 of the enclosure 300 a . This closed loop control network also allows the system to reconfigure the phased array enabled by these antennas 102 a and phase control circuitry 152 in the event that the positioning or orientation of the DUT 200 a changes within the enclosure 300 a . As a result, following minimization of the path loss using this feedback loop, accurate and repeatable conveyance of the DUT signal 203 a to the tester 100 a using the radiated signal environment within the enclosure 300 a can be achieved.
Referring to FIG. 8 , similar control and improvement in producing accurate and repeatable test results can be achieved for DUT receive signal testing. In this case, the test signal 111 a provided by the tester 100 a is replicated by the signal combiner/splitter 154 , and the respective phases of the replicated test signals 153 are adjusted as necessary by the phase control circuitry 152 before being radiated by the antenna elements 102 aa , 102 ab , . . . , 102 am . As in the previous case, the reflected signal components 103 br , 103 cr are significantly attenuated and result in reduced constructive and destructive interference with the primary incident signal component 103 ai . One or more feedback signals 203 a from the DUT 200 a provide the control system 156 with the information necessary for controlling the phases of the replicated test signals 153 to minimize the apparent signal path loss associated with the interior 301 of the enclosure 300 a , thereby establishing consistent and repeatable signal path loss conditions.
Referring to FIG. 9 , in accordance with one or more exemplary embodiments, the shielded enclosure 300 b can be implemented substantially as shown. As discussed above, the DUT can be positioned at one end 301 d of the interior 301 of the enclosure 300 b , opposite of the interior region 301 b containing or facing the interior surface 302 on which the tester antenna arrays 102 a , 102 b , . . . , 102 n ( FIG. 5 ) are located. In between is an interior region 301 a forming a waveguide cavity surrounded by the RF absorbent materials 320 .
Various other modifications and alterations in the structure and method of operation of this invention will be apparent to those skilled in the art without departing from the scope and the spirit of the invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. It is intended that the following claims define the scope of the present invention and that structures and methods within the scope of these claims and their equivalents be covered thereby.
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A system and method to facilitate wireless testing of a radio frequency (RF) signal transceiver device under test (DUT). With the DUT operating in a controlled electromagnetic environment, the tester exchanges multiple test signals wirelessly with the DUT. Signal phases of the respective test signals are controlled in accordance with feedback signals from the DUT and test equipment. Magnitudes of the respective test signals can also be controlled in accordance with such feedback signals, thereby enabling minimizing of apparent signal path loss between the tester and DUT to effectively simulate an electrically conductive signal path.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims the benefit of priority from the Japanese Patent Application No. 2008-060990, filed on Mar. 11, 2008, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a pattern recognition apparatus which reduces memory of feature value, and a method thereof, suppressing degradation of recognition performance.
DESCRIPTION OF THE BACKGROUND
[0003] In pattern recognition, “Pattern classification, Richard O. Duda, Peter, E. Hart, David G. Stork, Wiley-Interscience” has disclosed a method of reducing memory of a feature vector, suppressing degradation of recognition performance.
[0004] Application of this reduction method provides a subspace where sum of the square error of the feature vector approximation by projection is at a minimum. Projection on the subspace allows us to reduce dimension of the feature vector and memory, keeping the square error of the whole feature vector small. Unlike a data compression, distance and angle between the feature vectors can be calculated in an approximate state without returning to the original condition.
[0005] However, the above mentioned reduction method poses a problem that the amount of memory of the feature vectors may not be sharply reduced, suppressing degradation of recognition performance, since the dimension of the subspace to be projected needs to be remained to some extent in order to maintain recognition performance.
SUMMARY OF THE INVENTION
[0006] The invention allows compression of feature vectors to reduce amount of memory, suppressing degradation of recognition performance, without returning to the original state.
[0007] An embodiment of the invention provides a pattern recognition apparatus which comprises a pattern input unit configured to input a pattern of a recognition object, a feature extraction unit configured to perform feature extraction from the input pattern to generate a feature vector, a function generation unit configured to increase the number of quantization in an order from quantization number 1 or quantization number 2 to calculate a quantization threshold of each of the quantization number, the function generation unit calculating the quantization threshold of quantization number (n+1) using a quantization threshold of quantization number n (n>=1) and generating a quantization function having a quantization threshold corresponding to quantization number S (S>n), a quantization unit configured to quantize each component of the feature vector of the input pattern using the quantization function to generate an input quantization feature vector having each of the quantized component, a dictionary unit configured to store a dictionary feature vector of the recognition object, or a quantized dictionary feature vector in which each component of the dictionary feature vector of the pattern of a recognition object is quantized, a similarity calculation unit configured to calculate a similarity between the input quantization feature vector and the dictionary feature vector, or a similarity between the input quantization feature vector and the quantized dictionary feature vector, and a determination unit configured to recognize the recognition object based on the similarity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a block diagram of a pattern recognition apparatus according to the first embodiment of the invention.
[0009] FIG. 2 is a flow chart of quantization processing.
[0010] FIG. 3 is a flow chart of a similarity calculation processing.
[0011] FIG. 4 is a block diagram of a pattern recognition apparatus according to the second embodiment of the invention.
[0012] FIG. 5 is a flow chart of a similarity calculation processing.
[0013] FIG. 6 is a block diagram of a pattern recognition apparatus of a third embodiment.
[0014] FIG. 7 is a view of a quantization processing of each component of a feature vector generated from a face image.
[0015] FIG. 8 is a view of a vector (v 1 , v 6 ) rearranged when D=6.
[0016] FIG. 9 is a view of e i,j of the vector of FIG. 8 .
[0017] FIG. 10 is a view of vectors E i,M and T i,M of FIG. 8 .
[0018] FIG. 11 is a view of the quantization threshold search processing 204 for the vector of FIG. 8 in a case where N=3.
[0019] FIG. 12 is a view of re-search preparation processing 206 for the vector of FIG. 8 in a case where N=3 and i=5.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Reference will now be made in detail to the present embodiments of the invention, embodiments of which are illustrated in the accompanying drawings. A pattern recognition apparatus of the embodiments of the invention will be explained with reference to the drawings as follows. The pattern recognition apparatus of the embodiments is not limited to pattern recognition of an image but may be applied to various fields of pattern recognitions where a feature value such as a sound is used.
First Embodiment
[0021] Pattern recognition apparatus 10 of this embodiment quantizes both an input feature vector corresponding to an input pattern and a dictionary feature vector which is a candidate for comparison, calculates a similarity, and performs pattern recognition based on the similarity.
[0022] Pattern recognition apparatus 10 of this embodiment will be explained with reference to FIG. 1 . FIG. 1 is a schematic block diagram illustrating pattern recognition apparatus 10 . Pattern recognition apparatus 10 comprises a pattern input unit 101 , a feature extraction unit 102 , a feature vector quantization unit 103 , a dictionary feature storing unit 104 , a similarity calculation unit 105 , and a determination unit 106 . Functions of each unit 101 - 106 may be realized by a program stored in a computer. Functions of each unit 101 - 106 will be explained below.
[0023] Pattern input unit 101 inputs the pattern to be used as a candidate for recognition. When the pattern is an image, an image captured by, for example, a digital camera may be input into a computer or an image captured by a camera connected to a computer may be input into the computer. When the pattern is a sound, for example, a recorded sound may be input into a computer or a sound recorded by a microphone connected to a computer may be input into the computer.
[0024] Feature extraction unit 102 extracts feature values from a pattern input by pattern input unit 101 and converts the pattern into a vector. Hereafter, the vector converted by feature extraction unit 102 is called a “feature vector.” When the input pattern is an image, the pattern is changed into a vector by, for example, a raster scan. When the input pattern is a sound, for example, a vector which has frequency components of the sound within a definite period of time is used.
[0025] After converting into a vector, a processing of suppressing an input pattern change may be performed. For example, a processing of removing a noise component with a small eigen value obtained from the pattern prepared in large quantities beforehand by principal component analysis etc. may be performed.
[0026] Feature vector quantization unit 103 generates a quantization function for the feature vector (the input feature vector and the dictionary feature vector) generated by feature extraction unit 102 , and performs quantization processing of each component of the feature vectors based on the quantization function. The “quantization function” is a function defined from a set of sections which is divided from a set of real numbers into limited numbers or countable infinite numbers, and a set of values corresponding to the sections one-to-one, and the function which outputs the value corresponding to the section containing the input real number for the input real number. The “quantization threshold” means the above section. The “quantization value” is the value corresponding to the quantization threshold one-to-one and is included in the quantization threshold. The “quantization feature vector” means a feature vector quantized by feature vector quantization unit 103 .
[0027] FIG. 2 is a flow chart of details of quantization processing 20 performed in feature vector quantization unit 103 . Explanation for quantization processing 20 will be explained below. The image processed by quantization processing 20 for the feature vector generated from the face image is shown in FIG. 7 .
[0028] Dictionary feature storing unit 104 extracts a dictionary feature vector for a pattern of each class for recognition by feature extraction unit 102 , performs processing by feature vector quantization unit 103 and stores quantization feature vectors (hereinafter, referred to as “dictionary quantization feature vector”) of the generated dictionary into a storage area. Similarity calculation unit 105 calculates a value indicating a similarity (hereinafter, referred to as “similarity”) between a quantization feature vector of the input pattern generated by feature vector quantization unit 103 (hereinafter, referred to as “input quantization feature vector”) and a dictionary quantization feature vector of each class stored in dictionary feature storing unit 104 . Here, the distance between vectors is calculated.
[0029] FIG. 3 is a flow chart of a similarity calculation processing 30 performed by similarity calculation unit 105 . Explanation of similarity calculation processing 30 is mentioned later. Determination unit 106 identifies the class for recognition, when the class has the highest similarity among the registered classes fulfilling conditions of the similarity. When no class fulfills the conditions, determination unit 106 identifies that there is no class in the class. When the distance between vectors is used as the similarity, the distance is set to be smaller than a predetermined threshold and has higher similarity as the distance becomes smaller.
[0030] Quantization processing 20 is a quantization processing performed by feature vector quantization unit 103 . FIG. 2 is a flow chart of quantization processing 20 . Quantization processing 20 includes a feature vector input processing 201 , a rearrangement processing 202 , an initialization processing 203 , a quantization threshold search processing 204 , an error/quantization quantification processing 205 , a re-search preparation processing 206 , and a quantization feature vector output processing 207 . Explanation of each of the processing 201 - 207 is shown below.
[0031] Feature vector input processing 201 is a processing of inputting the feature vector (i.e., the input feature vector or the dictionary feature vector) output from feature extraction unit 102 . Hereafter, the dimension of the feature space of the feature vector is set to D.
[0032] Rearrangement processing 202 is a processing of rearranging the size of the value of each component of the feature vectors into an ascending order. Hereafter, the feature vectors after rearrangement processing 202 is set to (v 1 , . . . , v D ) (1<=I<=j<=D).
[0033] FIG. 8 is a view of a rearranged vector (v 1 , . . . , v 6 ) for D=6 (after rearrangement processing 202 ). In FIG. 8 , a vertical axis is a size of the value of each component of the feature vectors, and a horizontal axis is the number of dimensions of each component.
[0034] Initialization processing 203 is a processing of initializing a loop processing by the number of quantization to perform quantization processing 20 . Before explaining initialization processing, signs are defined (1<=I<=j<=D).
[0035] “e i,j ” is the minimum error when quantizing v i , . . . , v j by quantization number 1. That is, it is the minimum value of the error when replacing it into q. q is a real number; however, it is an average m of v i , . . . , v j as mentioned later. The error is calculated by the square sum of the difference of each component as shown in the equation (1) described below.
[0036] Next, calculation of e i,j will be explained. The quantization error when replacing all v i , . . . , v j with q is shown in the equation (1) described below.
[0000]
∑
k
=
i
j
(
q
-
v
k
)
2
=
(
j
-
i
)
(
q
-
m
)
2
+
(
j
-
i
)
σ
2
(
1
)
[0000] where m is an average value of v i , . . . , v j , and σ 2 is distribution of v i , . . . , v j .
[0037] According to equation (1), when q is an average m of v i , . . . , v j , the quantization error is at the minimum, and the value is (j−i)σ 2 .
[0038] FIG. 9 is a view of e i,j of the vector of FIG. 8 (D=6). “E i,M ” is the minimum error when quantizing v i , . . . , v j by quantization number M.
[0039] FIG. 10 is a view of the vector E i,M of FIG. 8 . “T i,M ” is a set of division values of the quantization threshold, which is at the minimum when quantizing v i , . . . , v j by quantization number M. The quantization number of value a is defined as follows for the division value group Ti, M={t 1 , . . . , t (M−1) }:
[0040] a quantization number is 1 for a<t 1 ,
[0041] a quantization number is i for t (i−1) <=a<t i , and
[0042] a quantization number is M for t (M−1) <=a.
[0043] FIG. 10 is a view of vectors E i,M and T i,M of FIG. 8 (D=6, N=2). That is, T 22 , . . . , T 62 are a set of division values of the minimum binary quantization errors as shown in FIG. 10 . As shown in FIG. 10 , E 22 , . . . , E 62 are the binary quantization errors at that time. In each graph of FIG. 10 , “the size of the value of each component of the feature vectors” of a vertical axis is divided by division value t, and each of the divided section is the quantization threshold. For example, there are two division values and three quantization thresholds, for quantization number N=3. “N” is the quantization number of the quantization function under processing.
[0044] Initialization processing 203 performs the following processing for each i=1, . . . , D. The first processing assigns an empty set to T i,l . The second processing assigns the value of e 1,i to Ei. The third processing assigns 1 to N.
[0045] The above-mentioned processing may be omitted and a processing of quantization threshold search processing 204 for N=2 as mentioned later may be initialization processing 203 .
[0046] Quantization threshold search processing 204 is a processing of adding 1 to N and calculate E D, N and T D,N using T i,(N−1) and E i,(N−1) (i=N−1, . . . , D). More specifically, the following processing is performed.
[0047] Calculate
[0000]
α
=
arg
min
(
N
-
1
)
≤
i
〈
D
{
E
i
,
(
N
-
1
)
+
e
(
i
+
1
)
,
D
}
[0048] Assign T a,(N−1) ∪{v (a+1) } to T D,N
[0049] Assign E a,(N−1) +e (a+1),D to E D,N
[0050] FIG. 11 illustrates quantization threshold search processing 204 of the vector of FIG. 8 for N=3. That is, the maximum division value is moved to v 3 , . . . , v 6 and calculates a quantization result with each division value to obtain each quantization error. As a division value which minimizes the quantization error of three-valued quantization, we let t 61 =t 41 and t 62 =v 5 .
[0051] An error/quantization quantification processing 205 moves on to quantization feature vector output processing 207 , when quantization error E D, N and quantization number N are evaluated and the quantization error and the quantization number meet the standard. On the other hand, when they do not meet the standard, the processing moves onto re-search preparation processing 206 .
[0052] The standard may be “a quantization error is below a predetermined value.” Also, the standard may be “a quantization number corresponds with a predetermined value” by calculating the quantization number from a desired compression rate.
[0053] Re-search preparation processing 206 is a processing of calculating E j,N and T j, N (=N, . . . , (D−1)) using T i,(N−1) and E i,(N−1) (I=N−1, . . . , D). More specifically, the following processing is performed for each j=N, . . . , (D−1).
[0054] Calculate
[0000]
β
=
arg
min
(
N
-
1
)
≤
i
<
j
{
E
i
,
(
N
-
1
)
+
e
(
i
+
1
)
,
j
}
[0055] Assign T β,(N−1) ∪{v (β+1) } to T j,N
[0056] Assign E β,(N−1) +e (β+1),i to E j,N
[0057] FIG. 12 illustrates re-search preparation processing 206 of the vector of FIG. 8 for N=3 and i=5 to calculate T 53 ={t 51 , t 52 } and E 53 . That is, the maximum division value is moved to v 3 , . . . , v 5 and calculates a quantization result with each division value to obtain each quantization error. As a division value which minimizes the quantization error of three-valued quantization of v 1 , . . . , v 5 , we let t 51 =t 31 , t 52 =v 4 and the minimum value be E 53 =E 32 +e 45 .
[0058] Quantization feature vector output processing 207 uses the quantization function which is determined by a set of division values T D, N ={t 1 , . . . , t (N−1) } of the quantization threshold which minimizes the quantization error and quantization values m 1 , . . . , m N (subscripts are quantization numbers), quantizes each component of the feature vectors to N values and outputs the quantization feature vector. We let the quantization function be a function of outputting the following value for input of real number x.
[0059] M 1 is output when x<t 1 ,
[0060] m i is output when t (i−1) <=x<t i ,
[0061] m N is output when t (N−1) <=X.
[0062] Similarity calculation processing 30 is a similarity calculation processing performed by similarity calculation unit 105 . The flow chart of similarity calculation processing 30 is shown in FIG. 3 .
[0063] Similarity calculation processing 30 includes quantization feature vector input processing 301 , coefficient table generation processing 302 , coefficient addition processing 303 , and output processing 304 . Each processing will be explained as follows.
[0064] Quantization feature vector input processing 301 is a processing of performing input of an input quantization feature vector and a dictionary quantization feature vector. The “quantization feature vector” is given as a set of array of the quantization value and array of the quantization number of each component.
[0065] Coefficient table generation processing 302 is a processing of generating a coefficient table from the array of each quantization value of the input quantization feature vector and the dictionary quantization feature vector.
[0066] The coefficient table which calculates the distance of the input quantization feature vector and the dictionary quantization feature vector is given by the following M×N matrix C=(c ij ), if the quantization number of each quantization feature vector is M and N, and two quantization values are (q 1 , . . . , q m ) and (r 1 , . . . , r M ), respectively.
[0000]
C
=
(
c
ij
)
=
(
(
q
1
-
r
1
)
2
…
(
q
1
-
r
N
)
2
⋮
⋱
⋮
(
q
M
-
r
1
)
2
…
(
q
M
-
r
N
)
2
)
(
2
)
[0067] Coefficient addition processing 303 is a processing of calculating a set corresponding to each component from the array of the quantization number of the input quantization feature vector and the dictionary quantization feature vector and calculates a total of the values of the coefficient table corresponding to the set.
[0068] The following value as shown in equation (3) will be calculated if the dimension of the feature space is D and arrays of two quantization numbers are (m 1 , . . . , m D ) and (n 1 , . . . , n D ), respectively.
[0000]
∑
i
=
1
D
c
m
i
n
i
(
3
)
[0069] After the calculation, a root square of the above mentioned value is calculated and the calculated value will be set as the similarity, since the above mentioned value is a square value of the distance between vectors.
[0070] Output processing 304 is a processing of outputting the similarity obtained by coefficient addition processing 303 .
[0071] According to this embodiment, the error caused by compression is suppressed by quantization of the input feature vector and the dictionary feature vector, and an amount of data may be compressed.
[0072] Since the error of the value defined between the input quantization feature vector before and after the compression and the dictionary quantization feature vector may be reduced and degradation of the recognition performance by compression may also be suppressed.
[0073] In similarity calculation processing 30 , a similarity, which is the distance between the feature vectors in a compressed state without decompression, may be calculated
Second Embodiment
[0074] Pattern recognition apparatus 40 of a second embodiment of this invention will be explained with reference to FIGS. 4 and 5 . Pattern recognition apparatus 40 of this embodiment calculates the similarity from an input feature vector corresponding to an input pattern, and a dictionary quantization feature vector which is created by quantizing a dictionary feature vector to be compared and performs pattern recognition from the similarity.
[0075] Pattern recognition apparatus 40 of this embodiment will be explained with reference to FIG. 4 . FIG. 4 is a schematic block diagram illustrating a pattern recognition apparatus 40 . Pattern recognition apparatus 40 comprises a pattern input unit 401 , a feature extraction unit 402 , a dictionary feature memory storing unit 403 , a similarity calculation unit 404 and a determination unit 405 . Functions of each unit 401 - 405 may be realized by a program stored in a computer. Functions of each unit 401 - 405 will be explained below.
[0076] Pattern input unit 401 inputs the pattern to be used as a candidate for recognition. When the pattern is an image, an image captured by, for example, a digital camera may be input into a computer or an image captured by a camera connected to a computer may be input into the computer. When the pattern is a sound, for example, a recorded sound may be input into a computer or a sound recorded by a microphone connected to a computer may be input into the computer.
[0077] Feature extraction unit 402 extracts feature values from a pattern input by pattern input unit 401 and converts the pattern into a vector. Hereafter, the vector converted by feature extraction unit 402 is called a “feature vector.” When the input pattern is an image, the pattern is changed into a vector by, for example, a raster scan. When the input pattern is a sound, for example, a vector which has frequency components of the sound within a definite period of time is used.
[0078] After converting into a vector, a processing of suppressing an input pattern change may be performed. For example, a processing of removing a noise component with a small eigen value obtained from the pattern prepared in large quantities beforehand by principal component analysis etc. may be performed.
[0079] Dictionary feature memory storing unit 403 performs a processing by feature extraction unit 402 and a quantization processing 20 for a pattern of each class for recognition and stores the obtained quantization feature vectors (hereinafter, referred to as “dictionary quantization feature vector”) into a storage area.
[0080] Similarity calculation unit 404 calculates a value indicating a similarity between a quantization feature vector of the input pattern generated by feature extraction unit 402 (hereinafter, referred to as “input quantization feature vector”) and a dictionary quantization feature vector of each class stored in dictionary feature memory storing unit 403 . Here, the distance between vectors is calculated.
[0081] FIG. 5 is a flow chart of a similarity calculation processing 50 performed by similarity calculation unit 404 . Explanation of similarity calculation processing 50 is mentioned later.
[0082] Determination unit 405 identifies the class for recognition, when the class has the highest similarity among the registered classes fulfilling conditions of the similarity. When no class fulfills the conditions, determination unit 405 identifies that there is no class in the class. When the distance between vectors is used as the similarity, the distance is set to be smaller than a predetermined threshold and has higher similarity as the distance becomes smaller.
[0083] Similarity calculation processing 50 includes quantization feature vector input processing 501 , feature vector input processing 502 , addition processing 503 which is classified by quantization number, addition result integrated processing 504 and output process 505 . The explanation of each processing is as follows.
[0084] Quantization feature vector input processing 501 is a processing of inputting dictionary quantization feature vector. Here, the dictionary quantization feature vector stored in dictionary feature memory storing unit 403 is input. The “quantization feature vector” is given as a set of array of the quantization value and array of the quantization number of each component.
[0085] Feature vector input processing 502 is a processing of inputting the input feature vector. Here, the input feature vector generated by feature extraction unit 402 is input.
[0086] Addition processing 503 , which is classified by quantization number, is a processing of calculating f i g i h i as defined below for each i=1, . . . , N, let the quantization number of the dictionary quantization feature vector which is input by quantization feature vector input processing 501 be N, array of quantization values be (q 1 , . . . , q N ), array of quantization number of each component be (n 1 , . . . , n N ) and the input feature vector input by feature vector input processing 502 be (a 1 , . . . , a D ) (Ai={j|n j =i}).
[0000]
f
i
=
∑
j
∈
A
i
1
(
4
)
g
i
=
∑
j
∈
A
i
a
j
(
5
)
h
i
=
∑
j
∈
A
i
a
j
2
(
6
)
[0087] Addition result integrated processing 504 is a processing of calculating the following values.
[0000]
∑
i
=
1
N
(
f
i
q
i
2
-
2
g
i
q
i
+
h
i
)
[0088] After the calculation, a root square of the above mentioned value is calculated, since the above mentioned value is a square value of the distance between vectors.
[0089] Output process 505 is a processing of outputting the value obtained by addition result integrated processing 504 .
[0090] According to this embodiment, the error caused by compression is suppressed by quantization of the input feature vector and the data may be stored in dictionary feature memory storing unit 403 in a compressed state. Since the error of the value defined between the input feature vector before and after compression and the dictionary feature vector may be small, and degradation of the recognition performance by compression may also be suppressed.
[0091] In similarity calculation processing 30 , a similarity, which is the distance between the feature vectors in a compressed state without decompression, may be calculated.
Third Embodiment
[0092] Pattern recognition apparatus 60 of a third embodiment of this invention will be explained with reference to FIGS. 6 and 7 . Pattern recognition apparatus 60 comprises a pattern input unit 601 , a feature extraction unit 602 , a feature vector quantization unit 603 , a dictionary feature storing unit 604 , a similarity calculation unit 605 , and a determination unit 606 . Functions of each unit 601 - 606 may be realized by a program stored in a computer. Functions of each unit 601 - 606 will be explained below.
[0093] Pattern input unit 601 inputs the pattern to be used as a candidate for recognition. When the pattern is an image, an image captured by, for example, a digital camera may be input into a computer or an image captured by a camera connected to a computer may be input into the computer. When the pattern is a sound, for example, a recorded sound may be input into a computer or a sound recorded by a microphone connected to a computer may be input into the computer.
[0094] Feature extraction unit 602 extracts feature values from a pattern input by pattern input unit 601 and converts the pattern into a vector. Hereafter, the vector converted by feature extraction unit 602 is called a “input feature vector.” When the input pattern is an image, the pattern is changed into a vector by, for example, a raster scan. When the input pattern is a sound, for example, a vector which has frequency components of the sound within a definite period of time is used.
[0095] After converting into a vector, a processing of suppressing an input pattern change may be performed. For example, a processing of removing a noise component with a small eigen value obtained from the pattern prepared in large quantities beforehand by principal component analysis etc. may be performed.
[0096] Feature vector quantization unit 603 performs quantization processing of each component of the feature vectors of quantization processing 20 for the input feature vector generated by feature extraction unit 602 . Hereinafter, a quantized input feature vector is referred to as “input quantization feature vector.”
[0097] Dictionary feature storing unit 604 performs processing performed by feature extraction unit 602 for a pattern of each class for recognition and stores generated dictionary feature vectors (hereinafter, referred to as “dictionary feature vector”) into a storage area.
[0098] Similarity calculation unit 605 calculates a value indicating a similarity between a input quantization feature vector of the input pattern output by feature vector quantization unit 603 and a dictionary quantization feature vector of each class stored in dictionary feature storing unit 604 . Here, the distance between vectors is calculated as a similarity between vectors.
[0099] Determination unit 606 identifies the class for recognition, when the class has the highest similarity among the registered classes fulfilling conditions of the similarity. When no class fulfills the conditions, determination unit 606 identifies that there is no class in the class. When the distance between vectors is used as the similarity, the distance is set to be smaller than a predetermined threshold and has higher similarity as the distance becomes smaller.
[0100] According to this embodiment, the error caused by compression is suppressed by the above quantization of the input feature vector and an amount of data may be compressed.
[0101] Since a similarity between the input quantization feature vector before and after the compression and the dictionary quantization feature vector may be reduced and degradation of the recognition performance by compression may also be suppressed.
[0102] In the above similarity calculation processing of the quantization feature vector, a similarity, which is the distance between the feature vectors in a compressed state without decompression, may be calculated.
[0103] This invention is not limited to the above-mentioned embodiments but may be changed variously if it falls within the scope of the invention.
[0104] Quantization error e i,j , which is used by initialization processing 203 , quantization threshold search processing 204 and re-search preparation processing 206 , may be calculated by the sum of the absolute value of the difference of each component.
[0105] In this case, the quantization error is given by the following equation (7) when replacing all components vi, . . . , vj with q (v l <=q l+1 ).
[0000]
∑
k
=
i
j
q
-
v
k
=
∑
k
=
i
l
(
q
-
v
k
)
+
∑
k
=
l
+
1
j
(
v
k
-
q
)
=
(
2
l
+
1
-
(
i
+
j
)
)
q
-
∑
k
=
i
l
v
k
+
∑
k
=
l
+
1
j
v
k
(
7
)
[0106] When i+j is even, the quantization error is at the minimum for p=(i+j−1)/2 and q=v p . The minimum values are given by the following equation.
[0000]
∑
k
=
p
+
1
j
v
k
-
∑
k
=
i
p
-
1
v
k
[0107] When i+j is odd, the quantization error is at the minimum for p=(i+j−1)/2. The minimum values are given by the following equation.
[0000]
∑
k
=
p
+
2
j
v
k
-
∑
k
=
i
p
-
1
v
k
[0108] The above mentioned quantization value, which minimizes the quantization error between each of the quantization thresholds to be used, is used by quantization feature vector output processing 207 .
[0109] The value of the Gaussian kernel equation (8) using the distance between two vectors as a similarity between the vectors calculated by similarity calculation unit 105 may be calculated.
[0000]
exp
(
x
-
x
2
σ
2
)
(
8
)
[0110] As a similarity between the vectors calculated by similarity calculation unit 105 , the inner product of two vectors and its square may be calculated.
[0111] If a coefficient table defined by coefficient table generation processing 302 by equation (9) instead of equation (2) is generated when calculating the inner product between the quantization feature vectors, the inner product between vectors may be calculated.
[0000]
C
=
(
q
1
r
1
…
q
1
r
N
⋮
⋱
⋮
q
M
r
1
…
q
M
r
N
)
(
9
)
[0112] Values such as a polynomial kernel equation (10) using this inner product and equation (11) may also be a similarity between vectors, let (u, u′) be an inner product of vector u and u′, and p be one or more integers, the value of p be set by a suitable value by experiment.
[0000] (u,u′) p (10)
[0000] ((u,u′)+1) p (11)
[0113] As a similarity between the vectors calculated by similarity calculation unit 105 , sum of the absolute value of the difference of each of two components may be calculated. Hereafter, this value is referred to as L1 distance between vectors.
[0114] If the coefficient table defined by equation (12) instead of equation (2) by coefficient table generation processing 302 is generated when calculating L1 distance between the quantization feature vectors, L1 distance between vectors may be calculated (| | is taken as an absolute value).
[0000]
C
=
(
(
q
1
-
r
1
…
q
1
-
r
N
⋮
⋱
⋮
q
M
-
r
1
…
q
M
-
r
N
)
(
12
)
[0115] As a similarity between the vectors calculated by similarity calculation unit 404 , the inner product of two vectors and its square may be calculated. When calculating the inner product between the quantization feature vectors, the inner product between vectors may be obtained by calculating g i of equation (5) by addition processing 503 which is classified by quantization number, and calculating equation (13) by addition result integrated processing 504 .
[0000]
∑
i
=
1
N
g
i
q
i
(
13
)
[0116] The value of the polynomial kernel equation (10) using this inner product and equation (11) may be used as a similarity between vectors.
[0117] As a similarity between the vectors calculated by similarity calculation unit 404 , L1 distance may be calculated. When calculating L1 distance between the quantization feature vectors, b i which is defined as shown below by addition processing 503 which is classified by quantization number may be calculated (| | is taken as an absolute value.).
[0000]
b
i
=
∑
j
∈
A
i
q
i
-
a
j
(
14
)
[0118] Next, L1 distance between vectors may be calculated by calculating equation (14) by addition result integrated processing 504 .
[0000]
∑
i
=
1
N
b
i
(
15
)
[0119] Lossless compression may be used when the quantization feature vector is stored in a storage area of dictionary feature storing unit 104 and dictionary feature memory storing unit 403 . When lossless compression is carried out, the stored quantization feature vector is restored and used in similarity calculation unit 105 .
[0120] For example, Huffman encoding (T. M. Cover and J. A. Thomas and Elements of information Theory.NewYork:Willey.2006 reference) etc. may be used as lossless compression.
|
A pattern recognition method comprises steps of inputting a pattern of a recognition object performing feature extraction from the input pattern to generate a feature vector, increasing the number of quantization in an order from quantization number 1 or quantization number 2 to calculate a quantization threshold of each of the quantization number, wherein the quantization threshold of quantization number (n+1) using a quantization threshold of quantization number n (n>=1) is calculated and a quantization function having a quantization threshold corresponding to quantization number S (S>n) is generated, quantizing each component of the feature vector of the input pattern using the quantization function to generate an input quantization feature vector having each of the quantized component, storing a dictionary feature vector of the recognition object, or a quantized dictionary feature vector in which each component of the dictionary feature vector of the pattern of a recognition object is quantized; calculating a similarity between the input quantization feature vector and the dictionary feature vector, or a similarity between the input quantization feature vector and the quantized dictionary feature vector; and recognizing the recognition object based on the similarity.
| 6
|
The present application is a 35 U.S.C. §371 submission of international application no. PCT/KR2012/004204 that was filed on 29 May 2012.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a composition for improving the stability of bacteriophage originated lysin proteins greatly even when the composition contains a high concentration of the bacteriophage originated lysin proteins. More precisely, the present invention relates to a method and a composition for improving significantly the stability of SAL-1 or LysK, the bacteriophage originated lysin protein, included at a high concentration in the composition.
2. Description of the Related Art
Since 1990s, the resistant bacteria showing the resistance against many antibiotics which had been widely used for the treatment of infectious diseases have been increased with causing problems. The most serious problem of them is the significantly lowered treatment effect of antibiotics in treating infectious diseases.
Therefore, it is an urgent request to develop a novel antibiotic substance that can overcome the said problem of resistance of the conventional antibiotics. The promising candidate for the novel antibiotic substance that draws our attention most is the bacteriophage originated lysin protein. This is called the bacteriophage lysin protein or lysin protein or lysin. The bacteriophage lysin protein is a kind of enzyme that is generated from the genetic information of a bacteriophage. The biological activity of the bacteriophage lysin protein, that is the enzymatic activity, is to destroy the peptidoglycan layer that is the major structure of bacterial cell wall. The bacteriophage lysin protein is mainly working in the course of destruction of bacterial cell wall. More precisely, when a bacteriophage is infected into a host, it is proliferated therein and the second generation bacteriophages are generated in the host bacteria. Then, the generated bacteriophages attempt to come out of the host bacteria through the cell wall, during which the bacteriophage lysin protein is working to destroy the cell wall (J. Bacteriol. 186: 4808-4812, 2004).
The bacteriophage lysin protein is naturally generated in the inside of bacteria from the genetic information of a bacteriophage, as explained hereinbefore, but is also synthesized by using recombinant protein technology and then applied to the bacterial cell wall in order to break the peptidoglycan layer. Because of this characteristics, the attempts to use the bacteriophage lysin protein as an antibacterial protein working against bacteria have been increased (U.S. Pat. No. 8,058,225; U.S. Pat. No. 8,105,585). In particular, the attempt to use this protein as a treatment agent for infectious diseases caused by the resistant bacteria is focused on a different mode of action from that of the conventional antibiotics (Science 294: 2170-2172, 2001; Curr. Opin. Microbiol. 8: 480-487, 2005).
SAL-1 that has been developed by the present inventors is also one of the bacteriophage lysin proteins (Antimicrob. Agents Chemother. 55: 1764-1767, 2011). SAL-1 comprises the amino acid sequence represented by SEQ. ID. NO: 1 and has the bacteriolytic activity specific to Staphylococcus aureus . In particular, SAL-1 also displays the bacteriolytic activity against the antibiotic-resistant MRSA (methicillin-resistant Staphylococcus aureus ) or VRSA (vancomycin-resistant Staphylococcus aureus ). Thus, it can be used as a treatment agent for infectious diseases caused by MRSA or VRSA. The said MRSA and VRSA are the representative antibiotic-resistant bacteria and the number of death caused by the infection with these is very big world-widely.
SAL-1 is very similar to LysK having the amino acid sequence represented by SEQ. ID. NO: 2 and the difference is found only in three residues. However, the antibacterial activity of SAL-1 is almost double the activity of LysK (Antimicrob. Agents Chemother. 55: 1764-1767, 2011).
To use the bacteriophage lysin protein commercially, it needs to be prepared in the form of a high concentration formula. Particularly, when it is used as a medicine, a high concentration unit is advantageous for the administration and handling because when a unit contains a high concentration of the protein, the dosage can be reduced.
In the previous study, the present inventors found out that when the said SAL-1 and LysK were included in a solution at a high concentration, aggregation was observed over the time of storage and this aggregation was also accelerated by an external physical impact, suggesting that the stability of the solution was in question. That kind of disadvantage was not preferred for the industrial use of the lysin protein. To secure the stability during the storage and for safe handling, it was required to develop a method to provide the stability high enough to a composition even when it is prepared in a high concentration liquid form.
The present inventors have confirmed that the addition of calcium ions or magnesium ions to the lysin protein is effective in increasing the biological activity thereof. However, even though the addition of such divalent cations was effective in increasing the biological activity, it also caused the decrease of the stability of the lysin protein included in the liquid form composition. To use industrially the composition comprising these two lysin proteins at high concentrations as active ingredients, it is also requested to develop a method to secure the stability of the lysin protein in the presence of calcium or magnesium ions.
Numbers of research papers and patent documents have been cited in this invention, which are presented in the brackets. At this time, the cited papers and patent documents are included in this invention as a whole in order to describe the arts and spirits and scope of the present invention more clearly.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and a composition for improving the stability of SAL-1 or LysK, the bacteriophage lysin protein, included at a high concentration in the composition.
It is another object of the present invention to provide a method and a composition for improving the stability of SAL-1 or LysK, the bacteriophage lysin protein, included at a high concentration in the composition in the presence of calcium ions or magnesium ions.
To achieve the above objects, the present inventors first screened a surfactant which was believed to be effective in improving the stability of the lysin protein in a solution comprising SAL-1 or LysK at a high concentration, and as a result the inventors confirmed that poloxamer was very suitable for that purpose. Further, the present inventors confirmed that when the said poloxamer was added to a composition, SAl-1 or LysK was still stable even in the presence of magnesium ions or calcium ions, leading to the completion of the present invention.
Therefore, the present invention provides primarily a method and a composition for using the poloxamer as a stabilizer since the poloxamer was considered to be advantageous not only for preparing a solution comprising SAL-1 or LysK at a high concentration but also for maintaining the stability thereof in handling and for storage. The present invention also provides a method and a composition using the poloxamer as a stabilizer that is appropriate for preparing a solution comprising SAL-1 or LysK at a high concentration and additionally comprising magnesium ions or calcium ions for the purpose of improving the biological activity thereof and thus is advantageous for maintaining the stability in handling and storage thereof.
The calcium ions or magnesium ions herein can be added in various forms of salt. The type of salt herein is not limited, but chloride is preferred.
The concentration of calcium ions or magnesium ions herein is 0.1˜20 mM, and more preferably 2˜15 mM, and most preferably 10 mM.
The said poloxamer is a synthetic polymer surfactant, which is a nonionic copolymer composed of a central hydrophobic polyoxypropylene chain and two surrounding hydrophilic polyoxyethylene chains. The poloxamer was invented in 1973 (U.S. Pat. No. 3,740,421) and has been on the market under the brand-name of Pluronic. The diversity of the poloxamer is made by the length of the chain. There might be a light property change over the difference of the length but the basic property is all the same, suggesting that the basic effect is expected to be the same. Thus, the poloxamer herein is not limited, but poloxamer 188 (Pluronic F-68), that had been used as a pharmaceutical ingredient, is preferred.
The poloxamer content varies from the concentration of the lysin protein in a solution containing them. In general, the poloxamer concentration to give enough effect expected by the inventors is 0.01˜2% (w/v), and preferably 0.1˜0.5% (w/v).
The method of the present invention is not just effective in preparing a solution comprising a high concentration of the protein but also effective in preparing any other solutions comprising the protein at different concentrations. It is understood therefore that the effect of the present invention is more peculiar in a solution having a high concentration of the lysin protein. The expression “high concentration” in this invention is not limited in a specific standard but generally indicates at least 5 mg/ml and more preferably at least 10 mg/ml.
ADVANTAGEOUS EFFECT
To use industrially the bacteriophage originated antibacterial protein, SAL-1 or LysK, it is necessary to prepare a solution comprising the protein at a high concentration. If a solution comprising the protein at a high concentration can be prepared, it can be applied as a medicine, particularly an injectable solution, that is advantageous for reducing the dose of administration. However, in the course of the preparation of a solution comprising SAL-1 or LysK at a high concentration, the stability of the protein is decreased. According to the present invention, the stability of SAL-1 or LysK in a solution can be greatly improved, that is, according to the method and the composition of the present invention, a solution comprising SAL-1 or LysK at a high concentration can be easily prepared without worry of lowering the stability. The solution comprising SAL-1 or LysK at a high concentration, prepared according to the method of the invention, displays the greatly improved stability of the protein in a solution, indicating the handling and storage of the solution comprising the protein at a high concentration would be also worry-free. According to the present invention, there is no problem in adding calcium ions or magnesium ions to the solution in order to increase the biological activity of SAL-1 or LysK. In conclusion, the present invention provides a very stable composition comprising SAL-1 or LysK at a high concentration with securing the stability of the protein and the optimum biological activity of the same.
BRIEF DESCRIPTION OF THE DRAWINGS
The application of the preferred embodiments of the present invention is best understood with reference to the accompanying drawings, wherein:
FIG. 1 is a diagram illustrating the outline of the purification process of SAL-1 used in this invention.
FIG. 2 is a set of photographs illustrating the process of the stability test performed in this invention.
FIG. 3 is a graph illustrating the result of the biological activity test performed in this invention. The horizontal axis presents the analysis time (min.) and the vertical axis presents OD 600 .
FIG. 4 is a graph illustrating the summary of the result of size exclusion liquid chromatography performed in order to analyze the effect according to the concentration of poloxamer. The horizontal axis presents the poloxamer content % (w/v), and the vertical axis presents the ratio (%) of the peak area of SAL-1 after stirring to the peak area of SAL-1 before stirring.
FIG. 5 is a graph illustrating the effect of the added magnesium ions or calcium ions to SAL-1 solution on the biological activity of SAL-1. The horizontal axis presents the analysis time (min.) and the vertical axis presents OD 600 . Δ: calcium ions addition; □: magnesium ions addition; ⋄: no addition.
FIG. 6 illustrates the result of the stability test over the long-term storage of the SAL-1 solution prepared according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As explained hereinbefore, the present invention provides a method and a composition characterized by containing poloxamer as a stabilizer to improve greatly the stability of the lysin protein in a solution comprising the bacteriophage lysin protein SAL-1 or LysK at a high concentration.
Practical and presently preferred embodiments of the present invention are illustrative as shown in the following Examples, Experimental Examples and Manufacturing Examples.
However, it will be appreciated that those skilled in the art, on consideration of this disclosure, may make modifications and improvements within the spirit and scope of the present invention.
Example 1
Investigation of a Surfactant Capable of Improving the Stability of a Solution Containing SAL-1
The SAL-1 used in this invention was prepared according to the method described in Korean Patent No 10-075998, particularly purified and prepared according to the method illustrated in FIG. 1 . The elution fraction of SAL-1 showing at least 95% purity was finally selected and concentrated until the concentration reached 20 mg/ml, resulting in SAL-1 solution. The concentrated SAL-1 solution was replaced with different buffers. The buffers herein were L-Histidine buffer (10 mM L-Histidine, 5% (w/v) Sorbitol, pH 6.0), Tris-buffer (10 mM Tris-HCl, 140 mM NaCl, pH 7.5), Acetate buffer (10 mM Sodium acetate, 5% (w/v) Sorbitol, pH 5.0), Phosphate buffer A (10 mM Sodium phosphate, 5% (w/v) Sorbitol, pH 6.0), Phosphate buffer B (10 mM Sodium phosphate, 140 mM NaCl, pH 6.0), and HEPES buffer (10 mM HEPES, pH 7.3). The SAL-1 solution replaced with each buffer was added with different surfactants. Then, the proper surfactant was investigated. Selection of the proper surfactant was performed by investigating the increase of the stability of SAL-1 and also by measuring the decrease of the biological activity of SAL-1 as well. That is, a surfactant that was capable of increasing the stability of SAL-1 in a solution without reducing the biological activity of SAL-1 was screened. In this investigation, every surfactant could not all be tested, so those considered to be applicable for a pharmaceutical composition were targeted, which were exemplified by Polyoxyethylene nonylphenyl ether, Polysorbate 20, Polysorbate 40, Polysorbate 60, Tyloxapol, Sorbitan Monostearate, and Polyethyleneglycol Monostearate.
Stability test of the SAL-1 solution was performed as follows.
{circle around (1)} adding a surfactant to SAL-1 solution (0.1%˜0.5%);
{circle around (2)} stirring the mixture at room temperature for 1 hour;
{circle around (3)} measuring turbidity at 600 nm using a spectrophotometer after stirring; and
{circle around (4)} judging the improvement of stability when the turbidity was least increased, compared with that before stirring.
Biological activity of SAL-1 was investigated as follows. Of course, those surfactants showing least stability improvement effect or none were eliminated from this investigation.
{circle around (1)} adding a surfactant to SAL-1 solution (0.1% 0.5%);
{circle around (2)} leaving the mixture at room temperature for 1 hour;
{circle around (3)} preparing a bacteria suspension comprising Staphylococcus aureus at the concentration of 8×10 8 cfu/ml by using 1×PBS (8 g/L NaCl, 0.2 g/L KCl, 1.44 g/L Na 2 HPO 4 , 0.24 g/L KH 2 PO 4 , pH 7.0);
{circle around (4)} adding the mixture of step {circle around (2)} to 1 ml of the bacteria suspension prepared in step {circle around (3)} to make the concentration of SAL-1 therein to be 1 μg/ml (using the diluent of the mixture of step {circle around (2)});
{circle around (5)} measuring OD 600 over the time by using a spectrophotometer (when bacteriolysis occurred by SAL-1, OD 600 was supposed to decrease over the time); and
{circle around (6)} judging the biological activity of SAL-1 as high when OD 600 was reduced greatly and fast over the time (judged by TOD 50 , which means the OD 600 was reduced to half the first measured OD 600 ).
As a result, considering the stability of SAL-1 in a solution and the biological activity of SAL-1, poloxamer 188 was selected as the most appropriate surfactant that can improve the stability of SAL-1 in a solution with maintaining the biological activity of the same. Other surfactants were either weak in increasing the stability or reduced the biological activity of SAL-1. The stability test process according to the present invention is illustrated in FIG. 2 . The biological activity test result is illustrated in FIG. 3 . Buffer type did not affect the stability or the biological activity of SAL-1.
Example 2
Investigation of a Proper Concentration of Poloxamer
A proper concentration of poloxamer was investigated in this example. The stability and the biological activity of SAL-1 in a solution was investigated by the same manner as described in Example 1. To investigate the stability more accurately, size exclusion high performance liquid chromatography was also performed as follows. BioSep-SEC-S2000 column (7.8 mm×300 mm) was used as the analysis column. Buffer A (10 mM Tris-HCl, pH 7.5, 500 mM NaCl) was used as the analysis buffer. The flow rate after the addition of the sample was 1 ml/min. The volume of the sample added thereto was 50 μl, and the detection was performed using UV detector at 280 nm.
Following is the result of the investigation obtained by using a spectrophotometer when poloxamer was added at the concentrations of 0.1˜0.5% (w/v). There was no significant difference over the concentration of poloxamer.
TABLE 1
Poloxamer Content
OD 600
(%, w/v)
Stirring
Non-stirring
0
1.2893
0.0008
0.10
0.0148
−0.0004
0.25
0.0195
−0.0003
0.50
0.0126
0.0003
The result of the size exclusion high performance liquid chromatography performed together is shown in FIG. 4 . The result was consistent with that of the turbidity analysis using a spectrophotometer.
Based on the above results, the proper concentration of poloxamer was determined as 0.1% (w/v) to expect the full effect of it.
Example 3
Investigation of the Effect of Poloxamer Addition to the Composition Comprising Additionally Calcium Ions or Magnesium Ions
It was previously confirmed that the addition of calcium ions or magnesium ions was effective in increasing the biological activity of SAL-1, unlike the addition of other ions ( FIG. 5 ). Unfortunately the stability of SAL-1 in a solution comprising calcium ions or magnesium ions was reduced even though the biological activity of SAL-1 was increased by the said ions. Based on the fact, the present inventors wanted to find out whether or not the addition of poloxamer to SAL-1 solution could be effective in improving the stability of SAL-1 in the presence of calcium ions or magnesium ions. The stability test was performed by the same manner as described in Example 1. Since the kind of buffer did not affect the result, L-Histidine buffer (10 mM L-Histidine, 5% (w/v) Sorbitol, pH 6.0) alone was used as the buffer in this example. Calcium ions or magnesium ions were in the form of chloride herein and the concentration thereof was 10 mM. The concentration of poloxamer was 0.1% (w/v) as determined in Example 2. The result is as follows.
TABLE 2
Addition
Calcium
Magnesium
OD 600 after
ions
ions
Poloxamer
stirring
x
x
x
0.200
x
∘
x
0.668
∘
x
x
1.093
x
x
∘
0.041
x
∘
∘
0.040
∘
x
∘
0.044
Example 4
Confirmation of the Effect of Poloxamer Addition in LysK Solution
The effect of poloxamer addition in LysK solution was also investigated by the same manner as described in Example 3. The LysK used in this example was prepared by the same manner as used for the preparation of SAL-1. Considering that the difference over the buffer was minor in Example 1, L-histidine buffer or Tris buffer (10 mM Tris-HCl, pH 7.0) was used to replace LysK solution (20 mg/ml), to which poloxamer was added at the concentration of 0.1% (w/v). As a result, the addition of poloxamer resulted in the significant increase of the stability of LysK, in both cases of using the above two buffers (data not shown).
Example 5
Investigation of the Long-Term Storage Stability
The stability that has been a target of the investigation in the above examples was the stability against external physical stimulus. In addition to the stability against physical stimulus, the storage stability is also very important for the industrial purpose. The SAL-1 solution prepared according to the present invention was kept in a refrigerator for 8 weeks, during which the stability of SAL-1 was investigated. Particularly, as shown in Example 2, size exclusion high performance liquid chromatography was performed for the stability analysis. The peak area presenting SAL-1 in the chromatography was analyzed to investigate the duration of SAL-1 peak over the time.
In this example, the concentrations of SAL-1 in the SAL-1 solution were 1 mg/ml, 13 mg/ml, and 20 mg/ml. The purpose of using different concentration was to find out what concentration of SAL-1 would be appropriate for the best effect of the present invention. The sample analysis was specifically performed 4 weeks later, 6 weeks later, and 8 weeks later, respectively.
As a result, as shown in FIG. 6 , the peak area was maintained at least 93% (chromatography peak area), compared with the early peak, in every concentration tested herein after the storage in a refrigerator. In the meantime, the peak area was only maintained 60% at best in the absence of poloxamer (data not shown).
The above results suggest that the composition of the present invention is effective in improving the stability of the lysin protein in the solution comprising the bacteriophage originated lysin protein as an active ingredient. In particular, the effect was high enough in a high concentration solution. The composition of the present invention has also been confirmed to be effective in the solution comprising particularly SAL-1 or LysK as an effective ingredient.
Those skilled in the art will appreciate that the conceptions and specific embodiments disclosed in the foregoing description may be readily utilized as a basis for modifying or designing, other embodiments for carrying out the same purposes of the present invention. Those skilled in the art will also appreciate that such equivalent embodiments do not depart from the spirit and scope of the invention as set forth in the appended Claims.
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The present invention relates to a composition for improving the stability of bacteriophage originated lysin proteins greatly even when the composition contains the bacteriophage originated lysin proteins at a high concentration. More precisely, the present invention relates to a method and a composition for improving significantly the stability of SAL-1 or LysK, the bacteriophage originated lysin protein, included at a high concentration in the composition.
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RELATED PATENT APPLICATIONS
This application is based on PCT Application GB96/00889 filed Apr. 12, 1996.
BACKGROUND OF THE INVENTION
The present invention relates to press heads and more particularly to a rotating system for a press head for pressing aluminium dross.
BRIEF SUMMARY OF THE INVENTION
In any aluminium furnace system a substantial amount of dross is produced and this dross can contain a large amounts of pure aluminium which is trapped in the dross. This aluminium can be released by mechanical action on the dross.
A system for mechanically pressing dross comprises a press head which is raised and lowered and acts on dross contained in a skim box the aluminium thus released being drained through a hole in the floor of the skim box into a press sow mould.
The press head generally comprises a semispherical shape which has a plurality of ridges thereon to increase pressure on the dross as the head is raised and lowered onto the dross.
It is advantageous to be able to incrementally rotate the head during processing since this will alter the position at which the ridges press on to the dross. Since the ridges exert greater localised pressure on the dross the rotation will incrementally change the positions at which such additional pressure is exerted on the dross.
The environment within the cabinet in which the dross processing is carried out is extremely hazardous. The dross is at a high temperature and emits fumes which are contained within the cabinet or exhausted to an afterburner or fume treatment plant. The machinery within the cabinet therefore gets extremely hot.
U.S. Pat. No. 5,397,104 discloses rotation of a dross press head using application of hydraulic pressure.
It is an object of the present invention to provide an incremental rotating system for an aluminium dross processing head which is extremely robust and which is economical in operation.
The present invention provides an incremental rotation system for an aluminium dross processing head including mechanical lever means for engaging with the head as the head moves up and down said means causing the head to rotate by a defined amount.
Preferably the mechanical lever means comprises of one lever or two opposed levers each opposed lever having a pivot and an actuating end the actuating end being shaped to engage with the head to cause the head to rotate as the head moves upwardly.
Preferably the levers are attached directly or indirectly to opposite sides of a cabinet within which the dross processing apparatus is contained.
Preferably the head is provided with a plurality of circumferentially arranged bosses which are engaged by the actuating end of each lever to cause the incremental rotation. The length of the levers and the spacing between each boss is selected to cause each lever to engage successively with adjacent bosses to cause continuous incremental rotation of the head.
Preferably the levers are made sufficiently heavy to return to a lowest position by their own weight. Alternatively they can be spring loaded to return to their lowest position.
Preferably the bosses on the head are provided by collars mounted onto studs or bolts, the studs or bolts serving to attach a cast semi-spherical operational portion of the head to a circular support plate.
In a particular embodiment twenty four bosses are provided.
In a preferred embodiment, a first thermal gasket means is inserted between the circular support plate and the cast portion.
A second thermal gasket means may also be provided between the circular support plate and an actuating rod for the press.
Embodiments of the present invention will now be described, by way of example with reference to the accompanying drawings in which.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows schematically in front elevation a press for aluminium dross;
FIG. 2 shows diagrammatically in front elevation a rotational system for incrementally rotating the dross press head of FIG. 1; and
FIG. 3 shows diagrammatically the system of FIG. 2 in plan view,
FIG. 4 shows in elevation a preferred design of press head; and
FIG. 5 shows the head of FIG. 4 in botton plan view.
DETAILED DESCRIPTION OF THE INVENTION
With reference now to the drawings the dross pressing apparatus will include in practice many electrical electronic and hydraulic control systems. These relate to the cyclical movements of the press head in a vertical direction as indicated by arrow V. Hydraulic drives and electronic control systems for such drives are known in machinery control systems and these will not be described in detail in this application which is directed to the rotating system for the head.
With reference to FIG. 1 the press system comprises a press 10 mounted for safety in a cabinet 20 (not shown in full detail) which for safety and environmental reasons substantially completely encloses the press 10 when it is being operated.
The press 10 comprises a press head 30, a skim box 40 and a press sow mould 50.
Aluminium dross 60 is loaded into box 40 with head 30 at its highest position 30' (dotted). The operation comprises cyclically raising and lowering head 30 onto the dross 60 to crush the dross and to release the aluminium 70 which drips from the skim box 40 into the mould 50 forming an ingot which can be later removed in a known manner.
The press head 30 is in operation cyclically moved up and down in the direction indicated by arrow V by means of a hydraulic cylinder 80 and actuating rod 82. The head 30 may comprise a plurality of ridges 32 which increase the pressure on the aluminium dross at predetermined positions.
The head 30 is normally a cast structure and is subjected to heat stress caused by repeatedly pressing the hot dross (at approximately 800° C.) and then being cooled when either not in contact with the dross or when the press is not in use. In this latter case the head 30 will cool to ambient (approximately 25° C.) and will receive a large thermal shock when commencing pressing of the dross.
It is advantageous to be able to incrementally rotate the press head and this operation will now be explained with reference to FIG. 2.
Two opposed levers 100, 102 are provided and these are shown pivotally attached at 104,106 to the cabinet walls 20 (see also FIG. 3). The levers are free to move and are not driven. Each lever 100,102 is preferably identical to the other but they could both be of different shapes as indicated by the offset design of lever 100 in FIG. 3.
At the ends of each lever 100,102 an actuating portion (108,110) is provided. Each lever 100,102 is provided with a stop means 112,114 which limits downward travel of each lever. An alternate stop means could be by a restraining chain 116 (shown only schematically for lever 102).
The lever 102 is shown in its lowermost position and the lever 100 in its uppermost position, the levers being moved between these positions by the press head 30 as it rises.
Rotation of head 30 is achieved by providing head 30 with a plurality of equispaced bosses 300 around its circumference. With reference to FIG. 3 in a preferred embodiment twenty four such bosses are provided.
As indicated in FIG. 3 the bosses comprise a collar 302 retained by a bolt 304 which bolt also serves to attach a support plate 306 to the cast head portion 30 (the internal shown nuts 308 in FIG. 2 would not be visible being within head 30).
With reference to lever 102 the rotational operation is as follows (lever 100 will operate on the opposite edge of head 30/plate 300 to assist and to balance the rotational forces).
As head 30 rises the actuating end 108 of lever 102 will contact one of the bosses 300.
As head 30 continues to rise lever 102 will move to the dotted position 102' and by this movement will push boss 300 to the left (see also FIG. 3) to rotate the head in the direction of arrow 312.
By selection of the length of levers 100,102 the incremental rotation of head 300 is made equal to the angle of arc subtended by the distance between two adjacent bosses. As the head descends it will therefore have been rotated by 15 degrees (see FIG. 3) and the ridges 32 will likewise be rotated to contact the dross in different positions.
The head 30 will then be lifted again and the process will be repeated.
In FIG. 2 a thermal gasket 320 may be provided between the cast head portion 30 and support plate 306.
If required a further thermal gasket 322 may be provided between an attachment means 84 for actuating rod 82 and plate 306. Attachment means 84 will then be bolted (324,326 etc.) to plate 306.
The gasket 320 provides a thermal shock buffer between plate 306 and head 30 and thereby assists in preventing cracking of head 30. This gasket is readily provided because plate 306 is bolted to head 30.
The gasket 320 also provides thermal isolation for plate 306, heat only being transferred via bolts 304.
If further thermal isolation is desired for actuating rod 82 and hence cylinder 80 then the further gasket 322 may be provided.
The head design shown in FIGS. 1 and 2 suffers from a number disadvantages. Principally the provision of ribs 32 which protrude from the main body of the head produces areas where thermal shock can crack the head.
In the present invention the head 500 is designed as shown in FIGS. 4 and 5 as a multi-faceted generally conical head with faces 502-510. The head preferably has five faces forming a pentagon 512.
The advantages of this head is that it can be moulded very easily and does not have any ridge as in the head of FIGS. 1 and 2. Thus this design of head is much more robust than the head of FIGS. 1 and 2 and also much easier to make. In addition the head of FIGS. 4 and 5 does not have any acute angles to trap dross and therefore is much less liable to dross sticking to the head during the pressing process.
Further since the number of facets is five in the preferred embodiment each facet subtends to an angle of 72° and the rotation of the head through an even number of steps will provide different areas of pressure on the dross.
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An incremental rotational system for an aluminium dross processing head includes lever means actuated by the head as it rises to rotate the head by a defined amount, no independent drive system being required.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based on Japanese Patent Application No. 2014-232609 filed on Nov. 17, 2014, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to a signal processing device having a signal processing circuit that processes an input signal from a sensor unit for detecting, for example, a physical quantity, and outputs a signal corresponding to the input signal.
BACKGROUND
[0003] For example, a capacitive acceleration sensor device mounted in an automobile airbag system includes a semiconductor acceleration sensor chip (sensor element), and a signal processing device mainly having a C/V conversion circuit that processes a detection signal from the sensor chip (for example, refer to JP-2009-75097 A (Patent Literature 1).
[0004] The acceleration sensor device is provided with a self-diagnosis function for diagnosing whether the acceleration sensor device per se operates normally, or not (a predetermined sensitivity is obtained, or abnormality such as foreign matter is present in the sensor chip). The self-diagnosis function forcedly supplies a self-diagnosis signal different from a carrier at the time of a normal acceleration detection to the acceleration sensor chip to perform a diagnosis according to whether a signal commensurate with the self-diagnosis signal is obtained, or not.
[0005] In the above Patent Literature 1, in order to realize the self-diagnosis function, there is a need to provide a process (phase) of the self-diagnosis separately from the normal acceleration detection time. For that reason, the self-diagnosis function needs to be executed at the time of starting the use of the sensor device (at the time of starting an engine), or to be performed with a changeover of the phase from the normal operation phase to the self-diagnosis process as occasion demands. In other words, up to now, the self-diagnosis can be performed only when the sensor unit is not used, and it is desirable that the self-diagnosis function can be always executed even during the use of the sensor unit (during acceleration detection).
SUMMARY
[0006] It is an object of the present disclosure to provide a signal processing device having a signal processing circuit that processes an input signal from, for example, a sensor unit, which always executes a self-diagnosis function.
[0007] According to an example aspect of the present disclosure, a signal processing device includes: a signal processing circuit that processes an input signal, and outputs a signal corresponding to the input signal; an offset input device that inputs a diagnosis offset signal as an internal signal in a passage between an input side and an output side of the signal processing circuit; a self-diagnosis device that performs a self-diagnosis of the signal processing circuit based on a variation in the signal output from the signal processing circuit when the diagnosis offset signal input by the offset input device is varied by a predetermined amount; and an extraction device that removes a component of the diagnosis offset signal from the signal output from the signal processing circuit, and extracts only a signal corresponding to the input signal.
[0008] In the above signal processing device, when the offset input device forcibly inputs the diagnosis offset signal into the signal processing circuit, the signal in the signal processing circuit is varied with a variation amount corresponding to the diagnosis offset signal, according to a predetermined variation of the diagnosis offset signal. Thus, the self-diagnosis device monitors a variation of the signal with respect to the diagnosis offset signal, and the device can determine whether the signal processing circuit functions normally.
[0009] At the same time as the self-diagnosis, the extraction device extracts only the signal corresponding to the input signal from the signal output from the signal processing circuit by cancelling a variation of the diagnosis offset signal. Thus, the device always detects the physical quantity detected by the sensor unit. Thus, the signal processing device includes the signal processing circuit, the device always executes the self-diagnosis function without setting a phase for performing the self-diagnosis at a period other than a normal operation period.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The above and other objects, features and advantages of the present disclosure will become more apparent from the following detailed description made with reference to the accompanying drawings. In the drawings:
[0011] FIG. 1 is a diagram schematically illustrating an electric configuration of a main portion of a semiconductor acceleration sensor device according to a first embodiment of the disclosure;
[0012] FIG. 2 is a timing chart illustrating an example of a waveform of a carrier, an offset input, and outputs of respective units;
[0013] FIG. 3A is a schematic top view of a sensor chip, and FIG. 3B is a vertically cross-sectional front view of the sensor chip;
[0014] FIG. 4 is a diagram illustrating a modification of a pattern of an offset input;
[0015] FIG. 5 is a diagram corresponding to FIG. 1 according to a second embodiment of the disclosure;
[0016] FIGS. 6A to 6C are diagrams illustrating a signal in each section;
[0017] FIG. 7 is a diagram corresponding to FIG. 1 according to a third embodiment of the disclosure; and
[0018] FIG. 8 is a timing chart illustrating an example of a waveform of a carrier, an offset input, and so on.
DETAILED DESCRIPTION
First Embodiment
[0019] Hereinafter, a description will be given of a capacitive semiconductor acceleration sensor device according to a first embodiment of the disclosure with reference to FIGS. 1 to 3 . FIG. 1 is a diagram schematically illustrating an electric configuration of a capacitive semiconductor acceleration sensor device 11 , and FIGS. 3A and 3B are schematic views of a sensor chip 12 in the capacitive semiconductor acceleration sensor device 11 . As illustrated in FIG. 1 , the semiconductor acceleration sensor device 11 includes the sensor chip 12 as a sensor unit (sensor element), and a signal processing device 13 according to this embodiment.
[0020] First, a schematic configuration of the sensor chip 12 will be described. As illustrated in FIG. 3B , the sensor chip 12 has an acceleration detection unit 14 as a physical quantity detection unit which is located in a rectangular region of a center portion of the sensor chip 12 . The acceleration detection unit 14 is formed, for example, in such a manner that a rectangular (square) SOI substrate where a single crystal silicon layer 12 c is formed over a support substrate 12 a made of silicon through an oxide film 12 b is provided as a base, and grooves are produced in the single crystal silicon layer 12 c of a surface of the SOI substrate through a micromachining technique.
[0021] In that case, the acceleration detection unit 14 has a detection axis (X-axis) in one direction, and detects an acceleration in an anteroposterior direction (X-axial direction) in FIG. 3A . The acceleration detection unit 14 includes a movable electrode part 15 that is displaced in the X-axial direction according to an action of acceleration, and a pair of first and second fixed electrode parts 16 , 17 on left and right sides. In the acceleration detection unit 14 , the movable electrode part 15 includes a weight part 15 a , spring parts 15 b , and an anchor part 15 c . The weight part 15 a extends in the center of the acceleration detection unit 14 in the anteroposterior direction. The spring parts 15 b are provided on both ends of the weight part 15 a in the anteroposterior direction, and each shaped into a slender rectangular frame in a lateral direction. The anchor part 15 c is disposed in front of the front side spring part 15 b in FIG. 3A . The movable electrode part 15 also includes multiple thin movable electrodes 15 d extending from the weight part 15 a toward the lateral direction in a so-called pectinate shape.
[0022] As illustrated in FIG. 3B , the movable electrode part 15 floats in a so-called cantilevered state where the oxide film 12 b on a lower surface side of the sensor chip 12 is removed except for the anchor part 15 c , and only the anchor part 15 c is supported by the support substrate 12 a . As illustrated in FIG. 1 , an upper surface part of the anchor part 15 c is equipped with an input terminal 18 formed of an electrode pad. As will be described later, a carrier D 1 is input to the input terminal 18 .
[0023] On the contrary, the first fixed electrode part 16 on the left side includes a rectangular base 16 a , multiple fixed electrodes 16 b extending from the rectangular base 16 a to the right in a pectinate shape, and a fixed electrode wire part 16 c extending forward from the base 16 a . The respective fixed electrodes 16 b are disposed to be adjacent to each other in parallel through a small gap immediately on a rear side of the respective movable electrodes 15 d . As illustrated in FIG. 1 , an upper surface of a front end of the fixed electrode wire part 16 c is equipped with a first output terminal 19 formed of an electrode pad.
[0024] The second fixed electrode part 17 on the right side includes a rectangular base 17 a , multiple fixed electrodes 17 b extending from the rectangular base 17 a to the left in a pectinate shape, and a fixed electrode wire part 17 c extending forward from the base 17 a . The respective fixed electrodes 17 b are disposed to be adjacent to each other in parallel through a small gap immediately on a front side of the respective movable electrodes 15 d . As illustrated in FIG. 1 , an upper surface of a front end of the fixed electrode wire part 17 c is equipped with a second output terminal 20 formed of an electrode pad.
[0025] As a result, capacitors C 1 and C 2 (refer to FIG. 1 ) having the movable electrode part 15 as a common electrode are formed between the movable electrode part 15 (movable electrodes 15 d ) and the first fixed electrode part 16 (fixed electrodes 16 b ) and between the movable electrode part 15 (movable electrodes 15 d ) and the second fixed electrode part 17 (fixed electrodes 17 b ), respectively. Capacitances of those capacitors C 1 and C 2 differentially change according to a displacement of the movable electrode part 15 caused by the action of acceleration in the X-axial direction, and therefore the acceleration can be extracted as a change in capacitance values.
[0026] Although not shown in detail, the sensor chip 12 has a so-called stack structure implemented on a circuit chip where the respective circuits of the signal processing device 13 are formed. The sensor chip 12 is housed in, for example, a package made of ceramic. The first and second output terminals (electrode pads 19 and 20 ) of the sensor chip 12 are connected to first and second input terminals (not illustrated) disposed in the signal processing device 13 , respectively. The electric connections are performed by bonding wire connections or bump connections.
[0027] Then, the signal processing device 13 according to this embodiment will be described. As illustrated in FIG. 1 , the signal processing device 13 has a signal processing circuit 21 for processing the signal from the sensor chip 12 . In addition, the signal processing device 13 includes a carrier signal input circuit 22 , a control logic circuit 23 , a determination logic circuit 24 , a diagnosis offset input circuit 25 , and a moving average filter circuit (MAF) 26 . The control logic circuit 23 and the determination logic circuit 24 each mainly include a computer, and perform controls and determinations to be described later with a software configuration of the computer.
[0028] The signal processing circuit 21 includes a fully differential C/V conversion circuit 27 that converts a capacitance change into a voltage change, a sample and hold (S/H) circuit 28 that samples and holds a voltage signal output from the C/V conversion circuit 27 at a predetermined timing, and an A/D conversion circuit 29 that converts a signal output from the sample and hold circuit 28 into a digital signal. The output signal processed in the signal processing circuit 21 is output from the A/D conversion circuit 29 .
[0029] The C/V conversion circuit 27 includes a fully differential amplifier 30 having two non-inverting and inverting input terminals and two first and second output terminals, a capacitor 31 and a first switch 32 which are connected in parallel to each other between the non-inverting input terminal of the fully differential amplifier 30 and the first output terminal on a negative side, and a capacitor 33 and a second switch 34 which are connected in parallel to each other between the inverting input terminal of the fully differential amplifier 30 and the second output terminal on a positive side. The first output terminal 19 of the sensor chip 12 is connected to the non-inverting input terminal of the fully differential amplifier 30 , and the second output terminal 20 of the sensor chip 12 is connected to the inverting input terminal of the fully differential amplifier 30 .
[0030] The carrier signal input circuit 22 generates the carrier D 1 , and inputs the carrier D 1 to the movable electrode part 15 (input terminal 18 ) of the sensor chip 12 on the basis of a command from the control logic circuit 23 . As illustrated in FIG. 2 , the carrier D 1 amplitudes between a predetermined voltage (for example, 5V equal to a power source voltage) and 0V, and is formed into a pulse shape (rectangular waveform) having a frequency of, for example, 120 kHz. In this situation, the carrier D 1 is always supplied to the movable electrode part 15 during the operation of the acceleration sensor device 11 .
[0031] The diagnosis offset input circuit 25 inputs a diagnosis offset to any internal signal of the signal processing circuit 21 on the basis of the command from the control logic circuit 23 . Therefore, the diagnosis offset input circuit 25 functions as offset input device. In this embodiment, the output signal is input to an input side of the C/V conversion circuit 27 (fully differential amplifier 30 ). In detail, as will be described in the description of the operation later, the diagnosis offset input circuit 25 inputs offset signals S 1 and S 2 to the non-inverting input terminal and the inverting input terminal of the fully differential amplifier 30 , respectively. Those offset signals S 1 and S 2 have magnitudes corresponding to +0.5 G and −0.5 G, for example, in acceleration conversion, respectively.
[0032] In this situation, as illustrated in FIG. 2 , the diagnosis offset input circuit 25 alternately inputs the positive offset signal S 1 and the negative offset signal S 2 to the positive side and the negative side with a substantially equal amplitude in synchronization with the timing of sampling of the signal from the signal processing circuit 21 (carrier D 1 at timing of Hi). In other words, the positive and negative offsets are input with a deflection width corresponding to 1 G (predetermined amount) (varied with an equal amplitude). As illustrated in FIG. 1 , an output signal from the signal processing circuit 21 (A/D conversion circuit 29 ) is input to the determination logic circuit 24 , and a self-diagnosis (determination of whether abnormality is present, or not) is performed on the basis of a variation in the output signal.
[0033] In addition, an output signal from the signal processing circuit 21 (A/D conversion circuit 29 ) is input to the moving average filter circuit 26 . The moving average filter circuit 26 calculates an average value [{X(n)+X(n−1)}/2] between a present signal X(n) and a last signal X(n−1) from the A/D conversion circuit 29 . Through the calculation in the moving average filter circuit 26 , the offset signals S 1 and S 2 (two offset inputs) are canceled, and only a signal (acceleration detection signal) corresponding to the input signal to the signal processing circuit 21 , that is, corresponding to the detection signal of the sensor chip 12 is extracted.
[0034] Therefore, the determination logic circuit 24 functions as self-diagnosis device, and the moving average filter circuit 26 functions as extraction device. The first and second switches 32 and 34 of the C/V conversion circuit 27 are intended for reset of the capacitors 31 and 33 , and as illustrated in FIG. 2 , are turned on at an appropriate timing (rising timing of the pulse of the carrier D 1 ) by the control logic circuit 23 .
[0035] Then, the operation of the above configuration will be described also with reference to FIG. 2 . FIG. 2 illustrates a relationship of a waveform of the carrier D 1 input to the movable electrode part 15 of the sensor chip 12 , and the offset signals S 1 and S 2 input to the input side of the C/V conversion circuit 27 (fully differential amplifier 30 ) in the signal processing circuit 21 by the diagnosis offset input circuit 25 , in the operation of the semiconductor acceleration sensor device 11 . FIG. 2 illustrates an example of an output signal from the C/V conversion circuit 27 , an output signal from the sample and hold circuit 28 , an output signal from the A/D conversion circuit 29 , and an output signal from the moving average filter circuit 26 together. FIG. 2 illustrates a state in which no abnormality is present in the sensor chip 12 and the signal processing device 13 , and the acceleration of, for example, 1 G acts on the sensor chip 12 and the signal processing device 13 .
[0036] As described above, in the operation of the semiconductor acceleration sensor device 11 , the offset signal S 1 (+0.5 G equivalent) and the offset signal S 2 (−0.5 G equivalent) are always alternately input in synchronization with the carrier D 1 . When it is assumed that the output signal from the A/D conversion circuit 29 when receiving the offset signal S 1 is X 1 (number 1 in each white circle in FIG. 2 ), and the output signal from the A/D conversion circuit 29 when receiving the offset signal S 2 is X 2 (number 2 in each white circle in FIG. 2 ), the signal X 1 and the signal X 2 are alternately output from the A/D conversion circuit 29 .
[0037] Those output signals X 1 and X 2 are input to the determination logic circuit 24 to perform the abnormality diagnosis. In the case of normal (no abnormality), the magnitude of the signal X 1 corresponds to +0.5 G, the magnitude of the signal X 2 corresponds to +1.5 G, and those signals are alternately output. On the contrary, when the abnormality is present in the signal processing circuit 21 or the sensor chip 12 , since the magnitude of the amplitude between the signal X 1 and the signal X 2 , or an average value between the signal X 1 and the signal X 2 is changed, it can be determined that the abnormality occurs in the signal processing circuit 21 or the sensor chip 12 .
[0038] For example, when abnormality that the sensitivity is too high is present, a value (X 2 −X 1 ) of the amplitude between the signal X 1 and the signal X 2 is larger than the 1 G equivalent. When abnormality that the sensitivity is too low is present, the value (X 2 −X 1 ) of the amplitude between the signal X 1 and the signal X 2 is smaller than the 1 G equivalent. When the abnormality of polarity inversion is present, the value of the amplitude between the signal X 1 and the signal X 2 is smaller than the 1 G equivalent. If the offset abnormality is present, the average value {(X 1 +X 2 )}/2} between the signal X 1 and the signal X 2 is deviated from the 1 G equivalent. In this way, the abnormality is determined by the determination logic circuit 24 according to the output signals X 1 and X 2 .
[0039] The output signals X 1 and X 2 from the A/D conversion circuit 29 are input to the moving average filter circuit 26 , and an average of the output signals X 1 and X 2 and the last output signal is taken twice. In other words, when the signal X 2 is input to the moving average filter circuit 26 , an average {(X 1 +X 2 )/2} between the input signal X 2 and the last signal X 1 is obtained. When the signal X 1 is input to the moving average filter circuit 26 , an average {(X 2 +X 1 )/2} between the input signal X 1 and the last signal X 2 is obtained. As a result, through the moving average filter circuit 26 , the offset signals S 1 and S 2 (two offset inputs) are canceled, and only a signal (for example, 1.0 G equivalent) corresponding to the input signal to the signal processing circuit 21 , that is, corresponding to the detection signal of the sensor chip 12 is extracted.
[0040] As described above, according to the signal processing device 13 of this embodiment, the diagnosis offset signals S 1 and S 2 can be forcedly input to the C/V conversion circuit 27 in the signal processing circuit 21 by the diagnosis offset input circuit 25 . The output signal from the signal processing circuit 21 (A/D conversion circuit 29 ) is varied with the variation commensurate with the offset according to a predetermined amount of variation of the offset input. As a result, the determination logic circuit 24 monitors the output variation to the offset input, thereby being capable of diagnosing whether the signal processing circuit 21 operates normally, or not.
[0041] At the same time as the above self-diagnosis, the variation in the offset input is canceled by the moving average filter circuit 26 to enable only a portion corresponding to the input signal (acceleration detection signal) to be extracted from the output signal from the signal processing circuit 21 (A/D conversion circuit 29 ), and the acceleration detected by the sensor chip 12 can be always detected. Therefore, this embodiment is provided with the signal processing circuit 21 , and obtains such excellent advantages that the self-diagnosis function can be always executed unlike the conventional art that provides the self-diagnosis phase at a time other than the normal operation.
[0042] In the above first embodiment, the offset signal S 1 on the positive side and the offset signal S 2 on the negative side are alternately input by the diagnosis offset input circuit 25 in synchronization with the carrier D 1 . Alternatively, the disclosure can employ another pattern of the input (variation) of the offset signals. In other words, as a modification of the pattern of the offset signal input, the input and input stop (offset is 0) of the offset signal S 1 on the positive side, and the input and input stop (offset is 0) of the offset signal S 2 on the negative side can be repeated in order in synchronization with the carrier D 1 (at timing when the carrier D 1 is Hi).
[0043] In this event, as illustrated in FIG. 4 , in the normal case, the output signal from the signal processing circuit 21 (A/D conversion circuit 29 ) repeats 1.5 G equivalent, 1 G equivalent, 0.5 G equivalent, and 1 G equivalent in correspondence with the input pattern of the offset signal. Similarly, in this case, when the abnormality is present in the signal processing circuit 21 or the sensor chip 12 , since the magnitude of the amplitude of the output signal from the A/D conversion circuit 29 , or an average value of the magnitude is changed, it can be determined in the determination logic circuit 24 that the abnormality occurs in the signal processing circuit 21 or the sensor chip 12 . The offset abnormality can be determined according to the output signal from the A/D conversion circuit 29 at the time of stopping the offset input regardless of whether a failure is present in the signal processing device 13 , or not.
[0044] In the moving average filter circuit 26 , an average value [{X(n)+2*X(n−1)+X(n−2) }/4] is calculated according to the present signal X(n), the last signal X(n−1), and a second last signal X(n−2) from the A/D conversion circuit 29 so that the signals at the time of inputting the positive and negative offset signal are input one by one. Alternatively, an average value [{X(n)+X(n−1)+X(n−2)+X(n−3)}/4] is calculated. As a result, the acceleration detected by the sensor chip 12 can be always detected.
Second Embodiment
[0045] FIGS. 5 and 6 illustrate a second embodiment of the disclosure. The second embodiment is different from the above first embodiment in the configuration of a signal processing circuit 41 . In other words, in the signal processing circuit 41 according to this embodiment, a chopping circuit 42 is disposed on an input side (subsequent stage to an input portion of the offset signals S 1 and S 2 by the diagnosis offset input circuit 25 ) of the totally differential C/V conversion circuit 27 .
[0046] The chopping circuit 42 includes a third switch 43 , a fourth switch 44 , a fifth switch 45 , and a sixth switch 46 . The third switch 43 is inserted between a first output terminal 19 and a non-inverting input terminal of a fully differential amplifier 30 . The fourth switch 44 is inserted between a second output terminal 20 and an inverting input terminal of the fully differential amplifier 30 . The fifth switch 45 is inserted between the first output terminal 19 and the inverting input terminal of the fully differential amplifier 30 . The sixth switch 46 is inserted between the second output terminal 20 and the non-inverting input terminal of the fully differential amplifier 30 .
[0047] The chopping circuit 42 , that is, the third to sixth switches 43 to 46 are controlled in on/off operation by the control logic circuit 23 . In this situation, a state in which the third switch 43 and the fourth switch 44 are on, and the fifth switch 45 and the sixth switch 46 are off in the chopping circuit 42 is called “forward state”. In the forward state, an offset signal S 1 is input to the non-inverting input terminal of the fully differential amplifier 30 , and an offset signal S 2 is input to the inverting input terminal of the fully differential amplifier 30 .
[0048] On the contrary, a state in which the third switch 43 and the fourth switch 44 are off, and the fifth switch 45 and the sixth switch 46 are on in the chopping circuit 42 is called “inversion state”. In the inversion state, the offset signal S 1 is input to the inverting input terminal of the fully differential amplifier 30 , and the offset signal S 2 is input to the non-inverting input terminal of the fully differential amplifier 30 .
[0049] In this case, the offset signal S 1 on the positive side, the offset signal S 1 on the positive side, the offset signal S 2 on the negative side, and the offset signal S 2 on the negative side are repetitively input to the positive side and the negative side with a substantially equal amplitude in the stated order from the diagnosis offset input circuit 25 in synchronization with a carrier D 1 (at a timing when the carrier D 1 is Hi). The forward state, the inversion state, the forward state, and the inversion state are alternately switched by the chopping circuit 42 at a timing synchronous with the above input.
[0050] FIGS. 6A to 6C illustrate a signal (Vcv+) of an acceleration (G) from a sensor chip 12 , an offset signal (positive offset input is Voff+, negative offset input is Voff−) input from the diagnosis offset input circuit 25 , and an output signal (VADO+ in a case including the positive offset input, and VADO− in a case including the negative offset input) from an A/D conversion circuit 29 , in eight sections (eight cycles of the carrier D 1 ) of AD 1 to AD 8 . FIG. 6A illustrates data that remains chopped, and FIG. 6B illustrates data when chopping is demodulated (ADCh 1 to ADCh 8 ). FIG. 6C illustrates an extracted signal by a moving average filter circuit 26 .
[0051] The section AD 1 shows an appearance in which the offset signal S 1 on the positive side is input to the chopping circuit 42 , and the chopping circuit 42 is in the forward state, and the section AD 2 shows an appearance in which the offset signal S 1 on the positive side is input to the chopping circuit 42 , and the chopping circuit 42 is in the inversion state. The section AD 3 shows an appearance in which the offset signal S 2 on the negative side is input to the chopping circuit 42 , and the chopping circuit 42 is in the forward state, and the section AD 4 shows an appearance in which the offset signal S 2 on the negative side is input to the chopping circuit 42 , and the chopping circuit 42 is in the inversion state. A pattern of those sections AD 1 to AD 4 is also repeated in the sections AD 5 to AD 8 .
[0052] As is apparent from FIG. 6 , similarly, in a configuration where the chopping circuit 42 described above is provided, even if the offset input from the diagnosis offset input circuit 25 is performed in the order of positive, positive, negative, and negative to implement the signal inversion by the chopping circuit 42 , the output signal from the A/D conversion circuit 29 which has been subjected to the demodulation of the chopping is alternately deflected to the positive and negative. As a result, the abnormality determination (self-diagnosis) can be performed by the determination logic circuit 24 . In the moving average filter circuit 26 , with the calculation of an average value of four output signals, a variation in the offset input is canceled, only a portion corresponding to an acceleration detection signal of the sensor chip 12 can be extracted to always detect the acceleration.
[0053] Therefore, similarly, the second embodiment is provided with the signal processing circuit 41 , and obtains such excellent advantages that the self-diagnosis function can be always executed unlike the conventional art that provides the self-diagnosis phase at a time other than the normal operation. In the second embodiment, the chopping circuit 42 is disposed in the subsequent stage to the input portion of the offset signals S 1 and S 2 by the diagnosis offset input circuit 25 . Alternatively, the chopping circuit 42 may be disposed on an output side of the C/V conversion circuit 27 or on an output side of the sample and hold circuit 28 , and can be implemented under the same control.
Third Embodiment, and Other Embodiments
[0054] Subsequently, a third embodiment of the disclosure will be described with reference to FIGS. 7 and 8 . FIG. 7 schematically illustrates an electric configuration of a main portion of a semiconductor acceleration sensor device 51 according to this embodiment. The semiconductor acceleration sensor device 51 includes a sensor chip 52 as a sensor unit, and a signal processing device 53 . In the semiconductor acceleration sensor device 51 , the sensor chip 52 includes a movable electrode part 15 , and a pair of fixed electrode parts 16 and 17 , and capacitors C 1 and C 2 are configured by those components.
[0055] The sensor chip 52 is equipped with first and second input terminals 54 and 55 connected to the fixed electrode parts 16 and 17 , respectively, and an output terminal 56 connected to the movable electrode part 15 . The input terminals 54 and 55 are connected with a carrier input circuit 57 , and pulsed carriers whose potential has an amplitude between Vp (for example, 5V) and Vm (for example, 0V), and are opposite in phase to each other are supplied to the input terminals 54 and 55 . The output terminal 56 is connected to a signal processing circuit 58 of the signal processing device 53 .
[0056] The signal processing circuit 58 includes a single end C/V conversion circuit 59 , a sample and hold (S/H) circuit 60 , and an A/D conversion circuit 61 . The C/V conversion circuit 59 includes an arithmetic amplifier 62 , and a feedback capacitor 63 and a switch 64 which are connected in parallel to each other between a non-inverting input terminal and an output terminal of the arithmetic amplifier 62 . The output terminal 56 is connected to the non-inverting input terminal of the arithmetic amplifier 62 . A predetermined (DC) voltage signal, for example, an intermediate voltage Vref of a carrier is input to an inverting input terminal of the arithmetic amplifier 62 .
[0057] In addition, the signal processing device 53 includes a control logic circuit 23 , a determination logic circuit 24 , and a moving average filter circuit (MAF) 26 . The signal processing device 53 also includes a diagnosis offset input circuit 65 . The diagnosis offset input circuit 65 inputs an offset signal S 1 (for example, a signal corresponding to +0.5 G, for example, in acceleration conversion) to an input side of the C/V conversion circuit 59 (arithmetic amplifier 62 ) on the basis of a command from the control logic circuit 23 . In this case, as illustrated in FIG. 8 , the diagnosis offset input circuit 65 alternately performs an input and an input stop (offset is 0) of the offset signal S 1 for each one cycle of Hi and Lo of the carrier D 1 in synchronization with a timing of sampling of a signal from the signal processing circuit 58 .
[0058] As in the above first embodiment ( FIG. 2 ), FIG. 8 illustrates a signal of each component when no abnormality is present in the sensor chip 52 and the signal processing device 53 , and the acceleration of, for example, 1 G acts on the sensor chip 52 and the signal processing device 53 . The waveform of the offset signal S 1 is different from that in the first embodiment, but the output signal from the C/V conversion circuit 59 is equal to that in the first embodiment. As a result, although not shown, an output signal from the sample and hold circuit 60 , an output signal from the A/D conversion circuit 61 , and an output signal from the moving average filter circuit 26 are equal to those shown in FIG. 2 .
[0059] As a result, similarly, in this embodiment, the determination logic circuit 24 monitors the output variation to the offset input, thereby being capable of diagnosing whether the signal processing circuit 58 operates normally, or not. At the same time as the above self-diagnosis, the variation in the offset input is canceled by the moving average filter circuit 26 to enable only a portion corresponding to the input signal (acceleration detection signal) to be extracted from the output signal from the signal processing circuit 58 (A/D conversion circuit 61 ), and the acceleration detected by the sensor chip 52 can be always detected. Therefore, similarly, the third embodiment is provided with the signal processing circuit 58 , and can obtain such an advantageous effect that the self-diagnosis function can be always executed.
[0060] Although not described in the above respective embodiments, the signal processing circuit may provide a zero point adjustment mechanism that adjusts an output (zero point) of the sensor unit in a state where a physical quantity does not act on the sensor unit. In the case of providing the zero point adjustment mechanism as described above, the offset input device (diagnosis offset input circuit) can also function as the zero point adjustment mechanism, and the configuration can be more simplified. In the above respective embodiments, the moving average filter is employed as the extraction device. Alternatively, the extraction device can be configured by the combination of a low pass filter or a band pass filter with the moving average filter.
[0061] In the above respective embodiments, the offset signal is input to the input side of the C/V conversion circuit by the diagnosis offset input circuit. Alternatively, the output signal may be input to the input side of the sample and hold circuit, or the input side of the A/D conversion circuit. In addition, in the above respective embodiments, the disclosure is applied to the semiconductor acceleration sensor device. Alternatively, the disclosure can be applied to another capacitive semiconductor sensor device such as a yaw rate sensor. Further, the disclosure can be applied to the general signal processing devices. The signal processing circuit may include no C/V conversion circuit, and the signal waveforms in the respective components merely show an example, and the disclosure can be implemented with an appropriate change without departing from the spirit of the disclosure.
[0062] While the present disclosure has been described with reference to embodiments thereof, it is to be understood that the disclosure is not limited to the embodiments and constructions. The present disclosure is intended to cover various modification and equivalent arrangements. In addition, while the various combinations and configurations, other combinations and configurations, including more, less or only a single element, are also within the spirit and scope of the present disclosure.
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A signal processing device includes: a signal processing circuit that processes an input signal, and outputs a signal corresponding to the input signal; an offset input device that inputs a diagnosis offset signal as an internal signal in a passage between an input side and an output side of the signal processing circuit; a self-diagnosis device that performs a self-diagnosis of the signal processing circuit based on a variation in the signal output from the signal processing circuit when the diagnosis offset signal input by the offset input device is varied by a predetermined amount; and an extraction device that removes a component of the diagnosis offset signal from the signal output from the signal processing circuit, and extracts only a signal corresponding to the input signal.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to a method and apparatus for quickly and easily mounting a faucet to a sink basin.
[0003] 2. Background
[0004] Faucets are constantly being removed, replaced, or installed. This can result because an existing faucet is damaged and needs to be repaired. A faucet can also be replaced simply to update or remodel the faucet and sink. A faucet can also be installed as part of new construction.
[0005] A common method for installing a faucet uses the faucet shanks. Faucet shanks are tubes that protrude from the bottom of the faucet assembly. The faucet shanks typically have threads along their outer surfaces and are open along their inner surfaces. The inner openings act as piping that allows water to flow from a source, such as a water supply tube, to the faucet spout. The threaded outer surface of the faucet shanks serve as the means for attaching the faucet to a counter top by a sink basin. The same threads also serve as the means for attaching the water supply lines to the faucet.
[0006] The installation of a typical faucet utilizing faucet shanks requires several steps. First the faucet assembly is placed on a counter top near a sink basin. The counter top will have holes located to align the faucet to the sink basin. The faucet shanks protrude through the holes in the counter top and extend to the area below the counter top and behind the sink basin. Plastic mounting nuts, which have internal threads that mate with the threads on the outside surface of the faucet shanks, are then threaded onto the faucet shanks and hand-tightened. The tightened mounting nuts secure the faucet to the counter top, which holds the faucet in place. Once the faucet is mounted in place by the mounting nuts, water supply nuts are attached to the faucet shanks. The water supply nuts have internal threads that also mate with the threads on the outside surface of the faucet shanks. As the water supply nuts join the water supply tubing to the faucet shanks so that water may pass from the water supply tubing to the faucet shanks, the water supply nut must be sufficiently tight to prevent leaks.
[0007] It should be noted that a typical faucet shank has an outside diameter of ¾ of an inch and has 14 threads per inch. Also a typical water supply nut will have a maximum outside dimension of 1 inch.
[0008] The removal of a typical faucet requires a reversal of these steps. First the water supply nuts must be loosened and removed from the faucet shanks. Then the mounting nuts must be removed from the faucet shanks. Finally, the faucet can be lifted free of the counter top.
[0009] This common mounting process requires the installer to work in very confined spaces. Because the mounting nuts and water supply nuts attach to the same threads on the faucet shanks, the faucet must be mounted to the counter top before the water supply nuts can be attached. When the faucet is mounted to the counter top, the faucet shanks extend into the confined space below the counter top and behind the sink basin. This confined space makes it extremely difficult to get a standard wrench on the water supply nuts.
[0010] The confined space has resulted in the creation of a specialized tool called a basin wrench. A basin wrench allows an installer to reach into the confined space and apply a tightening or loosening force to the supply nuts. The design and operation of a basin wrench makes it difficult to operate which in turn makes it difficult for the installer to quickly and easily attach the water supply nuts. The design and operation of the basin wrench also makes it difficult for the installer to know if the water supply nuts have been tightened sufficiently to prevent leaks.
[0011] This typical faucet mounting method creates several problems. First this method requires the faucet to be mounted to the sink before the water supply tubing is attached. This occurs because the mounting nuts and the water supply nuts attach to the same faucet shanks. Thus the mounting nuts must be threaded onto the faucet shanks before the water supply nuts and water supply tubing are attached. That requires the faucet to be in place on the top of the sink and the mounting nuts in place on the faucet shanks below the sink before the water supply nuts are attached. That requires the installer to attach the water supply nuts in the confined space below the counter top and behind the sink basin.
[0012] Because the mounting nuts and the water supply nuts have inside threads of the same diameter, the mounting nuts cannot be removed while the water supply nuts are in place. Similarly, the mounting nuts cannot be installed while the water supply nuts are in place. Thus the faucet cannot be lifted from the counter top without first detaching the water supply nuts.
[0013] Alternative apparatuses for installing a faucet to a counter top exist. However, these apparatus either involve complicated attachment methods, specialized tools, or both. Many of the alternative methods and apparatuses often involve completely re-designing the faucet shanks. This requires the construction of the faucet shanks to be changed by the manufacturer.
[0014] Additional problems exist with many of these alternatives because the faucet shanks are an integral part of the faucet assembly. Thus any design changes to the faucet shanks must be completed as part of the original construction of the faucet. Changing the way faucets are constructed in turn requires manufacturers to change part or all of the manufacturing process.
[0015] Further, the faucet shanks cannot be removed and replaced by an end user. That means that a new faucet shank design cannot be added to an existing faucet. Thus an end user wishing to take advantage of many of the alternative mounting methods must purchase a completely new faucet.
[0016] The disclosed invention is advantageous in that it provides a simple and convenient method for attaching a faucet to a sink.
[0017] Another advantage is that it allows the water supply nut to be connected to the faucet shank before the mounting nut is attached to the faucet shank. This permits the user to install the water supply nut before the faucet is mounted to the sink and eliminates the need for specialized tools or for the installer to attach the water supply nut while in a confined space.
[0018] A further advantage of the invention is that it can be incorporated into and used with any existing faucet shank that has typical threaded shanks.
[0019] Additional 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 combination particularly pointed out in the appended claims.
SUMMARY OF THE INVENTION
[0020] The present invention discloses an apparatus for mounting a common faucet to a counter top through the use of a cylindrical sleeve containing internal and external threads and a mounting nut of a sufficiently large inside diameter. The internal threads of the cylindrical sleeve are such that they mate with the external threads of a common faucet shank. The internal threads of the mounting nut mate with the external threads of the cylindrical sleeve. Further, the internal diameter of the mounting nut is sufficiently large as to allow the water supply nut to pass completely through the mounting nut.
[0021] In one embodiment of the present invention, the external threads on the outer surface of the cylindrical sleeve cover the entire outer surface of the cylindrical sleeve.
[0022] In accordance with an alternative embodiment of the present invention, the outside surface of the cylindrical sleeve contains at least two substantially flat surfaces on opposing sides of the sleeve. The substantially flat surfaces allow an installer to grip the cylindrical sleeve by hand and tighten it onto or loosen it from the faucet shank.
[0023] In accordance with an alternative embodiment of the invention, the cylindrical sleeve contains external threads along only a portion of its outer surface with the remainder of the outer surface having no threads.
[0024] In accordance with an alternative embodiment of the invention, the mounting nut is shaped to allow easy hand-tightening of the mounting nut after the water supply nut has been attached and the faucet has been lowered into place.
[0025] The described invention thus eliminates the limitations and problems caused by the typical faucet mounting method because it allows an installer to attach the water supply nut to the faucet shank before the faucet is mounted to the counter top. The described invention further eliminates the cost and manufacturing issues created by other more complex devices because the elements making up the apparatus are minimal and can be readily applied to an existing faucet having a typical faucet shank mounting system. The described invention further eliminates the need for a person to purchase an entirely new faucet to use the disclosed mounting method and apparatus because they can be applied to and used with an existing typical faucet shank.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is an exploded three-dimensional view of the present invention as it fits with a faucet.
[0027] FIG. 2 is an exploded two-dimensional view of the present invention.
[0028] FIG. 3 is a side view of the present invention on a mounted faucet.
[0029] FIG. 4 is an alternative embodiment of the present invention.
[0030] FIG. 5 is a further alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] Referring now to the drawings, FIG. 1 shows an embodiment of the present invention. In the illustrated embodiment, the faucet 1 contains faucet shanks 2 and 22 . The faucet shanks 2 and 22 are of a type typically encountered with a typical outside diameter and thread. Two cylindrical sleeves 3 and 23 contain cylindrical openings along each cylindrical sleeve's 3 and 23 vertical center axis about which are threads 4 and 24 that mate with the threads of the faucet shank 2 and 22 . The cylindrical sleeves 3 and 23 are threaded to the faucet shanks 2 and 22 by means of the interior threads 4 and 24 until the cylindrical sleeves 3 and 23 contact the underside of the faucet 1 .
[0032] The mounting nuts 8 and 28 can then be passed over the water supply nuts 7 and 27 and the water supply tubes 10 and 30 . The water supply nuts 7 and 27 and water supply tubes 10 and 30 are then passed through the counter top 6 . The water supply nuts 7 and 27 are then threaded to the faucet shanks 2 and 22 . The faucet 1 is then placed on the counter top 6 with the faucet shanks 2 and 22 , with cylindrical sleeves 3 and 23 attached, passing through the counter top 6 and extending into the space below. The mounting nuts 8 and 28 are then threaded to the cylindrical sleeves 3 and 23 by means of interior threads 9 and 29 on the interior of the mounting nuts 8 and 28 , which mate with exterior threads 5 and 25 on the exterior surfaces of the cylindrical sleeves 3 and 23 . The mounting operation is identical for both faucet shanks 2 and 22 .
[0033] FIGS. 2 and 3 show partial views of one embodiment of the invention in that these figures only display one side of the faucet, which displays only a single faucet shank 2 . FIG. 2 shows an exploded view of one embodiment of the present invention, while FIG. 3 shows an assembled view of the same embodiment of the present invention.
[0034] Referring solely to FIGS. 2 and 3 , the mounting process is the same as that described above. The cylindrical sleeve 3 is threaded onto the faucet shank 2 , until the cylindrical sleeve 3 contacts the base of the faucet 1 . The mounting nut 8 is then passed over the water supply nut 7 and water supply tube 10 . The water supply nut 7 is passed through the counter top 6 and threaded onto the faucet shank 2 . Then the faucet shank 2 with the cylindrical sleeve 3 and water supply nut 7 attached passes through the counter top 6 . Once the faucet 1 is resting on the counter top 6 , the mounting nut 8 is threaded onto the cylindrical sleeve 3 to secure the faucet 1 in place.
[0035] FIGS. 4 and 5 demonstrate additional embodiments of the present invention. In FIG. 4 , the exterior threads 5 of the cylindrical sleeve 3 ′ encompass less than the entire outer surface of the cylindrical sleeve 3 ′. In FIG. 5 , the cylindrical sleeve 3 ″ contains two substantially flat surfaces 11 and 12 along a portion of the outer surface of the cylindrical sleeve 3 ″. In the shown embodiment, the flat surfaces 11 and 12 are located directly opposite one another. The flat surfaces 11 and 12 permit the installer to grip and turn the cylindrical sleeve 3 ″ without disturbing or marring the exterior threads 5 . It should be noted that FIG. 5 represents just one embodiment and means for providing a gripping surface on the cylindrical sleeve 3 ″. Additional embodiments of the cylindrical sleeve 3 ″ with gripping surfaces could incorporate multiple flat or substantially flat surfaces or other surface shapes that permit an installer to grip and turn the cylindrical sleeve 3 ″ without contacting the exterior threads 5 .
[0036] It should be noted that despite the thread pitch and diameter of the faucet shanks 2 , the inner diameter of the mounting nut 8 must be sufficiently large as to allow the mounting nut 8 to pass completely over the water supply nut 7 . Thus, with the typical water supply nut 7 noted above, the inner diameter of the mounting nut 8 must be larger than 1 inch.
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An apparatus for mounting a faucet to a sink that can be quickly and easily incorporated into new and existing faucet assemblies and that will allow for the attachment of water supply tubes to the faucet shanks before the faucet is mounted to the sink.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor device, a method of producing the same, and semiconductor production equipment for carrying out the method. More specifically, the present invention relates to semiconductor production equipment for mounting a semiconductor chip on a die pad, and a method of operating the semiconductor production equipment.
2. Background Art
FIGS. 6A , 6 B and 6 C are views of assistance in explaining a conventional method of bonding a semiconductor chip to a substrate for supporting the semiconductor chip. As shown in FIG. 6A , in a semiconductor wafer 12 , a plurality of semiconductor chips 14 are formed. The semiconductor wafer 12 is diced into a plurality of semiconductor chips 14 . A collet 8 picks up one of the semiconductor chips 14 and carries the same to a die bonding apparatus, i.e., semiconductor production equipment.
As shown in FIG. 6B , a lead frame 16 provided with a die pad 18 in its central part is mounted on a heating block 4 , i.e., a hot stage, of the die bonding apparatus. An adhesive layer 20 for bonding the semiconductor chip 14 to the die pad 18 is placed on the die pad 18 . The collet 8 presses the semiconductor chip 14 lightly against the die pad 18 to bond the semiconductor chip 14 to the die pad 18 . Then, the heating block 4 heats the die pad 18 , the adhesive layer 20 and the semiconductor chip 14 to enable the adhesive layer 20 to bond the semiconductor chip 14 to the die pad 18 .
SUMMARY OF THE INVENTION
Semiconductor devices have been progressively miniaturized and the thickness of semiconductor wafers has been reduced accordingly. Sometimes, the semiconductor chips formed by dicing the semiconductor wafer are warped by stress induced in surfaces thereof when circuits are formed thereon. The warped semiconductor chip 14 cannot be satisfactorily bonded to the die pad 18 . When the collet 8 having the shape of a thin rod applies pressure to the semiconductor chip 14 to bond the semiconductor chip 14 to the die pad 18 , the pressure is concentrated on the portion where the collet 8 presses the chip directly, i.e., a central part of the semiconductor chip 14 as shown in FIG. 6B . Consequently, a peripheral part of the semiconductor chip 14 that receives a comparatively low pressure remains warped and are not bonded securely to the die pad 18 as shown in FIG. 6C .
When the warped semiconductor chip 14 is bonded to the die pad 18 with its peripheral part spaced apart from the die pad 18 as shown in FIG. 6C , the semiconductor device formed thus incompletely bonding the semiconductor chip 14 to the die pad 18 is connected electrically incompletely to an external circuit. Therefore, it is an object of the present invention to provide an apparatus and method capable of securely bonding a semiconductor chip to a substrate.
According to one aspect of the present invention, a Semiconductor production equipment for attaching a semiconductor chip to a semiconductor chip mounting substrate, comprises a chip mounting unit for mounting the semiconductor chip on and pressing the same against the semiconductor chip mounting substrate to bond the semiconductor chip temporarily to the semiconductor chip mounting substrate, and a chip pressing unit for pressing the semiconductor chip temporarily bonded to the semiconductor chip mounting substrate against the semiconductor chip mounting substrate. The chip mounting unit includes a first supporting device for supporting the semiconductor chip mounting substrate and the semiconductor chip thereon, and a holding device capable of holding the semiconductor chip, of carrying the semiconductor chip and pressing the semiconductor chip against the semiconductor chip mounting substrate to bond the semiconductor chip temporarily to the semiconductor chip mounting substrate. The chip pressing unit includes a second supporting device for supporting the semiconductor chip mounting substrate to which the semiconductor chip is bonded thereon, and a pressing device for pressing the semiconductor chip against the semiconductor chip mounting substrate. Accordingly, the semiconductor chip can be entirely and surely bonded to the mounting substrate.
In another aspect of the present invention, in a semiconductor device producing method, a semiconductor chip mounting substrate provided with a predetermined adhesive layer is placed on a first supporting device included in a chip mounting unit and a semiconductor chip is mounted on the semiconductor chip mounting substrate in a chip mounting substrate feeding process. In a chip bonding process, a semiconductor chip is bonded temporarily to the semiconductor chip mounting substrate by pressing the semiconductor chip against the semiconductor chip mounting substrate. In a transfer process, the semiconductor chip mounting substrate is transferred to which the semiconductor chip is bonded temporarily by the chip bonding process from the first supporting device to a second supporting device. In a pressing process, the semiconductor chip is pressed firmly against the semiconductor chip mounting substrate to bond the semiconductor chip entirely to the semiconductor chip mounting substrate. Accordingly, the semiconductor chip can be entirely and surely bonded to the mounting substrate.
Other and further objects, features and advantages of the invention will appear more fully from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of a die bonding apparatus, i.e., semiconductor production equipment, for carrying out a semiconductor device producing method in a first embodiment according to the present invention;
FIG. 2 is a flow chart of the die bonding method in the first embodiment according to the present invention;
FIGS. 3 to 5 are schematic views of assistance in explaining the die bonding method;
FIGS. 6A , 6 B and 6 C are views of assistance in explaining a conventional method of bonding a semiconductor chip to a substrate for supporting the semiconductor chip.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will be described with reference to the accompanying drawings, in which the same or like parts are denoted by the same reference characters and the duplicate description thereof will be omitted.
First Embodiment
FIG. 1 is a schematic perspective view of a die bonding apparatus 100 , i.e., semiconductor production equipment, for carrying out a semiconductor device producing method in a first embodiment according to the present invention.
A plurality of semiconductor chips 14 are formed in a semiconductor wafer 12 . Each of the semiconductor chips is formed by dicing a semiconductor wafer 12 .
A lead frame 16 is a package for semiconductor devices. Die pad 18 is portion for mounting a semiconductor chip. The lead frame 16 is provided with the die pads 18 . Adhesive layers 20 are attached to the die pads 18 . The Adhesive layers 20 are used for bonding the semiconductor chips 14 to the die pads 18 , respectively.
A heating block 4 is a portion on which the semiconductor chips 14 and the die pads 18 are placed when the semiconductor chip 14 is bonded to the die pad 18 . The heating block 4 is internally provided with a cartridge heater, not shown. The heating block 4 heats the lead frame 16 and the semiconductor chip 14 mounted thereon to bond the semiconductor chip 14 to the die pad 18 of the lead frame 16 .
A collet 8 picks up one of the semiconductor chips 14 formed by dicing the semiconductor wafer 12 and carries the same onto the heating block 4 . The collet 8 presses the semiconductor chip 14 lightly against the die pad 18 to bond the semiconductor chip 14 to the die pad 18 .
A chip mounting unit 110 of the die bonding apparatus 100 comprises the heating block 4 and the collet 8 . The chip mounting unit 110 is a portion for pressing the semiconductor chip 14 against the die pad 18 of the lead frame 16 to bond the semiconductor chip 14 to the die pad 18 .
The heating block is a portion on which the die pad 18 and the semiconductor chip 14 bonded to the die pad 18 by the chip mounting unit 110 is placed. Rubber rings 3 are extended between rotating pulley 2 such that the upper and under sides thereof extend past the heating blocks 4 and 6 as shown in FIG. 1 . The rubber rings 3 are moved by rotating the pulley 2 to transfer the lead frame 16 from the heating block 4 to the heating block 6 . The heating block 6 is internally provided with a cartridge heater, not shown, to heat the lead frame 16 and the semiconductor chip 14 when pressure is applied to the semiconductor chip 14 .
A heating tool 10 applies heat and pressure to the semiconductor chip 14 . The heating tool 10 has a surface area greater than that of the semiconductor chip 14 to apply pressure all over the semiconductor chip 14 at a time. The heating tool 10 presses the semiconductor chip 14 so that the entire contact surface of the semiconductor chip 14 including that of a warped peripheral part of the semiconductor chip 14 is bonded to the die pad 18 . The heating tool 10 is internally provided with a cartridge heater, not shown, to apply both pressure and heat to the semiconductor chip 14 .
A chip pressing unit 120 of the die bonding apparatus 100 comprises the heating block 6 and the heating tool 10 . The chip pressing unit 120 straightens a warped peripheral part, which cannot be satisfactorily bonded to the die pad 18 , of the semiconductor chip, so that the semiconductor chip 14 can be entirely bonded to the die pad 18 . The die bonding apparatus 100 comprises the chip mounting unit 110 and the chip pressing unit 120 .
A die-bonding method of bonding the semiconductor chip 14 to the die pad 14 by the die bonding apparatus 100 will be described. FIG. 2 is a flow chart of the die bonding method, and FIGS. 3 to 5 are schematic views of assistance in explaining the die bonding method.
Referring to FIG. 2 , a lead frame 16 is fed to the die bonding apparatus 100 in step S 1 . Adhesive layers 20 are formed on die pads 18 , on which semiconductor chips 14 are mounted, of the lead frame 16 . The lead frame 16 is moved onto the heating block 4 of the chip mounting unit 110 of the die bonding apparatus 100 .
In step S 2 , semiconductor chips 14 are carried. A semiconductor wafer 12 is divided into a plurality of semiconductor chips 14 by dicing as shown in FIG. 3 . The collet 8 picks up the semiconductor chip 14 and carries the same onto the die pad 18 of the lead frame 16 , located on the heating block 4 .
Then, in step S 3 , the semiconductor chip 14 is bonded to the die pad 18 . The collet 8 presses the semiconductor chip 14 carried onto the die pad 18 in step S 2 lightly against the die pad 18 as shown in FIG. 4A . At this time, the heating block 4 heated by the cartridge heater heats the adhesive layer 20 to bond the semiconductor chip 14 to the die pad 18 .
Sometimes, a peripheral part of the semiconductor chip 14 is warped by stress induced in a surface provided with a circuit of the semiconductor chip 14 because the semiconductor wafer 12 is thin, and the collet 8 having the shape of a thin rod applies pressure to a central part of the semiconductor chip 14 in step S 3 . Therefore, only the central part of the semiconductor chip 14 is bonded to the die pad 18 and a peripheral part of the semiconductor chip 14 remains warping away from the die pad 18 as shown in FIG. 4B .
Then, in step s 4 , the lead frame 16 supporting the semiconductor chips 14 each having only the central part bonded to the die pad 18 is transferred from the chip mounting unit 110 to the heating block 6 of the chip pressing unit 120 . Since the rubber rings 3 are extended past the heating block 4 of the chip mounting unit 110 and the heating block 6 of the chip pressing unit 120 , the rotating Pulley 2 are rotated to move the rubber rings 3 so as to carry the lead frame 16 from the chip mounting unit 110 to the chip pressing unit 120 .
A pressing operation is executed in step S 5 . As shown in FIGS. 5A and 5B , the heating tool 10 applies pressure to the semiconductor chip 14 temporarily bonded to the die pad 18 of the lead frame 16 placed on the heating block 6 to depress the semiconductor chip 14 entirely. At the same time, the heating block 6 and the heating tool 10 heated by the cartridge heaters apply heat through the semiconductor chip 14 and the die pad 18 to the adhesive layer 20 to bond the semiconductor chip 14 securely to the die pad 18 . Consequently, the warped semiconductor chip 14 is straightened and the semiconductor chip 14 can be bonded properly to the die pad 18 as shown in FIG. 5C .
In this embodiment, the semiconductor chip 14 is temporarily bonded to the die pad 18 , the warped peripheral part of semiconductor chip 14 is straightened, and then the semiconductor chip 14 is bonded to the die pad 18 . Thus, the semiconductor chip 14 including a warped peripheral part of the semiconductor chip 14 can be surely entirely bonded to the die pad 18 .
In this specification, a chip mounting substrate thereon is a substrate which supports a semiconductor chip thereon in a semiconductor device, and different types of packages of semiconductor devices use different chip mounting substrates, respectively. In this embodiment, the package is the lead frame 16 and hence the die pad 18 is the chip mounting substrate. However, packages and chip mounting substrates other than the lead frame 16 and the die pad 18 may be employed.
A holding device in the present invention is, for example, the collet 8 employed in this embodiment. The holding device may be any device other than the collet 8 , provided that the device is capable of carrying a semiconductor chip and placing the same on a mounting member.
A first supporting device of a chip mounting unit and a second supporting device of a chip pressing unit according to the present invention correspond to, for example, the heating block 4 and the heating block 6 , respectively, of the die bonding apparatus in this embodiment. The respective supporting devices of the chip mounting unit and the chip pressing unit are not limited thereto and may be any devices capable of supporting the semiconductor chip and the mounting substrate thereon when bonding the semiconductor chip to the mounting substrate.
The heating blocks 4 and 6 are interconnected by the rubber rings 3 which carry the lead frame 16 having the die pads 18 to which the semiconductor chips 14 are bonded in the chip mounting unit 110 . The chip mounting unit 110 and the chip pressing unit 120 may be completely separate units, and the lead frame 16 may be held and transferred from the heating block 4 to the heating block 6 by a carrying mechanism capable of gripping the lead frame 16 .
Heating devices according to the present invention, for example, correspond to the cartridge heaters incorporated into the heating blocks 4 and 6 . The heating devices are not limited to the cartridge heaters and may be any suitable heating devices capable of heating the heating blocks 4 and 6 . Although both the heating blocks 4 and 6 are provided with the heating devices in this embodiment, heating blocks not provided with any heating devices may be used.
A pressing device according to the present invention is, for example, the heating tool 10 in this embodiment. The surface area of the heating tool 10 in this embodiment is greater than that of the semiconductor chip to straighten the warped peripheral part of the semiconductor chip by a single pressing operation. The pressing device does not necessarily need to be formed in such a shape and may be formed in any suitable shape provided that the pressing device is capable of straightening a warped peripheral part of a semiconductor chip.
The die bonding apparatus 100 used by this embodiment is provided with the single heating tool 10 . The die bonding apparatus 100 may be provided with a plurality of heating tools to straighten a plurality of warped semiconductor chips simultaneously.
A heating device of the chip pressing unit according to the present invention, for example, corresponds to the cartridge heater incorporated into the heating tool 10 . However, the heating device of the chip pressing unit is not limited to the cartridge heater, and the heating tool 10 does not necessarily need to be provided with the heating device.
A mounting substrate feeding process according to the present invention is executed, for example, in step S 1 of this embodiment. A chip bonding process according to the present invention is executed, for example, in steps S 2 and S 3 . A workpiece transfer operation according to the present invention is executed, for example, in step s 4 . A pressing process according to the present invention is executed, for example, in step S 5 . A method according to the present invention is not limited to the foregoing method including steps S 1 to S 5 .
Although the lead frame 16 having the die pads 18 respectively provided with the adhesive layers 20 is fed onto the heating block 4 in step S 1 in this embodiment, step S 1 is not limited thereto; the adhesive layers 20 may be formed on the die pads 18 after mounting the lead frame 16 on the heating block 4 . An additional heating block may be disposed on the path of the rubber rings 3 , the adhesive layers 20 may be formed on the die pads 18 on the additional heating block, and then the lead frame 16 may be carried to the heating block 4 by the rubber rings 3 .
The feature and advantage of the present invention as described above may be summarized as follow.
According to the present invention, the semiconductor chip is mounted on and bonded temporarily to the mounting substrate, the warped part of the semiconductor chip is straightened, and then the semiconductor chip is bonded completely to the mounting substrate. Accordingly, the semiconductor chip can be entirely and surely bonded to the mounting substrate.
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 by practiced otherwise than as specifically described.
The entire disclosure of a Japanese Patent Application No. 2001-290713, filed on Sep. 25, 2001 including specification, claims, drawings and summary, on which the Convention priority of the present application is based, are incorporated herein by reference in its entirety.
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A semiconductor chip, substrate employing plural bonding steps to ensure complete bonding particularly of peripheral edges. Embodiments include placing an adhesive layer on a chip mounting substrate positioned on a first supporting device, pressing a semiconductor chip against the chip mounting substrate to bond the semiconductor chip temporarily to the chip mounting substrate temporarily bonded chip on a second supporting device, and applying chip to straighten warpage and to bond the chip entirely to the chip mounting substrate.
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FIELD OF THE INVENTION
The present invention relates to an apparatus employed in multi-shed weaving looms, in particular, an improved beat-up apparatus that continuously maintains the spacing between warp theads while beating up weft thread into the fell of the fabric.
DESCRIPTION OF THE RELATED ART
Weaving looms of the multiple movable warp shed type are known in the art. In this type of loom, after a weft thread is inserted into one of the multiple moving sheds formed in the warp threads, the weft thread is moved toward the cloth fell as usual and is eventually beat-up into the fell of the fabric. A mechanism for beating up the weft thread in a multi-shed loom is described in U.S. Pat. No. 4,351,367 granted Sept. 28, 1982.
In one prior art embodiment the beat-up mechanism in a multi-shed loom is formed as part of a shed retaining member and is carried by a conveyor toward the fell of the fabric. The beat-up mechanism advances the weft thread towards the fell of the fabric and operates to beat up the weft thread into the fell. The beat up element is then withdrawn from the warp threads to be returned along the lower run of the conveyor along with the shed retaining mechanism to repeat another cycle. In such arrangements, the number of beat-up elements extending transversely across the loom corresponds to the number of shed retaining members and is very large. The beat-up elements and retaining members must be closely spaced in order to retain the sheds and beat up the weft thread. Because of the large number of beat up elements and their close spacing, as they are moved in the direction of the warp thread towards the fell, friction is produced between the beat up elements and the warp threads. The friction produced increases the likelihood of one of the warp threads breaking.
In another embodiment, the conveyor of a multi-shed weaving mechanism carries a plurality of weft advancing arms which advance the inserted weft thread toward the fell of the fabric. The weft advancing arms push the weft thread into a rotating reed member, and the weft advancing arms are withdrawn from between the wrap threads and returned along the lower run of the conveyor to repeat another cycle. The reed member rotates to beat up the weft threads into the fell of the fabric. The rotating reed member continuously rotates against the warp threads at the fell of the fabric and thereby causes undesired friction on the warp threads. As stated above, this friction increases the likelihood of the warp thread breaking.
The beat-up system of U.S. Pat. No. 4,351,367 provided a beat-up mechanism which reduced the friction on the warp threads and operated to continuously maintain a spacing between the warp threads while the weft threads were beat-up into the fell of the fabric. The beat-up mechanism consisted of two parts, with at least one part of the two part beat up mechanism always inserted in a position between the warp threads to continuously maintain the spacing of the warp threads.
However, the accuracy of the operation of the beat-up mechanism as described in U.S. Pat. No. 4,351,367 depended on the accurate registration and alignment of the index reed and the beat-up reed. The two components of the warp wave beat-up system cooperated in transferring the warp threads from one component to the other. But when the teeth or finger elements of one component are not correctly aligned with the corresponding teeth or finger elements of the other component, it is possible for warp threads to be transferred to an incorrect space in the beat-up system.
Accordingly, it is an object of the present invention to provide an improved apparatus which overcomes the aforesaid problems of warp thread friction and misalignment. Specifically, it is an object of the present invention to provide an improved index reed and beat-up reed comprising teeth or finger elements of varying transverse thickness. The change in thickness of both beat-up components is so arranged as to effectively prevent transfer of the warp threads from one space between the finger elements to another even when the teeth or finger elements are not in perfect alignment.
It is a further object of the present invention to provide in the blocks holding the teeth or finger elements, corresponding guide pins and openings. The pin and opening feature of the present invention is a cooperating interlocking feature that allows constant mutual contact and registration between the index reed and the beat-up reed throughout their motion relative to each other during the beat-up operation of the mechanism and is effective to prevent the transfer of warp threads from one finger spacing to another during beat-up operation.
SUMMARY OF THE INVENTION
In accordance with the objects of the present invention, an improvement is provided over the beat-up system disclosed in U.S. Pat. No. 4,351,367 which is incorporated herein by reference for its general description of the operating environment of and actuating system for the present invention. The present invention comprises a plurality of indexing fingers disposed between the end of the weft guide conveyor and the fell of the fabric and movable into and out of a position between the warp threads for maintaining the proper spacing between the warp threads. In addition, a plurality of beat-up fingers cooperate with the indexing fingers and are also movable into and out of a position between the warp threads and operate to beat-up the weft threads into the fell of the fabric and also operate to maintain the spacing of the warp threads when the indexing fingers are withdrawn from the warp threads. The index and beat-up fingers each have a thicker root section than the tip section (at least widthwise across the fingers) with a transition section between the root and tip.
In accordance with the present invention, before the indexing fingers are withdrawn from between the warp threads, the beat-up fingers are inserted between the warp threads to an extent that the thinner tip sections of the beat-up fingers are inserted between the warp threads. The beat-up fingers of this invention then maintain the spacing between the warp threads. The indexing fingers are then withdrawn and the beat-up fingers operate to beat-up the weft threads into the fell of the fabric. After the beat-up operation is completed, the narrower tips of the indexing fingers are reinserted between the warp threads which are now separated to a greater degree than normal by the wider root sections of the beat-up fingers. The beat-up fingers are then withdrawn so that the subsequent weft thread can be engaged and moved forward towards the fell of the fabric.
In accordance with the present invention, there is also provided a guide feature for maintaining mutual contact between the indexing reed and the beat-up reed throughout the beat-up operation. The guide feature preferably comprises at least one guide pin fixed to either of the indexing reed or beat-up reed and which is in continuous sliding engagement with a guide opening in the other of the indexing reed or beat-up reed. The continuous sliding engagement between the guide pin and guide opening of the corresponding indexing and beat-up reed ensures the continuous alignment of the indexing fingers and the beat-up fingers. The mutual contact between the guide pin and guide opening ensures that the warp threads are not transferred to an incorrect space between the fingers of the beat-up system due to improper positioning of the beat up fingers.
The invention also contemplates a modular construction of indexing and beat-up fingers.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects, features, and advantages of the present invention will become apparent upon the consideration of the following detailed description of the preferred embodiment of the invention when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a side elevational view of a section of the beat-up reed embodying the present invention;
FIG. 2 is a front elevational view of a section of the beat-up reed embodying the present invention;
FIG. 3 is a side elevational view of a section of the indexing reed embodying the present invention;
FIG. 4 is a front elevational view of a section of the indexing reed embodying the present invention;
FIG. 5 is a side elevational view of both the indexing reed and the beat-up reed relatively positioned for beating up a weft thread;
FIG. 6 is a side elevational view of the indexing reed and the beat-up reed relatively positioned for engaging a subsequent weft thread to be moved to the beat-up position;
FIG. 7 is a front elevational view showing the alignment between the fingers of the indexing reed and the beat-up reed and the thicker cross-sectional sections of the fingers of both reeds;
FIGS. 8 and 9 show partial sectional views of the improved guide pin and guide opening feature for maintaining mutual contact between the indexing reed and the beat-up reed during the beat-up operation;
FIGS. 10-15 illustrate in sequence the operation of the improved beat-up apparatus in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is an improvement over the beat-up system disclosed in U.S. Pat. No. 4,351,367 incorporated herein by reference. A weaving machine embodying the general principles of operation of the present invention and comprising a conveyor, a shed forming mechanism, a beat-up mechanism (FIGS. 6-11) over which the present invention constitutes an improvement, and associated operating systems are all disclosed in the aforesaid patent and will not be described in detail herein.
Referring now to FIGS. 1-6, the improved beat-up mechanism of the present invention is more clearly illustrated. As shown in FIGS. 2 and 4, the beat-up mechanism consists of a plurality of beat-up fingers 1 and a plurality of indexing fingers 2 which extend across the width of the loom and are adapted to be inserted between longitudinally extending warp threads (see FIGS. 10-15). These fingers 1, 2 cooperate with each other to maintain the proper spacing between the warp threads while beating up the weft threads W into the fell F of the fabric, all as described in U.S. Pat. No. 4,351,367 in respect of the embodiment shown in FIGS. 6-11 of the patent. In FIG. 6 the weft thread w is illustrated at its position relative to the indexing and best up fingers.
As specifically shown in FIGS. 1 and 2, the beat-up reed la comprises a series of cantilevered fingers 1 extending parallel from a modular base portion 3 of the beat-up reed towards the warp sheet. The beat-up reed la also includes a connecting portion 4 for connecting the reed to a means 4a for imparting motion to the reed as described in U.S. Pat. No. 4,351,367 and not further described herein. The fingers 1 of the beat-up reed 1a are divided into two sections of different transverse widths. The distal or tip sections 5 of the fingers have a smaller width than the root sections 6 which connect the fingers to the base 3 of the beat-up reed. A transition portion 7 forms a continuous surface connecting the wider root section 6 with the narrower tip section 5 so as not to interfere with sliding contact of the warp threads along the length of the fingers.
The indexing reed 2a (FIGS. 3 and 4) also comprises a series of cantilevered parallel fingers 2 extending from the modular base 8 of the indexing reed. The indexing fingers 2 include two sections of different widths, with the distal or tip sections 9 having a narrower width than the root sections 10 which connect the indexing fingers to the indexing base portion 8. An indexing finger transition portion 11 forms a continuous surface connecting the tip sections 9 with the root sections 10 of the fingers 2. The continuous transition surface 11 permits the fingers to be smoothly inserted between and retracted from the warp threads. The indexing reed 2a also includes a connecting portion 12 for connection to the motion imparting means 12a.
It will be noted that the index and beat-up fingers are constructed as modular units, as best seen in FIGS. 2 and 4. That is, the connecting portions 4 and 12 are arranged to be secured by suitable fastening means as illustrated in FIGS. 5 and 6 to the motion imparting elements 4a and 12a connected to a loom driving mechanism. The motion imparting means 4a, 12a for example, may extend continuously along the loom width, with modular sections of the indexing and beat-up portions secured thereto by suitable fasteners. The modular construction enables repairs and replacement of discreet sections of indexing and beat-up reed portions without replacing the entire indexing and beat-up reed systems.
FIG. 7 illustrates the relative thicknesses between the two section of the fingers of the beat-up and indexing reeds and shows the positions of the warp sheet at beat-up (AX) and when the indexing fingers and beat-up fingers are at their highest position (AY) as shown at FIG. 11. As an be seen from this figure, when the beat-up fingers 1 are extended through the warp threads of a shed to the extent that the warp threads of the shed are spaced apart by the wider root sections 6 of the beat-up fingers, the tips 9 of the indexing fingers 2 can be easily inserted in the spacing provided by the wider finger sections 6 of the beat-up reed even though the fingers may be not perfectly aligned. The indexing fingers 2 will be extended at times through the warp threads to the extent that the warp threads are spaced apart by the wider root portions 10. When the wider portions 10 separate the warp threads, the fingers of the beat-up reed 1 can be easily withdrawn and reinserted between the spacings maintained by the wider root portions 10 of the indexing fingers. It can be easily seen from FIG. 7 that even when the beat-up and the indexing fingers of the two reeds are not in perfect alignment, the narrow tips of one set of reed fingers can be easily inserted in the larger spaces provided in the warp threads by the wider root sections of the other reed fingers. In this manner, the beat-up fingers 1 and the indexing fingers 2 cooperate to continuously maintain the spacing of the warp threads.
In addition to the improved beat up fingers 1 and indexing fingers 2, the present invention includes a means for maintaining mutual contact between the beat-up reed 1a and the indexing reed 2a in order to continuously maintain the spacing of the warp threads. This means for maintaining continuous mutual contact includes a guide pin means and guide opening means on the base portions of both the beat-up reed 1a and the indexing reed 2a.
FIGS. 1-6, 8 and 9 show a preferred embodiment of the means for maintaining mutual contact between the beat-up reed 1a and the indexing reed 2a. Specifically, FIGS. 1 and 2 show guide pin means 13 which extend from the base portion 3 of the beat-up reed 1a toward the indexing reed 2a, and a guide opening means 14 extending through the base portion 3 of the beat-up reed 1a. FIGS. 3 and 4 show guide pin 15 which extends from the base portion 8 of the indexing reed 2a in a direction toward the beat-up reed 1a, and guide openings 16 which extend through the base portion 8 of the indexing reed 2a. As seen in FIGS. 5 and 6, the guide pin means and guide opening means of the respective beat-up and indexing reeds extend in parallel directions.
FIG. 5 shows the closest relative positions occupied by the beat-up reed and the indexing reed 2a during the beat-up operation of the present invention. In FIG. 5, the pin means 13 of the beat-up reed engage the openings 16 of the indexing reed, and the pins means 15 of the indexing reed engages the opening 14 of the beat-up reed. In this manner, mutual contact and alignment of the reed sections and the respective fingers of the beat-up reed and indexing reed are maintained by an interlocking relationship.
FIG. 6 shows the relative position between the beat-up reed 1a and the indexing reed 2a when they are moved to their furthest extent from each other during the beat-up operation of the mechanism. As seen in the figure, mutual contact between the reeds is maintained by the overlapping engagement of the respective guide pins means of the beat-up reed 13 and the indexing reed 15. The overlapping relationship between the guide pin means, and the engagement of the pin and the guide opening of the respective beat-up and indexing reeds are best seen in FIGS. 8 and 9, respectively. As seen in FIG. 8, mutual contact between the reeds is maintained by the contact between the pins 13 of the beat-up reed with the pin 15 of the indexing reed which are rectangular in cross section in the preferred embodiment. Even when the reeds are moved to their furthest extent from each other, the mutual contact is maintained (FIG. 8). Also in FIGS. 8 and 9, the relative positions between the pins means 13 and opening 14 of the beat-up reed, and the respective positions of the pin means 15 and openings 16 of the indexing reed can best be seen. The beat-up reed and indexing reed move relative to each other but maintain mutual contact during the sequence of operations involved in the beat-up of a weft thread. The sequence of operations involved in beating up the weft thread are shown in FIGS. 10-15. It should be noted that, for some applications a single guide pin in either the indexing or beat-up reed and a cooperating guide opening in the other red will suffice to provide the desired guiding contact.
In FIG. 10, the previous cycle for beating up the weft thread into the fell of the fabric F has just been completed, and the cycle for beating up the subsequent weft thread W is about to begin. The shed retainers 17 have been rotated to their shed disengaging positions and retracted from between the lower warp threads 18. At this stage of the loom operation, the spacing between adjacent warp threads at the fell of the fabric F is maintained by the tip sections of the beat-up fingers 1. As the shed retainers 17 are retracted from between the lower warp thread 18, and the weft thread advancing means 19 moves a subsequent weft thread W into a beat-up position (FIG. 10), the spacing between adjacent warp threads is maintained by the beat-up reed fingers 1, and the series of movements of the beat-up system to beat-up the subsequent weft thread W just removed from the shed retainers 17 begins.
Initially, the beat-up reed 1a and the indexing reed 2a moves as a unit first backwards (towards the inserted weft) and then in an upward direction to insert the tips of the indexing reed 2 in the space between the warp threads which at this point are spaced by the wide root portions 6 of the beat-up reed 1 (FIG. 11). As the indexing reed fingers 2 project through the spaces between adjacent warp threads maintained by the beat-up reed fingers 1, the beat-up reed 1a begins to move in downward direction relative to the indexing reed 2a. As the beat-up reed 1a is moved downward and retracted from the plane of the fabric, the beat-up reed and the indexing reed move as a unit to the left (i.e., rearwards) as shown in FIGS. 12 and 13, toward the weft thread W most recently removed from the shed retainers 17. At the furthest extent of the leftward movement of the beat-up reed and the indexing reed, the indexing reed fingers 2 just contact the recently removed weft thread W along the entire length of the indexing reed 2a to accurately locate the weft thread W relative to the indexing reed 2a and beat-up reed 1a (FIG. 13). At this stage of the beat-up operation, the beat-up reed 1a has moved to the limit of its downward motion beneath the plane of the warp sheet so as not to interfere with the weft thread W contacting the fingers 2 of the indexing reed 2a as the indexing reed is moved to the left toward the weft thread W.
Following the indexing fingers 2 contacting the weft thread W, the beat-up reed 1a begins to move upward (FIG. 14) until its fingers 1 once again project through the plane of the warp sheet, at a position just behind the most recently removed weft thread W. At this point of the operation, the spacing between adjacent warp threads is maintained by the wide root sections 10 of the indexing reed 2. The wide root sections 10 of the indexing reed 2 provide a wider spacing between adjacent warp threads to facilitate the insertion of the tips of the fingers 1 of the beat-up reed 1a between the same warp threads the fingers 2 of the indexing reed are positioned between. When the fingers 1 of the beat-up reed have been inserted between the warp threads behind the weft thread W, the beat-up of the weft thread begins. As the beat-up fingers 1 move the weft thread W toward the fell F of the fabric, the indexing fingers 2 are concurrently withdrawn from between the warp threads to the position below the plane of the fabric where the indexing reed 2a seats on the beat-up reed 1a (FIG. 15). The beat-up reed 1a and the indexing reed 2a then move together toward the fell of the fabric F, pushing the weft thread W toward the fell. In the position of the beat-up reed 1a and the indexing reed 2a shown in FIG. 10, the beat-up operation is completed. The beat-up reed 1a and the indexing reed 2a are ready to repeat the sequence of movements to receive the next weft thread to be removed from the shed retainers and beat it into the fell of the fabric.
A suitable driving means for imparting motion to the beat-up reed and the indexing reed is disclosed in the U.S. Pat. No. 4,351,367 which has been incorporated herein by reference. Other driving arrangements may be employed, of course, to drive the beat-up and indexing reeds 1, 2 and the arrangement disclosed in the aforesaid patent is merely exemplary.
In view of the foregoing, it is seen that there has been provided in accordance with the present invention an improved beat-up system that substantially reduces the friction of the beat-up apparatus on the warp threads, and also operates to continuously maintain the spacing between adjacent warp threads while beating up the weft threads into the fell of the fabric. In addition, the wider root sections of the indexing fingers and beat-up fingers operate to increase the spacing between the warp threads, and ensure that the beat-up fingers or the indexing fingers removed from the plane of the warp threads are reinserted into the plane of the warp threads at their proper locations. The guide pin and guide opening system of the present invention also ensure that alignment between the beat-up fingers and indexing fingers of the beat-up and indexing reeds are continuously maintained throughout the beat-up operation. The modular construction of the indexing and beat-up fingers facilitates repair and adjustment of the index and beat-up system. Although a preferred embodiment of the present invention has been disclosed herein, it is not intended that the subject matter should be limited by this disclosure. For example, the present invention may be employed in a loom other than the multi-shed type, and more than the disclosed number of pins and openings may be employed without departing from the scope of the invention.
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A beat-up mechanism for a weaving loom includes a relatively movable indexing reed and beat-up reed adjacent each other and arranged to transport weft threads adjacent the fell of the fabric and then beat-up the weft threads into the fell by means of beat-up fingers inserted between warp threads. The indexing and beat-up reeds each are constructed as modular units and include multiple, parallel fingers having narrow tip portions and wider root portions, whereby the wider root portions of one reed maintain the warp threads spaced apart for insertion of the tip portions of the other reed during weft transfer. The indexing and beat-up reeds are particularly useful in a multi-shed weaving loom wherein multiple sheds are progressively moved toward the fell of the fabric during the weaving operation with insertion of a pick in each shed. The indexing and beat-up reeds, moreover, include a guiding arrangement whereby the reeds are positively maintained in lateral alignment during weft transfer and beat-up.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of and claims the benefit of co-pending U.S. patent application Ser. No. 13/080,069, which was filed Apr. 5, 2011, the disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a support apparatus and more particularly an adjustable support bracket for height adjustably supporting a display device and input apparatus.
BACKGROUND OF THE INVENTION
[0003] In order to maximize accurate and convenient data input and retrieval, it has become common for industries and particularly the hospital industry to have computer terminals located at various locations throughout the building instead of a dedicated office or desk. These locations include hallways and patient rooms as well as offices so that these terminals or workstations can be used by various individuals on different shifts. Few, if any of the workstations are dedicated to an individual user. Therefore, instead of having office space dedicated to a single user and workstation, the workstations are placed where they are accessible by staff as needed and are usually accessed from a standing position.
[0004] Therefore it is important to have a workstation that does not take up much space and accommodates frequent use for short periods at a time. Furthermore, since users come in a variety of heights, it is necessary that the support bracket for the workstation be vertically adjustable. It is also desirable that the workstation when not in use takes up as little space as possible and can be retracted to avoid being bumped by carts or passersby. The invention as described herein addresses these issues and provides advantageous solutions.
OBJECTS AND SUMMARY OF THE INVENTION
[0005] One object of the invention is to provide a mounting bracket for a supporting a monitor and a keyboard.
[0006] Another object of the invention is to provide mounting bracket having a track for attachment to a vertical wall or post.
[0007] Yet another object of the invention is to provide a height-adjustable monitor support for slidably engaging the track.
[0008] Still another object of the invention is to provide mounting bracket having a keyboard support.
[0009] Yet another object of the invention is to provide an autoflip rotatable keyboard support.
[0010] It must be understood that no one embodiment of the present invention need include all of the aforementioned objects of the present invention. Rather, a given embodiment may include one or none of the aforementioned objects. Accordingly, these objects are not to be used to limit the scope of the claims of the present invention.
[0011] In summary the present invention is directed to an adjustable support member for mounting a device, comprising a vertically elongated support track having a top end and a bottom end and a plurality of parallel channels extending between said top end and said bottom end and a carriage assembly having a support surface and channel engaging members wherein said carriage assembly is adapted to be retained by said channels and slide along said channels and an actuator assembly being operable to releasably retain said carriage assembly in a fixed position relative to said support track.
[0012] The present invention is further directed to a height-adjustable support system, comprising a vertically elongated mounting bracket adapted to be attached to a support surface and said mounting bracket including a vertically elongated support track having a top end and a bottom end and a plurality of parallel channels extending between said top end and said bottom end and a carriage assembly having a support surface and channel engaging members wherein said carriage assembly is adapted to be retained by said channels and slide along said channels and said carriage assembly including a support plate adapted to support a computer monitor and said carriage assembly further including a keyboard support and an actuator assembly being operable to releasably retain said carriage assembly in a fixed position relative to said support track.
[0013] The present invention is still further directed to an adjustable support bracket for mounting a device, including a vertically elongated support track having a plurality of parallel channels extending vertically, a carriage assembly having a support surface and channel engaging members wherein said carriage assembly is retained by and slidable along said channels, an actuator assembly including a gas spring assembly that includes a valve, wherein said gas spring assembly releasably retains said carriage assembly at desired locations along said support track, and said actuator assembly further includes a lever that is connected to a rod having an actuator trigger operatively connected to the valve of said gas spring assembly, wherein the lever is movable to open and close said valve.
[0014] The present invention also is directed to a height-adjustable support system, including a vertically elongated support track having a top end and a bottom end and a plurality of parallel channels extending between said top end and said bottom end, a carriage assembly having a support surface and channel engaging members wherein said channel engaging members of said carriage assembly are retained by and slidable along said channels of said support track, said carriage assembly including a support plate spaced apart from and being positioned above a keyboard support, an actuator assembly including a movable rod having an actuator trigger at one end and being pivotally connected to an actuator lever at an opposed end, the actuator trigger being connected to a valve of a gas spring assembly that is connected at a first end to said support track and at a second end to said carriage assembly, and wherein said actuator assembly releasably retains said carriage assembly at positions along said support track.
[0015] The present invention is further directed to a spring-biased keyboard support, comprising a substantially flat keyboard support surface and a spring-biased hinge connected to said keyboard support surface and to a second support surface whereby said spring-biased hinge operates to automatically flip said keyboard support surface upright.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of the adjustable support bracket;
[0017] FIG. 2 is an exploded view of the adjustable support bracket of FIG. 1 ;
[0018] FIG. 3 is a rear perspective view of the track extrusion;
[0019] FIG. 4 is a front perspective view of the track extrusion;
[0020] FIG. 5 is a top view of the track extrusion of FIGS. 3 and 4 ;
[0021] FIG. 6 is a rear perspective view of the carriage assembly;
[0022] FIG. 7 is a perspective view of the actuator assembly;
[0023] FIG. 8 is enlarged view of the actuator trigger block of FIG. 7 ;
[0024] FIG. 9 is an enlarged view of the actuator chassis of FIG. 7 ;
[0025] FIG. 10 is a perspective view of the actuator trigger;
[0026] FIG. 11 is a perspective view of the lever;
[0027] FIG. 12 is a perspective view of the autoflip keyboard support; and,
[0028] FIG. 13 is an exploded view of the autoflip keyboard support of FIG. 12 .
[0029] FIG. 14 is a perspective view of a second example adjustable support bracket;
[0030] FIG. 15 is a front exploded perspective view of the adjustable support bracket of FIG. 14 , without the wallmount plate used to connect to a wall;
[0031] FIG. 16 is a rear perspective view of the carriage assembly;
[0032] FIG. 17 is a top view of the track extrusion of adjustable support bracket of FIG. 14 ;
[0033] FIG. 18 is a rear exploded perspective view of the track extrusion and wallmount plate of the adjustable support bracket of FIG. 14 ;
[0034] FIG. 19 is a front perspective view of the actuator assembly of the adjustable support bracket of FIG. 14 ;
[0035] FIG. 20 is a rear perspective view of the actuator assembly of the adjustable support bracket of FIG. 14 ;
[0036] FIG. 21 is a rear exploded perspective view of the actuator assembly of the adjustable support bracket of FIG. 14 ;
[0037] FIG. 22 is a front perspective view of the autoflip keyboard support of the adjustable support bracket of FIG. 14 ;
[0038] FIG. 23 is a rear perspective view of the autoflip keyboard support shown in FIG. 22 ; and,
[0039] FIG. 24 is a front exploded perspective view of the autoflip keyboard support shown in FIG. 22 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] The preferred forms of the invention will now be described with reference to two example embodiments, shown in FIGS. 1-13 and 14 - 24 , respectively. The appended claims are not limited to the preferred forms and no term and/or phrase used herein is to be given a meaning other than its ordinary meaning unless it is expressly stated otherwise.
[0041] In FIG. 1 , a mount or adjustable support bracket 10 is shown having an elongated vertical section 12 having a plate 14 for attachment to a computer monitor or the like (not shown) and a horizontally extending surface 16 suitable for supporting a computer keyboard (also not shown). Now with reference the exploded view of FIG. 2 , the mount or adjustable support bracket 10 includes a wallmount plate 20 which is designed to be fixedly secured by conventional fasteners to a vertical surface such as a wall or post. The wallmount plate 20 is preferably formed of substantially rigid material, preferably aluminum and is generally flat. The wallmount plate 20 includes pairs of upper and lower flanges 22 and 24 extending outwardly from the main body 26 .
[0042] A track extrusion 28 formed of rigid material and preferably aluminum is shown in FIGS. 1 , 2 , 3 , 4 and 5 . Looking at the rear wall 30 of the track extrusion 28 in FIG. 3 , a pair of recesses 32 is formed and extends the length of the extrusion 28 . Four flanges 34 extend from the recesses 32 and engage wallmount flanges 22 and 24 when the track extrusion 28 is connected to the wallmount plate 20 . Track extrusion 28 as seen in FIG. 4 includes a pair of channels 36 and 38 extending vertically preferably the entire length of track extrusion 28 . As shown in FIG. 5 , channels 36 and 38 each include a slot-forming flange or rail 40 , 42 respectively. Track extrusion 28 also includes a central tube 44 extending the length of the track extrusion 28 . A slot 46 is formed on front wall 48 .
[0043] A carriage assembly 50 is moveably mounted to the track extrusion 28 . As shown in FIGS. 1 , 2 , and 6 , carriage assembly 50 includes a generally elongated front flat surface 52 and carriage roller wheel supporting strips 54 on each side of the front flat surface 52 . The carriage roller wheels 56 are retained on the supporting strips 54 by shoulder bolts 58 .
[0044] The carriage assembly 50 is mounted to the track extrusion 28 by inserting roller wheels 56 into channels 36 and 38 . The roller wheels are then retained in channels 36 and 38 by flanges 40 and 42 respectively, but are free to roll within the channels.
[0045] A pair of end caps 58 and 60 joins the wallmount plate 20 and the track extrusion 28 together and keeps them from sliding relative to each other. End caps 58 and 60 also provide stops for the carriage assembly 50 and keep it from rolling out of the channels 36 and 38 .
[0046] Now the actuator assembly 70 will be described with respect to FIGS. 1 , 2 , 7 , 8 and 9 . The actuator assembly 70 preferably includes a gas spring cylinder 72 having a gas spring rod 74 . The gas spring cylinder 72 is mounted to a footing plate 76 preferably by a threaded fastener assembly 78 . The footing plate 76 is attached at the foot 78 of the track extrusion 28 and is covered by end cap 60 . The gas spring cylinder 72 extends into the central tube 44 of the track extrusion.
[0047] At the top 80 of the gas spring rod is a valve 82 which allows air into and out of the gas spring cylinder 72 . Operation of the valve 82 is accomplished by movement of an actuator trigger 84 held within the actuator trigger block 86 . The actuator trigger block 86 is connected by conventional screws to the flat front surface 52 of the carriage assembly 50 . The actuator trigger 84 as shown in FIG. 10 is generally rectangular and has a recess 88 on the bottom thereof and a U-shaped forked slot 90 on one end. The recess 88 engages the valve 82 to limit airflow and when the trigger 84 is released air is allowed to flow into or out of the valve 82 . A trigger pivot screw 92 is provided to adjust the degree of movement of the trigger 84 . The U-shaped forked slot 90 receives the top end 94 of pull cable 96 . Pull cable 96 extends downwardly from the trigger block 86 to actuator lever chassis 100 .
[0048] Actuator chassis 100 includes a lever 102 . Lever 102 as shown in FIG. 11 includes a chiseled end 104 . Spaced from chiseled end 104 is a horizontal opening 106 for receiving a pivot pin 108 . Pivot pin 108 is fixed to the actuator chassis 100 and retains the lever 102 within the chassis 100 . Spaced from horizontal opening 106 is a round vertical opening 110 having a slot 112 extending along the lever 102 away from chiseled end 104 . Opening 110 and slot 112 are adapted to receive and retain the second end 114 of the pull cable 96 . Pull cable 96 includes an outer housing 116 which includes upper fasteners 118 and lower fastener 120 to connect the housing 116 to the trigger block 86 and the actuator chassis 100 . A compression spring 122 is located within the actuator chassis 100 and operates to bias the lever 102 upwardly. A plunger screw 124 operates to engage the chiseled end 104 of the lever 102 to limit movement of the lever 102 . When the plunger screw 124 is backed off, the lever 102 is free to rotate.
[0049] Now with reference to FIGS. 1 , 2 , 12 and 13 the auto flip keyboard support assembly will be described. Preferably at the flat front surface 52 of the carriage assembly 50 , a keyboard support assembly 200 is mounted. The keyboard support 200 is attached to an auto flip chassis 202 having a base member 204 for attachment to the flat front surface 52 . The base member 204 includes an arcuate base wall 206 having a pair of spaced apart circular flanges 208 extending therefrom. Each of the flanges 208 includes a central opening 210 for receiving preferably a brass bushing 212 . On each outer side of the circular flanges 208 are preferably fastened a nylon washer 214 , a pivot lobe 216 , an SAE washer 218 , and a pair of bore caps 224 . Located between the circular flanges 208 is a torsion spring 226 and an alignment bushing 228 . A shoulder bolt 229 passes through these parts and is connected to a nylock nut 220 to hold the parts together. A keyboard attachment plate 230 is preferably screwed to the pivot lobes 216 . A set screw 232 is attached to the base member 204 and engages a first arm 234 of the torsion spring 226 . A second arm 238 of the torsion spring engages the keyboard plate 230 so that the spring can cause rotation of the keyboard plate 230 relative to the base member. The set screw 232 can be adjusted so that tension on the torsion spring 226 can be increased or decreased.
[0050] In operation, the actuator assembly 70 permits vertical adjustment of the plate 14 and the keyboard support assembly 200 in a single handed motion vertically by moving the lever 102 downwardly which causes pull cable 96 to move actuator trigger 84 and open valve 82 of the gas spring cylinder 72 . Once the valve 82 is opened, the carriage assembly 50 can be slid upward or downward. To lock the carriage assembly 50 in a desired position, the lever 102 is simply released and valve 82 is closed by the actuator trigger 84 .
[0051] It should be understood that the rigid materials used in the manufacture of the mount or adjustable support bracket 10 unless specifically identified can be aluminum or other suitably rigid materials such as other metals or plastics.
[0052] A second preferred form of the invention will now be described with reference to FIGS. 14-24 .
[0053] In FIG. 14 , an adjustable support bracket 310 is shown having an elongated vertical section 312 having a plate 314 for attachment to a computer monitor or the like (not shown) and a horizontally extending surface 316 suitable for supporting a computer keyboard (also not shown). Now with reference the exploded views of FIGS. 15 and 18 , the adjustable support bracket 310 includes a wallmount plate 320 which is designed to be fixedly secured by conventional fasteners to a vertical surface such as a wall or post. The wallmount plate 320 is preferably formed of substantially rigid material, preferably aluminum or other suitable material and is generally flat. The wallmount plate 320 includes pairs of upper and lower flanges 322 and 324 , respectively, extending outwardly from a main body 326 .
[0054] A track extrusion 328 formed of rigid material and preferably aluminum or other suitable material is shown in FIGS. 14 , 15 , 17 and 18 . Looking at the rear wall 330 of the track extrusion 328 , in FIGS. 17 and 18 , a pair of recesses 332 is formed and extends the length of the extrusion 328 . Four flanges 334 extend from the recesses 332 and engage wallmount flanges 322 and 324 when the track extrusion 328 is connected to the wallmount plate 320 . Track extrusion 328 as seen in FIGS. 15 and 17 includes a pair of channels 336 and 338 extending vertically preferably the entire length of track extrusion 328 . As shown in FIG. 17 , channels 336 and 338 each include a slot-forming flange or rail 340 , 342 respectively. Track extrusion 328 includes a central tube 344 extending the length of the track extrusion 328 . A slot 346 is formed through a front wall 348 . Opposed channels 347 of the track extrusion 328 receive covers 349 for a more finished appearance.
[0055] A carriage assembly 350 is moveably mounted to the track extrusion 328 . As shown in FIGS. 14 and 15 , carriage assembly 350 includes a generally elongated front flat surface 352 and carriage bushing supporting strips 354 on each side of the front flat surface 352 . The carriage bushings 356 are retained on the bushing supporting strips 354 by friction and by being located within the channels 336 and 338 . The plate 314 also is pivotally connected at post 357 to the carriage assembly 350 .
[0056] The carriage assembly 350 is mounted to the track extrusion 328 by inserting the carriage bushings 356 on the bushing supporting strips 354 into channels 336 and 338 . The carriage bushings 356 are then retained in channels 336 and 338 by flanges 340 and 342 , respectively, but are free to slide within the channels 336 and 338 .
[0057] A pair of end caps 358 and 360 joins the wallmount plate 320 and the track extrusion 328 together and keeps them from sliding relative to each other. End caps 358 and 360 also provide stops for the carriage assembly 350 and keep it from sliding out of the channels 336 and 338 .
[0058] An actuator assembly 370 will be described with respect to FIGS. 14 and 19 - 21 . The actuator assembly 370 preferably includes a gas spring cylinder 372 having a gas spring rod 374 . The gas spring cylinder 372 is mounted to a footing plate 376 preferably by a threaded fastener assembly 378 . The footing plate 376 is attached at the foot of the track extrusion 328 and is covered by end cap 360 . The gas spring cylinder 372 extends into the central tube 344 of the track extrusion 328 .
[0059] At the top 380 of the gas spring rod 374 is a valve 382 which allows air into and out of the gas spring cylinder 372 . Operation of the valve 382 is accomplished by movement of an actuator trigger 384 at the upper end of a flat rod 385 that is slidably held by an actuator trigger block 386 . The actuator trigger block 386 is efficiently connected to the carriage assembly 350 . The actuator trigger block 386 has flanges 388 that extend outwardly. The actuator trigger block 386 is inserted rearwardly through an aperture 390 in the carriage assembly 350 until the flanges 388 engage the front surface 352 thereof. Fasteners 392 , such as screws, rivets or other suitable fastening means, then are passed through apertures 394 in the carriage assembly 350 . The trigger block 386 extends through the slot 346 in the front wall 348 of the track extrusion 328 where it is connected to the gas spring rod 374 of the gas spring cylinder 372 that is located within the central tube 344 of the track extrusion 328 .
[0060] The components of the actuator assembly 370 are best seen in FIGS. 15 and 19 - 21 . The rod 385 of the actuator assembly 370 is pivotally connected at its opposite end 395 to a post 396 on a lever 398 . The lever 398 has a handle 400 at one end for grasping by a user and the opposite end 399 is pivotally connected to a post 402 on the rear of a lever chassis 404 . The posts 396 and 402 are spaced apart, such that pivotal movement of the lever 398 drives the rod 385 up or down. A biasing member 406 biases the lever 398 upwardly to a position that closes the valve 382 . The lever chassis 404 is connected to the carriage assembly 350 by fasteners 408 , such as conventional screws, rivets or other suitable means of connection. The lever chassis 404 has rearward and downward extending bayonet type hooks 410 that are inserted into slots 412 in the front surface 352 of the carriage assembly 350 , while a lower flange 414 on the lever chassis 404 is inserted into a further slot 416 in the face 352 of the carriage assembly 350 . The lever chassis 404 then is moved downward to engage the hooks 410 and lower flange 414 with the carriage assembly 350 . Fasteners 418 , such as screws, rivets or other suitable fastening means are then used to fix the lever chassis 404 in a position connected to the carriage assembly 350 .
[0061] Now with reference to FIGS. 14 and 22 - 24 an auto flip keyboard support assembly will be described. Preferably at the flat front surface 352 of the carriage assembly 350 , a keyboard support assembly 400 is connected. The keyboard support assembly 400 is attached to an auto flip chassis 402 having a base member 404 for attachment to the flat front surface 352 . The base member 404 includes an arcuate base wall 406 having a pair of spaced apart circular shaped flanges 408 extending therefrom. Each of the flanges 408 includes a central opening 410 for receiving preferably a bushing 412 . The bushing 412 includes a washer portion 414 that contacts the outer side of the flange 408 . A keyboard plate 415 includes a pair of pivot lobes 416 . The keyboard plate 415 is connected to the base member 404 by using shoulder bolt 417 , washers 418 , and a nylock nut 420 . The head of the bolt 417 and nut 420 are covered, respectively, by a pair of bore caps 424 .
[0062] Located between the flanges 408 is an alignment bushing 428 that is received through the center of a torsion spring. The torsion spring is not shown in FIG. 24 but may be similar to the torsion spring 226 of the first example embodiment. An arm of the torsion spring engages the keyboard plate 415 to cause rotation of the keyboard plate 415 relative to the base member 404 . A cover 430 fits over the torsion spring and alignment bushing 428 and includes a flange 432 by which the cover 430 is held in place when the base member 404 is connected to a keyboard support tray 434 . A pair of set screws 436 is attached to the keyboard plate 415 in threaded bores 438 and may be rotated to advance inward and engage apertures 440 in the flanges 408 in the base member 404 . Optionally, a set screw 442 , such as the set screw 232 from the first example embodiment, engages an arm of the torsion spring and may be used to adjust the tension of the torsion spring, as desired. The base member 404 is connected to the carriage assembly 350 , and the keyboard support tray 434 is connected to the keyboard plate 415 , by fasteners, such as screws or other suitable fastening means.
[0063] In operation, the actuator assembly 370 permits vertical adjustment of the plate 314 and the keyboard support assembly 400 in a single handed motion vertically by moving the lever 398 downwardly, which in turn moves the rod 385 and its actuator trigger 384 and opens the valve 382 of the gas spring cylinder 372 . Once the valve 382 is opened, the carriage assembly 350 can be slid upward or downward on the track extrusion 328 . To lock the carriage assembly 350 in a desired position, the lever 398 is simply released and valve 382 is closed by the actuator trigger 384 .
[0064] It should be understood that the rigid materials used in the manufacture of the adjustable support bracket 310 unless specifically identified can be aluminum or other suitably rigid materials such as other metals or plastics.
[0065] While this disclosure describes preferred example embodiments, it is understood that the designs may be further modified or adapted while still practicing the general principles of the invention. The claims are not limited to the preferred embodiments and have been written to preclude such a narrow construction using the principles of claim differentiation.
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A height-adjustable support system including a vertically elongated support track having a top end and a bottom end and a plurality of parallel channels extending therebetween, a carriage assembly having a support surface and channel engaging members wherein said carriage assembly is adapted to be retained by said channels and slide along said channels, said carriage assembly including a support plate adapted to support a computer monitor and a keyboard support, and an actuator assembly being operable to releasably retain said carriage assembly along said support track.
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BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to color conversion of display devices, and more particularly, to an apparatus for converting a first color in a first color space to a second color in a second color space and a method thereof.
[0003] 2. Description of the Prior Art
[0004] Graphic systems convert image signals into a visible form and vice versa. Examples of common graphic systems include: cathode-ray tube (CRT) monitors, liquid crystal display (LCD) monitors, projection displays, digital cameras, scanners, camcorders, printers, etc. Different graphic systems have different image signal requirements meaning that the image signals for a particular graphic system are notnecessarily compatible with other graphic systems. For example, the image signal format used in a digital overhead projector is not the same image signal format used in a printer. Even among graphic systems that both use RGB image signals, such as two LCD monitors, because each monitor has different display characteristics, the image signals producing a particular color on one monitor do not necessarily produce the identical color on another monitor. The particular display characteristics for a graphic system are also referred to as the device color space. Difficulties arise when trying to accurately reproduce color across open systems having different devices using different color spaces. Particularly with the advent of the Internet, it is imperative that all graphic systems exchange color information accurately and easily.
[0005] The International Color Consortium (ICC) has proposed a solution to the problem of communicating color in open systems, which involves attaching a profile for the input color space to the image file in question. This is appropriate for high end users but there are a broad range of users that do not require this level of flexibility and control. Additionally, most existing file formats do not support color profile embedding and, in fact, there are manyapplications that oppose appending any extra data to data files.
[0006] The standard default RGB color space (sRGB) developed by Hewlett-Packard and Microsoft provides a single RGB representation of color independent of the graphic system and has been standardized by the International Electrotechnical Commission (IEC) as IEC 61966-2-1. When using the sRGB specification, RGB values in the sRGB color space must be mapped to a corresponding RGB value in the destination color space and vice versa. Performing a mapping involves executing a matrix multiplication to adjust a first color value in the first color space to a second color in a second color space.
[0007] FIG. 1 shows the sRGB conversion formula 10 for mapping an sRGB value (R, G, B) to a destination dependent color space value (R′,G′, B′) according to the sRGB specification. As shown in FIG. 1 , the second red value R′ is formed using a portion of the first red value R, the first green value G, and the first blue value B depending on the adjustment coefficients r1, g1, and b1 respectively. Similarly, the second green value G′ and the second blue value B′ are both formed using a portion of the first red value R, the first green value G and the first blue value B. The sRGB values are stored as 8 bit integers and the adjustments coefficients are stored as 10-bit floating-point values. Using standard matrix multiplication, the following formulas for the R′, G′, and B′values are derived:
R ′=( R*r 1+ G*g 1+ B*b 1) G ′=( R*r 2+ G*g 2+ B*b 2) B ′=( R*r 3+ G*g 3+ B*b 3)
[0008] To calculate the second red value R′, the first RGB values are first converted to floating-point values:
R float =R /255.0
G float =G /255.0
B float =B /255.0
[0009] A multiplier then multiplies the R float , G float , and B float with the first red adjustment coefficient r1, the first green adjustment coefficient g1, and the first blue adjustment coefficient b1 respectively and adds the multiplication results together. The second floating-point red value is then converted back to an 8-bit integer and similar procedures are followed for the G′ and the B′ values. The following formulas show the full process and can be computed concurrently if sufficient hardware resources are available:
R ′=round(255.0 *[r 1 *R float +g 1 *G float +b 1 *B float ])
G ′=round(255.0 *[r 2* R float +g 2 *G float +b 2 *B float ])
B ′=round(255.0 *[r 3* R float +g 3 *G float +b 3 *B float ])
[0010] In today's competitive consumer electronic marketplace, the performance of graphic systems must be as high as possible while keeping the price as low as possible. In other words, the conversion from a first color space to a second color space needs to be executed as fast as possible and with minimal hardware requirements. However, the conversions from integer to floating point, the conversions from floating point to integer, and the multiplications all require non-trivial processing time and specialized hardware. An efficient and cost effective implementation is needed.
SUMMARY OF INVENTION
[0011] It is therefore a primary objective of the claimed invention to provide a method and apparatus for color conversion having high-speed and minimal hardware, to solve the above-mentioned problems.
[0012] According to the claimed invention, a color conversion apparatus is disclosed for converting a first color space to a second color space, wherein both the first and the second color space at least include a first color element and a second color element. The color conversion apparatus comprises a look-up-table for storing a relationship between the first color space and the second color space and a converter for converting the first color space to the second color space according to the relationship stored in the look-up-table.
[0013] According to the claimed invention, a method of color conversion is disclosed for converting a first color space to a second color space, wherein both the first and the second color space at least include a first color element and a second color element. The method comprises providing a look-up-table for storing a relationship between the first color space and the second color space, and converting the first color space to a second color space according to the relationship stored in the look-up-table.
[0014] These and other objectives of the claimed invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIG. 1 is the sRGB conversion formula according to the prior art.
[0016] FIG. 2 is a lookup table for implementing the G*g1 multiplication according to the present invention.
[0017] FIG. 3 is a diagram showing the lookup table of FIG. 1 implemented with a 32-byte memory.
[0018] FIG. 4 is a first embodiment of a color conversion apparatus of the present invention.
[0019] FIG. 5 is a second embodiment of a color conversion apparatus of the present invention.
[0020] FIG. 6 is a third embodiment of an LCD color conversion apparatus of the present invention.
[0021] FIG. 7 is a flowchart describing the method of color conversion according to the present invention.
DETAILED DESCRIPTION
[0022] According to the present invention, a lookup table is used to replace the hardware circuit for calculating each multiplication in the formula 10 shown in FIG. 1 . For example, the multiplication of R with the adjustment coefficient r1 can be replaced with a 256-element lookup table. The lookup table is indexed with the R-value and maps to the result of the multiplication of R with the adjustment coefficient r1. The lookup table can be implemented with a 256-byte memory having the address inputs connected to the R-value and the value stored at each address being the result of R*r1 for all values of R. This implementation runs much faster than a hardware multiplier and eliminates the need for specialized conversion and multiplication hardware. The disadvantage of a 256-element lookup table is that nine 256-byte memories are required, one for each multiplication by an adjustment coefficient.
[0023] FIG. 2 shows a simplified lookup table 12 for implementing the G*g1 multiplication. Although, the second red value R′ is affected by the first red value R, the first green value G, and the first blue value B; in actual practice, the first green value G and the first blue value B have a very small effect on the second red value R′. This means that the lookup tables for the adjustment coefficients g1 and b1 can be simplified. As shown in FIG. 2 , first green values G are grouped together and the members of each group return the same result for the multiplication of G*g2. For example, G-values belonging to the set of {0, 1, 2, 3, 4, 5, 6, 7} all return the same output value g1[0]. Although mathematically incorrect, this approximation is justified due to the insignificant difference between the different members of each group and the small overall effect of the first green value G on the second red value R′. Similar simplified lookup tables are used for the other low effect adjustment coefficients b1, r2, b2, r3, and g3.
[0024] Additionally, it should be mentioned that although FIG. 2 shows groups of eight first green values G, depending on different destination color spaces, other group sizes can also be used. If, for a particular destination color space, the first green value G has a greater effect on the second red value R′, the g1 lookup table can have smaller groups of G-values. Smaller groups of G values increases the resolution of the g1 lookup table at the cost of increased table size. Likewise, if the first green value G has an even smaller effect on the second red value R′, the g1 lookup table can have larger groups of G values. The group sizes for the other lookup tables b1, r2, b2, r3, and g3 can also be adjusted to reflect their actual effect on the second color value.
[0025] FIG. 3 shows a schematic diagram 20 of the lookup table of FIG. 2 implemented with a 32-byte memory 22 . The memory 22 has a 5-bit address input having an MSB of A 4 and an LSB of A 0 , and an 8-bit data output having an MSB of D 7 and an LSB of D 0 . The first green value G is an 8-bit value having an MSB of G 7 and an LSB of G 0 and the top five most significant bits (G 7 to G 3 ) are connected to the memory 22 address inputs (A 4 to A 0 ) respectively. Based on the address, the memory 22 returns the result of the multiplication of G*g1, which is stored at the particular address location. By not using the least significant bits of the first green value G, the G-values are effectively grouped into groups of eight as in FIG. 2 .
[0026] As stated earlier, the second red value R′ is primarily determined by the first red value R. In fact, the color conversion between the first red value R and the second red value R′ can be accomplished through gamma correction. Similarly the second green value G′ is primarily determined by the gamma correction of the first green value G and the second blue value B′ is primarily determined by the gamma correction of the first blue value B. To further simply the implementation, the multiplications by the adjustment coefficients r1, g2, and b3 in FIG. 1 can be directly replaced with the result of a gamma correction circuit. Gamma correction accounts for the non-linear detection of luminance by the human eye under different light conditions. As gamma correction is well known in the art, further description of the actual gamma correction circuit is herby omitted.
[0027] FIG. 4 shows a first embodiment of a color conversion apparatus 30 of the present invention. The color conversion apparatus 30 converts a first color having red, green, and blue values (R, G, B) in a first color space to a second color having second red, green, and blue values (R′, G′, B′) in a second color space. The color conversion apparatus 30 includes a gamma correction circuit 32 , a g1 lookup table 34 , a b1 lookup table 36 , an r2 lookup table 38 , a b2 lookup table 40 , an r3 lookup table 42 , a g3 lookup table 44 , a first adder 46 , a second adder 48 , and a third adder 50 . Each of the lookup tables 34 , 36 , 38 , 40 , 42 , 44 is implemented with a 32-byte memory as shown in FIG. 3 . The first red value R is connected to the gamma correction circuit 32 , the g1 lookup table 34 , and the b1 lookup table 36 . The first green value G is connected to the gamma correction circuit 32 , the r2 lookup table, and the b2 lookup table. Finally the first blue value B is connected to the gamma correction circuit, the r3 lookup table, and the g3 lookup table. The output of the g1 lookup table 34 , which is the result of the multiplication of G*g1; the output of the b1 lookup table 36 , which is the result of the multiplication of B*b1; and the gamma corrected R-value r1-gamma are added together by the first adder 46 . The output of the first adder 46 is the second red value R′. The second adder 48 adds together the output of the r2 lookup table 38 , which is the result of the multiplication of R*r2; the output of the b2 lookup table 40 , which is the result of the multiplication of B*b2; and the gamma corrected G-value g2-gamma to produce the second green value G′. Similarly, the third adder 50 adds together the output of the r3 lookup table 42 , which is the result of the multiplication of R*r3; the output of the g3 lookup table 44 , which is the result of the multiplication of G*g3; and the gamma corrected B-value b3-gamma to produce the second green value B′.
[0028] FIG. 5 shows a second embodiment of a color conversion apparatus 51 of the present invention. The color conversion apparatus 51 converts a first color having red, green, and blue values (R, G, B) in a first color space to a second color having second red, green, and blue values (R′, G′, B′) in a second color space. The color conversion apparatus 51 includes a g1 lookup table 52 , a b1 lookup table 54 , an r2 lookup table 56 , a b2 lookup table 58 , an r3 lookup table 60 , a g3 lookup table 62 , a first adder 64 , a second adder 66 , a third adder 68 , and a gamma correction circuit 70 . Each of the lookup tables 52 , 54 , 56 , 58 , 60 , 62 is implemented with a 32-byte memory as shown in FIG. 3 . The first red value R is connected to the g1 lookup table 52 and the b1 lookup table 54 . The first green value G is connected to the r2 lookup table 56 and the b2 lookup table 58 . Finally the first blue value B is connected to the r3 lookup table 60 and the g3 lookup table 62 . The output of the g1 lookup table 52 , which is the result of the multiplication of G*g1, and the output of the b1 lookup table 54 , which is the result of the multiplication of B*b1, are added together by the first adder 64 . The second adder 66 adds together the output of the r2 lookup table 56 , which is the result of the multiplication of R*r2, and the output of the b2 lookup table 58 , which is the result of the multiplication of B*b2. Similarly, the third adder 68 adds together the output of the r3 lookup table 60 , which is the result of the multiplication of R*r3, and the output of the g3 lookup table 62 , which is the result of the multiplication of G*g3. The output of the first adder 64 (R″), the second adder 66 (G″), and the third adder 68 (B″) are connected to the gamma correction circuit 70 and the output of the gamma correction circuit 70 is the second color value comprising the second red value R′, the second green value G′, and the second blue value B′.
[0029] FIG. 6 shows a third embodiment of an LCD color conversion apparatus 80 of the present invention. The LCD color conversion apparatus 80 includes an A/D converter 82 , a converter 84 , a plurality of color lookup tables 86 , a gamma correction circuit 88 , a D/A converter 90 , an amplifier 92 , and an LCD display 94 . The converter 84 , the plurality of color lookup tables 86 , and the gamma correction circuit 88 form a color conversion apparatus 76 , which can be implemented as shown in FIG. 4 or FIG. 5 . A first color having red, green, and blue components in the sRGB color space is converted to 8-bit digital form by the A/D converter 82 . The converter 84 uses the plurality of lookup tables 86 and the gamma correction circuit 88 to convert the incoming color in the sRGB color space to a corresponding color in the color space of the LCD display 94 . The output of the converter 84 is connected to the D/A converter 90 , which converts the corresponding color to analog RGB signals. The analog RGB signals are amplified by the amplifier 92 and drive the LCD display 94 .
[0030] FIG. 7 shows a flowchart 100 describing the method of color conversion according to the present invention. The flowchart 100 describes the method for converting a first color having red, green, and blue values (R, G, B) in a first color space to a second color having second red, green, and blue values (R′, G′, B′) in a second color space and includes the following steps:
[0031] Step 102 :Provide a plurality of color lookup tables for the multiplications by the adjustment coefficients r2, r3, g1, g3, b1, and b2. The lookup tables provide the multiplication of R*r2, R*r3, G*g1, G*g3, B*b1, and B*b2 respectively, as required by the sRGB conversion formula 10 shown in FIG. 1 .
[0032] Step 104 :Minimize the lookup table sizes by grouping similar input colors. Because there is very little numerical difference between the adjacent input colors and a very small overall effect on the second color, each lookup table is reduced in size by lowering the number of output values. Similar input colors values are grouped together and mapped to the same multiplication result in each lookup table. A memory can be used to implement each lookup table, the address inputs of the memory being connected to the upper most significant bits of the input color. With 8-bit RGB values, if groups of eight input colors map to the same output value, the lookup table implementation is reduced from a 256-byte memory to a 32-byte memory with no adverse effect on color conversion performance.
[0033] Step 106 :Use a gamma correction circuit to calculate the adjustment coefficients r1, g2, and b3. Because the gamma correction of the first color value is the primary cause of adjustment on the second color value, the multiplications by r1, g2, and b3 are directly replaced with the result of the gamma correction circuit. By using the gamma correction circuit, three lookup tables are eliminated and the overall design is simplified.
[0034] Those skilled in the art will readily observe that numerous modifications and alterations of the device may be made while retaining the teachings of the invention. Accordingly, that above disclosure should be construed as limited only by the metes and bounds of the appended claims.
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A color conversion apparatus and a method of color conversion are described for converting a first color in a first color space to a second color in a second color space. The color conversion apparatus includes a plurality of lookup tables storing color mappings relating the first color space to the second color space and a converter using the lookup tables to convert the first color to the second color. The first color space is the sRGB color space and the second color space is a device dependent color space, or vice versa. To reduce the table size, tables having little effect on the second color contain groups of input colors mapping to a same output color and are implemented with a memory having the address inputs connected to the upper most significant bits of an incoming color value. A gamma correction circuit is used to calculate the remaining tables.
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FIELD OF INVENTION
This invention relates generally to a process for forming semiconductor devices, and more particularly to a process for forming complementary insulated gate field effect transistors including doped field isolation regions.
BACKGROUND OF THE INVENTION
Trends in the semiconductor industry indicate a growing importance for devices of the complementary insulated gate field effect transistor (Complementary IGFET or CMOS) type. As used in integrated circuits, complementary IGFET devices, in turn, are decreasing in size and increasing in density. To successfully manufacture these devices requires a process which is easily manufacturable, provides adequate isolation between devices, and provides acceptably low leakage within each device.
Isolation between devices is achieved by providing a thick field oxide with a suitably doped region aligned beneath the thick oxide. The doped region is usually formed by ion implantation and must have a concentration of dopant which is carefully controlled to provide an acceptably high field threshold voltage without reducing the breakdown voltage of the junction formed between the doped region and an adjacent source or drain region to a value below the value of operating voltages used within the circuit.
As the size of the devices used in an integrated circuit are reduced further and further, the so called "short channel" effects begin to become important. As the channel length decreases, for a given operating voltage, punch through caused by the spread of the drain depletion region into the channel region becomes significant. Some protection against punch through is afforded by a subsurface increase, for example by ion implantation, in the doping of the device substrate beneath the channel region. The punch through protection implant is of the same doping type as the field enhancement implant, but is typically of a different magnitude and a different location within the device.
In addition to meeting electrical specifications, the integrated circuit must be commercially manufacturable. The ability to successfully manufacture an integrated circuit is enhanced by reducing the number of masking layers required to implement the process and by reducing the criticality of alignment of each masking layer. A process for fabricating a complementary IGFET circuit which will have the required physical and electrical characteristics and which will be useful in a manufacturing environment, therefore, requires steps for implementing doped field regions and, where needed, punch through protection. These must be implemented with a minimum of additional masking steps and with a minimum of critical masking steps.
It is therefore an object of this invention to provide an improved process for fabricating a complementary insulated gate field effect transistor circuit.
It is another object of this invention to provide an improved process for fabricating complementary IGFET devices having complementary doped field regions.
It is still another object of this invention to provide an improved process for fabricating semiconductor devices including doped field regions and punch through protection.
It is yet a further object of this invention to provide an improved process for fabricating semiconductor devices including non-compensating doped field regions with optional punch through protection.
SUMMARY OF THE INVENTION
The foregoing and other objects and advantages of the invention are achieved through a process in which a minimum number of masking layers are used in combination with multiple ion implantations. In accordance with one embodiment of the invention complementary insulated gate field effect transistors are fabricated by first providing a silicon substrate having first and second surface regions which are doped N-type and P-type, respectively. A first masking layer is formed overlying the two surface regions and is patterned to leave portions of the masking layer overlying the active regions of each of the first and second surface regions. P-type impurities are then implanted into those portions of both the first and second surface regions which are not covered by and protected by the patterned first masking layer. A second masking layer is formed overlying the P-type second surface region and N-type impurities are implanted into the surface at an implant energy which is sufficient to cause the implanted ions to penetrate through the first masking layer but not through the second masking layer. A second implant of N-type material is then performed into those portions of the first surface region which are not protected by the first masking layer. Isolation is completed by oxidizing the silicon substrate to form a field oxide at portions of the first and second surface regions which are not covered by the first masking layer. Fabrication of the complementary devices in the active regions then proceeds in the normal manner as, for example, with a standard silicon gate MOS process.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-4 illustrate, in cross-section, process steps in accordance with one embodiment of the invention;
FIGS. 5-7 illustrate, in cross-section, process steps in accordance with a further embodiment of the invention;
FIGS. 8-11 illustrate, in cross-section, process steps in accordance with a still further embodiment of the invention;
FIGS. 12-15 illustrate, in cross-section, process steps in accordance with yet another embodiment of the invention; and
FIG. 16 illustrates, in cross-section, a partially completed complementary insulated gate field effect transistor structure in accordance with the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1-15 illustrate schematically, in cross-section, a portion of a semiconductor substrate during the processing of that substrate in accordance with various embodiments of the invention.
FIGS. 1-4 illustrate one such embodiment of the invention. FIG. 1 illustrates a semiconductor substrate 10 which has been processed in preparation for the fabrication of complementary insulated gate field effect transistors. The substrate includes a first region 12 having a surface of N-type conductivity and a second region 14 having a surface of P-type conductivity. In this embodiment the substrate is illustrated as being of the "twin well" type although the invention is equally applicable if the substrate is prepared with either a single N-type or a single P-type well. Overlying the upper surface 16 of substrate 10 is a patterned masking layer here illustrated to include masking portions 18,20. As will be described more fully below, the masking layer in a preferred embodiment, includes a thin layer of silicon dioxide in contact with surface 16 and an overlying layer of silicon nitride. The two masking portions 18,20 overlie what will become the active areas of the integrated circuit structure and leave exposed the field region of the circuit.
The processes continues is illustrated in FIG. 2 by applying an additional patterned masking layer 22 overlying region 12 having the surface of N-type conductivity and leaving region 14 exposed. Masking layer 22 can be, for example, a layer of patterned photoresist. Using the combination of the two masking layers 20,22, two P-type implants are performed into the surface of region 14. Ions of boron, BF 2 , or the like are implanted into region 14 in two steps to provide an enhanced field doping and to provide punch through protection. The range of an implant describes the location of the peak of the implanted distribution. As is well known, the range is determined mainly by the energy (accelerating voltage) of the implant and by the material into which or through which the implant is performed. A first P-type impurity is implanted into region 14 at an implant energy which is low enough so that the implant is masked by both masking layers 20,22. This implant provides a shallow P-type region 24 as indicated by the x's near the surface of the region. A second P-type impurity is implanted at a sufficiently high energy so that the implanted ions penetrate through masking layer 20 and into the underlying silicon in P-type region 14. The implant energy is not sufficiently high, however, to penetrate masking layer 22, and the implant is thus restricted to region 14. The location of the second implant 26 is schematically illustrated by the o's. The second implant is preferably at a depth in the substrate such that after all subsequent heat treatment the implanted region is at approximately the junction depth of the device source and drain regions.
The first shallow P-type implant provides field doping to increase the threshold voltage in the field region and the second deeper implant increases the doping in the channel region and provides punch through protection. Masking layer 22 is then removed and an additional mask 28 is applied and patterned to cover the P-doped region 14, leaving region 12 exposed. Two N-type ion implantations are then performed to provide a doped field region and to provide punch through protection in a manner similar to that done with the P-type doping. The first N-type implant is done at an implant energy which is masked by both masking layers 18,28. The result is a shallow N-type implant 30 indicated by the +'s. The second N-type implant is done at a higher energy, sufficient to penetrate through masking layer 18 but insufficient to penetrate through masking layer 28. The second N-type implant increases the doping in the active area and specifically in the channel region to provide the desired punch through protection. The location of the second implant 32 is indicated schematically by the t's. Again, to maximize punch through resistance, the implanted region should be at approximately the source and drain junction depth.
After removing mask layer 28, the silicon substrate is oxidized to grow a thick field oxide 34 at those portions of the surface of substrate 10 which are not protected by masking layers 18,20. The resulting structure is illustrated in FIG. 4. A region of enhanced P-type doping 36 underlies the thick field oxide in the P-doped region 14 and a region of enhanced N-type doping 38 underlies the thick field oxide in N-doped region 12. Punch through protection implants 37 and 39 are positioned below the substrate surface in the active areas of the device.
In accordance with a further embodiment of the invention, when punch through protection is not needed with the N channel devices to be formed in the P-type surface region, the process can be simplified and one masking operation eliminated. The process illustrated in FIGS. 5-7 depicts such an embodiment of the invention and includes many steps which are similar to those described above.
As illustrated in FIG. 5, the process begins, as above, with a silicon substrate 10 including complementary regions 12,14 haVing N and P-type doping at the surface thereof, respectively. A masking layer of, for example, a layer of silicon dioxide and an overlying layer of silicon nitride is formed on the surface of substrate 10. The oxide preferrably has a thickness of about 50 nanometers and the nitride preferably has a thickness of about 75 nanometers. The oxide can be thermally grown or can be deposited by CVD. The nitride layer is preferrably formed by CVD. A further layer of masking material such as conventional photoresist is formed overlying the silicon nitride. The photoresist is patterned in conventional manner and is subsequently used to pattern the nitride and oxide. The result is a patterned masking layer 40,42 of silicon oxide and silicon nitride with an overlying patterned layer of photoresist 44,46. These masking layers are positioned over what will be the active area of the integrated circuit to be formed. The composite masking layers of oxide, nitride, and photoresist are used as an ion implantation mask to mask a boron implant into the exposed portions of both region 12 and region 14. The boron is implanted at a sufficiently high energy, such as about 90 keV, so that the peak of the implant will be located below the surface of the silicon substrate. At that energy, for example, the implant will be peaked at about 0.33 micrometers below the surface. The location of implant 47 is indicated by the x's. Photoresist regions 44,46 which are used to pattern the underlying layers of silicon oxide and silicon nitride are retained on the surface during the ion implantation to insure that the high energy boron implant is adequately masked. Alternatively, the photoresist alone can be used as an implant mask and the implant can be performed through the layers of silicon oxide and silicon nitride before those layers are patterned. The implant is then performed at an energy of about 135 keV since it must penetrate the additional layers. The oxide and nitride are then patterned after the implant using the photoresist as an etch mask.
Following the boron implant, photoresist regions 44,46 are stripped from the wafer and a new layer of photoresist is applied and patterned to form a masking layer 48 which covers region 14 having a P-type doped surface. As with the previously described process, masking layer 48 is used in combination with masking layer 40 to selectively mask two N-type implants. A first, shallow N-type impurity, for example, phosphorus at an energy of about 30 keV, is implanted into the exposed surface of region 12. The implant energy is selected so that the implant is masked by both masking layer 40 and masking layer 48. The position of the shallow N-type implant 50 is indicated in FIG. 6 by the + signs. A second, deeper N-type impurity, for example phosphorus at an implant energy of 300 keV, is then implanted into the exposed portions of N-type region 12 and through masking layer 40. The implant energy is selected so that the implant penetrates through implant mask 40 and deposits the phosphorus material in the underlying semiconductor substrate, but the implant does not penetrate through the thicker masking layer 48. The implant energy selected depends, of course, on the thickness of the masking layer through which the ions must penetrate. The position of the resulting implant 52 is indicated by the t's. The same result is achieved by using doubly ionized phosphorus at a lower energy. A further alternative (not shown), when punch through protection is not needed, is to omit the second N-type implant.
The silicon substrate is then heated in an oxidizing ambient to form a thick field oxide 54 as illustrated in FIG. 7. The field oxide can be grown, for example, by heating the substrate to about 1000° C. in an oxidizing ambient for a sufficient time to grow a thermal oxide having a thickness of about 0.7 micrometers. P-type implant 47 forms a P-type doped field region 56 beneath the thick field oxide in the P-type region 14. The shallow N-type implant 50 forms a doped field region 58 located beneath the thick field oxide in N-type region 12. The segregation coefficients of phosphorus and boron in silicon and silicon dioxide cause the phosphorus to pile up in the silicon and the boron to segregate into the oxide during the field oxide growth. The shallow phosphorus implant is thus able to overcompensate the boron layer in N-type region 12. The deeper N-type implant 52 also compensates for the P-type implant 47 which was located in N-type region 12 and forms a punch through protection region 60 which is located in the active portion of the N-type doped region 12. The structure illustrated in FIG. 7 is achieved with one less masking step than in the previous process, but has a compensated field region in N-type region 12 and has no punch through protection in P-type region 14.
FIGS. 8-11 illustrate a further embodiment of the invention. As above, a silicon substrate 10 is prepared by forming regions 12,14 having N and P-type doping at the surfaces thereof, respectively. Overlying the surface of substrate 10 are formed sequential masking layers which are patterned to retain the masking layers overlying what will become the active areas of regions 12,14. For example, overlying region 12 are sequential layers of silicon oxide and silicon nitride 60 (as above), silicon dioxide 61, and photoresist 62. In similar manner overlying region 14 are sequential layers of silicon oxide and silicon nitride 63, silicon oxide 64, and photoresist 65. The photoresist is used to pattern the underlying layers and then is retained as part of the ion implantation mask.
The composite masking layers are used as an ion implantation mask to mask a shallow implant of P-type impurity into the exposed portions of the surface of substrate 10. The location of the P-type implant 66, indicated by the x's, is preferrably at a depth in the silicon substrate of about 0.07 micrometers. The implant can be performed, for example, using singly ionized boron implanted at an energy of about 20 keV with a dose of about 2×10 13 cm -2 or singly ionized boron diflouride implanted at an energy of about 90 keV and a dose of about 2×10 13 cm -2 .
After the implantation, the photoresist masking material 62, 65 is removed and a further masking layer 68 of photoresist is applied and patterned to overlie region 14. The photoresist 68 is used in combination with masking layers 60,61 as an etch mask to etch away the surface of region 12 and thereby to etch away most or all of the boron doping which was implanted into that surface. The surface can be etched, for example, to a depth of about 50 nanometers using a chlorine containing plasma etchant in a conventional dry etching apparatus. During the etching, the silicon oxide layer 61 protects the underlying silicon nitride. The result of this etching step is illustrated in FIG. 9.
As illustrated in FIG. 10, the process proceeds as before by implanting shallow and deep N-type dopants into region 12 using masking layers 60,61 and 68 to selectively mask the implants. A shallow implantation of phosphorus or arsenic 70, illustrated by the +'s, is implanted at an energy insufficient to penetrate through masking layers 60 and 61. A second N-type implant 72 is carried out at an energy sufficient to penetrate through masking layer 60,61 but not through masking layer 68. The resulting implant 72 is illustrated by the t's.
Because of the etching step, the two field regions are implanted with N-type and P-type dopants, respectively, and the N-doped region 12 is provided with a punch through protection implant, all accomplished essentially without compensation. That is, there is essentially no compensation between N-type and P-type field dopant implants because most of the P-type implant is removed by etching.
As above, the process is continued as illustrated in FIG. 11 by thermally oxidizing the silicon substrate 10. The oxidation grows a thick field oxide 74 which is aligned with a doped field region 76 in region 14 and by a doped field region 78 in region 12. A doped punch through protection region 80 is located within the active area of N-type region 12.
A still further embodiment of the invention is illustrated in FIGS. 12-15. This embodiment provides non-compensating field implants together with punch through protection for the N-channel transistors. The process begins, as illustrated in FIG. 12, in a manner similar to that used in the previous embodiment. A silicon substrate 10 is provided having regions 12 of N-type conductivity and regions 14 of P-type conductivity. Overlying the surface of the substrate are patterned masking layers 60-65 as before. The exposed surface of the substrate is then ion implanted with an N-type conductivity determining dopant, preferrably either phosphorus or arsenic. Doped region 82, indicated by the +'s, is located within about 40 nanometers of the surface of the substrate. For example, the doped region can be formed by the ion implantation of arsenic at an implantation energy of 40 keV with an implant dose of 2×10 12 cm -2 .
As illustrated in FIG. 13, masking layers 62,65 are removed and a new masking layer 84 is applied and patterned to form a mask over the N-type region 12. Using mask 84 together with mask 63,64, the exposed surface of region 14 is etched to a depth of about 50 nanometers as indicated at 86 to remove most or all of the N-type dopant material implanted there. During the etching of the silicon, oxide layer 64 protects the top surface of nitride layer 63.
The process is continued, as illustrated in FIG. 14, by one or two implantations of P-type dopant impurity. The first 88 is a shallow implantation 88 of boron or BF 2 as indicated by the x's.
This implant of boron is done, for example, at an implant energy of 15 keV and with a dose of 2×10 13 cm -2 . The implant energy is low enough so that the implantation is masked by masking layer 63,64. A second implant 90 is a more energetic implant which locates boron in P-type region 14 at the locations indicated by the o's . The second implant can be, for example, singly ionized boron at an implant energy of 120 keV and with an implant dose of 3×10 11 cm -2 . This implant energy is sufficient to penetrate through masking layer 63,64, but not through masking layer 84. In this manner heavily doped field regions are implanted for both N-channel and P-channel transistors without compensation and, in addition, punch through protection is provided for the N-channel transistors to be formed in region 14. If the punch through protection is not needed, the second N-type implant can be omitted.
Following the P-type implants, masking layer 84 is removed from the surface of substrate 10 and the substrate is heated in an oxidizing ambient to grow a thick field oxide 92 as illustrated in FIG. 15. The process provides for the self-aligned orientation of P-doped field regions 94 beneath the thick field oxide in the P-well region and N-doped field regions 96 aligned beneath the thick field oxide in the N-region. In addition, as needed, a P-doped region 98 is located within the active device portion of the P-type region to provide punch through protection.
With any of the foregoing embodiments of the invention, the structure as obtained and as illustrated in FIGS. 4, 7, 11, or 15 is used in conventional manner to form complementary insulated gate field effect transistors as illustrated in FIG. 16. In FIG. 16 a device is illustrated which includes a region 12 having an N-doped surface, a region 14 having a P-doped surface, and a thick field oxide 100. Enhanced N-type regions 102 underlie the thick field oxide in region 12 and enhanced P-type regions 104 underlie the thick field oxide in region 14. P-channel transistor 106 includes P-doped source region 108 and drain region 109. A gate structure includes a gate insulator 111 and a gate electrode 112. An enhanced punch through protection region 114 underlies the gate structure. N-channel transistor 116 includes N-type drain 117 and source 118, a gate structure including a gate insulator 120 and a gate electrode 121. Underlying the gate structure is a punch through protection region 122.
Thus it is apparent that there has been provided, in accordance with the invention, a process for the fabrication of device structures having doped field regions which fully meets the objects and advantages set forth above. Although the invention has been described and illustrated with reference to specific embodiments thereof, it is not intended that the invention be limited to these illustrative embodiments. Those skilled in the art will recognize, after review of the foregoing detailed description, that variations and modifications are possible which depart from these embodiments without departing from the invention. For example, the order of the implantations indicated in the illustrative embodiments can be interchanged. Likewise, other insulators than those specified, other implant energies and doses, and the like can be employed. Thus it is intended to encompass within the invention all such variations and modifications as fall within the scope of the appended claims.
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A process is disclosed for fabricating complementary insulated gate field effect transistors including doped field isolation regions and optional punch through protection. In one embodiment of invention, a silicon substrate is provided which has N-type and P-type surface regions. First and second masks are formed overlying active areas of the two surface regions. A third mask is then formed overlying the first region and the first mask. P-type impurities are implanted into the second region with an implant energy which is sufficient to penetrate through the second mask but insufficient to penetrate through the third mask. A second P-type implant is performed with an implant energy insufficient to penetrate through either mask. The first implant will aid in preventing punch through while the second implant dopes the field region. A fourth mask is then formed overlying the second region and the second mask. A first N-type implant is performed at energy sufficient to penetrate through the first mask but insufficient to penetrate through the fourth mask. This implant provides punch through protection for P channel transistors to be formed later. A second N-type impurity is implanted into the surface at an implant energy insufficient to penetrate through the first mask to provided field doping. The silicon substrate is then oxidized to form a field oxide at portions of the first and second surface regions which are not covered by the first and second masks.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
The present application related in subject matter to U.S. patent application Ser. No. 11/231,616, filed Sep. 21, 2005 and entitled “System to Control an Atmosphere Between a Body and a Substrate,” and listing Yeong-Jun Choi and Byung-Jin Choi as inventors, the entirety of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
The field of the invention relates generally to micro-fabrication techniques. More particularly, the present invention is directed to a system of controlling an atmosphere between a mold and a substrate.
Nano-fabrication involves the fabrication of very small structures, e.g., having features on the order of nano-meters or smaller. One area in which nano-fabrication has had a sizeable impact is in the processing of integrated circuits. As the semiconductor processing industry continues to strive for larger production yields while increasing the circuits per unit area formed on a substrate, nano-fabrication becomes increasingly important. Nano-fabrication provides greater process control while allowing increased reduction of the minimum feature dimension of the structures formed. Other areas of development in which nano-fabrication has been employed include biotechnology, optical technology, mechanical systems and the like.
An exemplary nano-fabrication technique is commonly referred to as imprint lithography. Exemplary imprint lithography processes are described in detail in numerous publications, such as United States patent application publication 2004/0065976 filed as U.S. patent application Ser. No. 10/264,960, entitled, “Method and a Mold to Arrange Features on a Substrate to Replicate Features having Minimal Dimensional Variability”; United States patent application publication 2004/0065252 filed as U.S. patent application Ser. No. 10/264,926, entitled “Method of Forming a Layer on a Substrate to Facilitate Fabrication of Metrology Standards”; and U.S. Pat. No. 6,936,194, entitled “Functional Patterning Material for Imprint Lithography Processes,” all of which are assigned to the assignee of the present invention.
The fundamental imprint lithography technique disclosed in each of the aforementioned United States patent application publications and United States patent includes formation of a relief pattern in a polymerizable layer and transferring a pattern corresponding to the relief pattern into an underlying substrate. The substrate may be positioned upon a motion stage to obtain a desired position to facilitate patterning thereof. To that end, a template is employed spaced-apart from the substrate with a formable liquid present between the template and the substrate. The liquid is solidified to form a solidified layer that has a pattern recorded therein that is conforming to a shape of the surface of the template in contact with the liquid. The template is then separated from the solidified layer such that the template and the substrate are spaced-apart. The substrate and the solidified layer are then subjected to processes to transfer, into the substrate, a relief image that corresponds to the pattern in the solidified layer.
United States patent application publication 2005/0074512 filed as U.S. patent application Ser. No. 10/898,037 entitled “System for Creating a Turbulent Flow of Fluid between a Mold and a Substrate” describes a system for introducing a flow of a fluid between a mold and a substrate. More specifically, the system includes a baffle coupled to a chuck, the baffle having first and second apertures in communication with a fluid supply to create a turbulent flow of the fluid between the mold and the substrate.
To that end, it may be desired to provide an improved system of controlling the atmosphere between a mold and a substrate.
SUMMARY OF THE INVENTION
The present invention is directed towards a method of controlling an atmosphere about a substrate, the method including, inter alia, positioning a body a distance from a surface of the substrate, the body having a wall coupled thereto placed in a position to create a flow resistance of a fluid between first and second regions of the substrate; and altering the position of the wall such that when a magnitude of the distance between the body and the surface of the substrate is decreased, a probability of the wall contacting the substrate is minimized. These and other embodiments are described more fully below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified side view of a lithographic system having walls coupled to an imprint head;
FIG. 2 is a side view of a portion of the system shown in FIG. 1 , with the walls placed in a first position;
FIG. 3 is a side view of a portion of the system shown in FIG. 1 , with the walls placed in a second position;
FIG. 4 is a side view of a portion of the lithographic system shown in FIG. 1 , with a template in contact with a material on a substrate; and
FIG. 5 is a side view of a portion of the lithographic system shown in FIG. 1 , with the walls being positioned to expose a portion of an atmosphere between a template and a substrate to an ambient environment.
DETAILED DESCRIPTION OF THE INVENTION
A system 10 employed to form a relief pattern in a substrate 12 includes a stage 14 upon which substrate 12 is supported, and a template 16 having a mold 18 with a patterning surface 20 thereon. In a further embodiment, substrate 12 may be coupled to a substrate chuck (not shown), the substrate chuck (not shown) being any chuck including, but not limited to, vacuum and electromagnetic.
Template 16 and/or mold 18 may be formed from such materials including but not limited to, fused-silica, quartz, silicon, organic polymers, siloxane polymers, borosilicate glass, fluorocarbon polymers, metal, and hardened sapphire. As shown, patterning surface 20 comprises features defined by a plurality of spaced-apart recessions 22 and protrusions 24 . However, in a further embodiment, patterning surface 20 may be substantially smooth and/or planar. The plurality of features of patterning surface 20 defines an original pattern that forms the basis of a pattern to be formed on substrate 12 .
Template 16 may be coupled to an imprint head 26 to facilitate movement of template 16 , and therefore, mold 18 . In a further embodiment, template 16 may be coupled to a template chuck (not shown), the template chuck (not shown) being any chuck including, but not limited to, vacuum and electromagnetic. A fluid dispense system 27 is coupled to be selectively placed in fluid communication with substrate 12 so as to deposit a polymerizable material 28 thereon. It should be understood that polymerizable material 28 may be deposited using any known technique, e.g., spin-coating, dip coating, chemical vapor deposition (CVD), physical vapor deposition (PVD), and the like. In the present example, however, polymerizable material 28 is deposited as a plurality of spaced-apart discrete droplets 30 on substrate 12 .
A source 32 of energy 34 is coupled to direct energy 34 along a path 36 . Imprint head 26 and stage 14 are configured to arrange mold 18 and substrate 12 , respectively, to be in superimposition, and disposed in path 36 . Either imprint head 26 , stage 14 , or both vary a distance between mold 18 and substrate 12 to define a desired volume therebetween that is filled by polymerizable material 28 .
Typically, polymerizable material 28 is disposed upon substrate 12 before the desired volume is defined between mold 18 and substrate 12 . However, polymerizable material 28 may fill the volume after the desired volume has been obtained. After the desired volume is filled with polymerizable material 28 , source 32 produces energy 34 , which causes polymerizable material 28 to solidify and/or cross-link, forming a polymeric material conforming to the shape of a surface 38 of substrate 12 and patterning surface 20 of mold 18 . Control of this process is regulated by processor 40 that is in data communication with stage 14 , imprint head 26 , fluid dispense system 27 , and source 32 , operating on a computer-readable program stored in memory 42 .
System 10 further comprises a pair of conduits 44 a and 44 b . As shown, conduits 44 a and 44 b are coupled to imprint head 26 ; however, conduits 44 a and 44 b may be coupled to any part of system 10 , i.e., substrate 12 , stage 14 , template 16 , the substrate chuck (not shown), or the template chuck (not shown). Further, system 10 may comprise any number of conduits. Conduits 44 a and 44 b may be in fluid communication with a pump system 46 via throughways 48 . As shown, throughways 48 are contained within imprint head 26 . However, in a further embodiment, throughways 48 may be positioned anywhere throughout system 10 and may be coupled to any part of system 10 , i.e., substrate 12 , stage 14 , template 16 , the substrate chuck (not shown), or the template chuck (not shown). Pump system 46 may be in communication with processor 40 operating on memory 42 to control an introduction/evacuation of a fluid 54 in an atmosphere 56 defined between mold 18 and droplets 30 , described further below.
Further, system 10 comprises walls 50 coupled to imprint head 26 . In a further embodiment, walls 50 may be coupled to any part of system 10 , i.e., substrate 12 , stage 14 , template 16 , the substrate chuck (not shown), or the template chuck (not shown). Walls 50 may be positioned at an interface between first and second regions 58 and 60 of substrate 12 , with first region 58 being in superimposition with mold 18 and droplets 30 . Further, walls 50 may substantially surround imprint head 26 , and therefore, atmosphere 56 . However, for simplicity of illustration, walls 50 are shown surrounding a portion of imprint head 26 and atmosphere 56 .
Walls 50 may be in communication with a motor 52 , with motor 52 controlling a motion thereof. For simplicity of illustration, motor 52 is shown as two separate bodies. Motor 52 may comprise a solenoid selected from a group of solenoids including but not limited to, electric, pneumatic, and hydraulic. Further, motor 52 may be employed without feedback. Motor 52 may be in communication with processor 40 operating on memory 42 .
As mentioned above, during imprinting, template 16 and therefore, mold 18 , are brought into proximity with substrate 12 before positioning polymerizable material 28 in droplets 30 upon substrate 12 . Specifically, template 16 is brought within hundreds of microns of substrate 12 , e.g., approximately 200 microns. It has been found desirable to perform localized control of atmosphere 56 that is proximate to both template 16 and substrate 12 . For example, to avoid the deleterious effects of gases and/or gas pockets present in polymerizable material 28 in droplets 30 and/or subsequently trapped in a patterned layer, described further below, formed from droplets 30 , it has been found beneficial to control desired properties of atmosphere 56 and/or the pressure of atmosphere 56 . More specifically, it may be desired to control fluid 54 within atmosphere 56 . To that end, a system and a method to facilitate control of atmosphere 56 is described below.
Referring to FIG. 2 , a portion of system 10 is shown. More specifically, mold 18 is shown spaced-apart from surface 38 of substrate 12 a first distance ‘d 1 ’. Distance ‘d 1 ’ may be on the order of hundreds of microns, i.e., approximately 200 to 300 microns. Walls 50 of system 10 are shown placed in a first position spaced-apart a distance ‘d 2 ’ from surface 38 of substrate 12 . Distance ‘d 2 ’ may be on the order of tens of microns, i.e., approximately 50 microns.
Pump system 46 may introduce fluid 54 into atmosphere 56 through throughways 48 and conduits 44 a and 44 b . Fluid 54 may comprise a gas selected from a group of gases including, but not limited to, helium, hydrogen, nitrogen, carbon dioxide, and xenon. Fluid 54 may be introduced into atmosphere 56 through conduits 44 a and 44 b employing any desired method. For example, fluid 54 may be introduced through both conduits 44 a and 44 b concurrently, or sequentially pulsed through the same, i.e., first fluid is introduced through conduit 44 a and subsequently through conduit 44 b and then again through conduit 44 b , with the process being repeated for a desired time or during the entire imprinting process. Methods for introduction/evacuation of fluid 54 through conduits 44 a and 44 b is disclosed in United States patent application publication 2005/0072755 filed as U.S. patent application Ser. No. 10/677,639 entitled “Single Phase Fluid Imprint Lithography Method,” which is incorporated by reference herein in its entirety. In an example, conduits 44 a and 44 b may introduce fluid 54 within atmosphere 56 at a flow rate of 9 liters/minute.
To that end, it may be desired to control atmosphere 56 , and more specifically, it may be desired to maintain fluid 54 within atmosphere 56 preceding to and until contact between mold 18 and polymerizable material 28 in droplets 30 . In a further embodiment, it may be desired to maintain fluid 54 within atmosphere 56 prior to and subsequent to contact between mold 18 and polymerizable material 28 in droplets 30 . In an example, it may be desired to have atmosphere 56 comprise more than a 95% mass fraction of fluid 54 therein. To that end, walls 50 facilitate control of atmosphere 56 by creating a flow resistance between first and second regions 58 and 60 of substrate 12 . More specifically, as mentioned above, walls 50 are spaced-apart a distance ‘d 2 ’ from surface 38 of substrate 12 ; and mold 18 , in superimposition with polymerizable material 28 in droplets 30 , is spaced-apart a distance ‘d 1 ’ from surface 38 of substrate 12 . Further, distance ‘d 1 ’ is substantially greater than distance ‘d 2 ’. As a result, a greater resistance to a flow of fluid 54 is established between walls 50 and surface 38 of substrate 12 than between mold 18 and surface 38 of substrate 12 ; and thus, fluid 54 may tend to be maintained within atmosphere 56 , which may be desired. For a given flow rate of fluid 54 through conduits 44 a and 44 b and a given volume of atmosphere 56 , the distance ‘d 2 ’ may be selected to achieve a desired resistance to the flow of fluid 54 between first and second regions 58 and 60 of substrate 12 .
However, as mentioned above, a desired volume is defined between mold 18 and substrate 12 that is filled by polymerizable material 28 in droplets 30 . More specifically, imprint head 26 may position mold 18 such that polymerizable material 28 in droplets 30 are in contact therewith. As a result, walls 50 may translate to minimize a probability of the same contacting substrate 12 during a decrease in a magnitude of distance ‘d 1 ’, and more specifically, during contact of mold 18 with polymerizable material 28 in droplets 30 . Contact of substrate 12 by walls 50 may result in, inter alia, structural comprise of system 10 , impedance of contact between mold 18 and droplets 30 , misalignment of mold 18 with respect to substrate 12 , and damage to substrate 12 and/or mold 18 , all of which are undesirable.
Referring to FIG. 3 , to that end, walls 50 may translate in a first direction away from substrate 12 . More specifically, motor 52 may position walls 50 such that the same are positioned a distance ‘d 3 ’ from surface 38 of substrate 12 , with distance ‘d 3 ’ being greater than distance ‘d 1 ’. Distance ‘d 3 ’ may be on the order of hundreds of microns.
Referring to FIG. 4 , mold 18 is shown in mechanical contact with polymerizable material 28 , spreading droplets 30 , shown in FIG. 1 , so as to generate a contiguous formation 62 of polymerizable material 28 over surface 38 of substrate 12 . Template 16 , and further, mold 18 , may translate in a second direction towards substrate 12 , with the second direction being opposite to the aforementioned first direction. In a further embodiment, stage 14 , and further, substrate 12 may translate in a third direction towards mold 18 , with the third direction being in a direction substantially the same as the first direction. Furthermore, walls 50 may translate in the first direction concurrently or asynchronously with translation of mold 18 and/or substrate 12 .
Referring to FIG. 1 , in a preferred embodiment, fluid 54 may be introduced into atmosphere 56 at any time prior to contact between mold 18 and droplets 30 . However, in a further embodiment, introduction of fluid 54 into atmosphere 56 may be ceased at any time.
Referring to FIG. 5 , in a preferred embodiment, it may be desired to expose a portion of atmosphere 56 , shown in FIG. 1 , to an ambient environment to facilitate control of fluid 54 within atmosphere 56 , shown in FIG. 1 . To that end, walls 50 a and 50 b may be positioned distance ‘d 2 ’ from surface 38 of substrate 12 , as mentioned above. However, wall 50 c may be positioned a distance ‘d 4 ’ from surface 38 of substrate 12 . Distance ‘d 4 ’ may have a magnitude approximately between 200 microns and 1 millimeter. As a result, atmosphere 56 may be exposed to an ambient environment. In a further embodiment, walls 50 may substantially surround imprint head 26 , and thus atmosphere 56 , forming a chamber (not shown). The chamber (not shown) may be completely evacuated or pressurized.
Referring to FIG. 2 , in a further embodiment, to increase a quantity of fluid 54 disposed within atmosphere 56 , distance ‘d 1 ’ may be increased prior to contact of mold 18 with droplets 30 . More specifically, distance ‘d 1 ’ may be on the order of millimeters, i.e., approximately 1 millimeter.
The embodiments of the present invention described above are exemplary. Many changes and modifications may be made to the disclosure recited above, while remaining within the scope of the invention. Therefore, the scope of the invention should not be limited by the above description, but instead should be determined with reference to the appended claims along with their full scope of equivalents.
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The present invention is directed towards a method of controlling an atmosphere about a substrate, the method including, inter alia, positioning a body a distance from a surface of the substrate, the body having a wall coupled thereto placed in a position to create a flow resistance of a fluid between first and second regions of the substrate; and altering the position of the wall such that when a magnitude of the distance between the body and the surface of the substrate is decreased, a probability of the wall contacting the substrate is minimized.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to drain shields for rain gutters in the form of a screen and support structure placed atop the gutter to prevent leaves and other debris from impairing proper operation of the rain gutter.
2. Description of the Prior Art
Many different designs for the protection of rain gutter operation are disclosed in the prior art. These designs are inadequate because they are too complex and too costly, or provide poor accessibility to the gutter assembly for cleaning.
U.S. Pat. No. 4,959,932 discloses a rain gutter screen in the form of a laminate of two or more sheets of various types of mesh, a leading edge of the screen, composed of a bondable, flexible material, to be placed beneath the end shingles of a roof and a means for attaching the discharge end of the screen to the inside and outside edge of a cave gutter. However, the device of '932 is cumbersome to install, requiring the raising of the end roof shingles to secure the device, which then must be permanently bonded to the roof top. Additionally, the device has the distinct disadvantage that a support screen must be placed inside the screen mesh which increases the complexity of the device and increases cost.
U.S. Pat. No. 4,841,686 discloses a filter attachment to fit over the open end of a gutter which includes an elongated screen to which is added a pad of fibrous glass material which must be clamped to the underside thereof, increasing cost. Additionally, the device requires adjustable clamps for holding the filter in place on the gutter opening. U.S. '686 is directed toward providing a gutter screen which cannot be opened for cleaning of the gutter. The design of the device increases the difficulty in accessing the inside of the gutter assembly to clear away debris which is not retained by the filter.
U.S. Pat. No. 3,977,135 discloses a gutter screen which is affixed with hinges that are spring loaded to keep the screen against the gutter until it is desired to open the screen to remove debris therefrom. This device is complex and cumbersome in design, increasing the cost of the device as well as the cost of installation. Additionally, removal of the device from the gutter assembly is burdensome, since the hinges are permanently fastened to the gutter itself.
Other prior art references such as U.S. Pat. Nos. 5,095,666, 5,040,750, 4,907,381, and 4,888,920 all disclose various cumbersome and costly means of fastening a gutter protection device to the top of the gutter using a variety of permanent clamps and other fasteners, which increase the cost of installation and increase the difficulty in accessing the inside of the gutter for the cleaning of debris not retained by the protection device.
Furthermore, many conventional gutter protection devices are mounted inside the gutters and tend to be deformed and pushed down into the area near the bottom of the gutter, due to the weight of leaves and other debris retained by the device. This makes it difficult to clean the gutters, or even to remove the deformed screens.
Finally, gutter protection devices formed from polymeric materials tend to soften and sag when heated by direct sunlight. This problem is exacerbated by the weight of debris on the softened surface.
SUMMARY OF THE INVENTION
It is an object of this invention to provide solutions to the problems associated with conventional gutter protection devices. Specifically, the primary objective of this invention is to provide an improved rain gutter guard which is easy to clean and has increased strength and resistance to damage, while reducing cost and maintenance requirements.
Another object of this invention is to provide a rain gutter guard that allows easy access for removing debris from the inside of the gutter.
Other objects and advantages of this invention will further appear hereinafter and in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional side view of an embodiment of the gutter guard according to this invention.
FIG. 2 is a front perspective view of the embodiment of the gutter guard shown in FIG. 1 mounted on a gutter assembly.
FIG. 3 is a cross-sectional side view of another gutter guard according to this invention.
FIG. 4 is a top view of a section of the gutter guard shown in FIG. 3.
FIG. 5 is a perspective view of the gutter guard shown in FIGS. 3 and 4 mounted on a gutter assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description of the preferred embodiments is meant for the purpose of illustration only and is no way meant to limit the invention in spirit or scope as defined in the appended claims.
The rain gutter guard is installed atop the rain gutter assembly by bending the solid back portion of the guard along a score line to form a flap. This flap is secured by means of a pressure sensitive adhesive to the back of the gutter assembly. The pressure sensitive adhesive is an important feature of this invention in that it strongly secures the flap in place but allows for its removal from the rain gutter for the purpose of cleaning or otherwise. The solid front portion of the guard is affixed by means of a pressure sensitive adhesive to the front of the gutter assembly. The gutter guard portion intermediate the front and back portions is provided with gaps which allow for the passage of water while retaining leaves and other debris.
Referring to FIG. 1, gutter assembly 1 is covered by rain gutter guard 9. Back portion 2 is scored along score line 3 and bent over the back edge of gutter assembly 1, forming flap 4 which secures the back portion of the gutter guard to the gutter assembly. Screen 5 is connected between back portion 2 and front portion 6 to provide for the passage of water into gutter assembly 1 and the retention of leaves and other debris. Front portion 6 is affixed with pressure sensitive adhesive strip 7, which advantageously secures the front portion of gutter guard 9 to gutter assembly 1 but allows upward removal of the gutter guard thereby allowing for easy access to the inside of gutter assembly 1 for cleaning.
The gutter guard may be composed of traditional materials, which includes vinyl polymer or metals such as aluminum or steel, but is not limited thereto. When it is configured in roll form, it may have, for example, a thickness of about 0.016" (26 gage) or when used as a stamped product it may have a thickness of about 0.020" (24 gage). These thicknesses are not critical but typically provide sufficient flexibility for easy installation and use while still providing enough strength to support the weight of animals, such as squirrels without excessive deformation.
Back portion 2, score line 3 and flap 4 form a pivoting member which allows gutter guard 9 to be opened by lifting front portion 6 and separating pressure sensitive adhesive strip 7 from gutter assembly 1. After the cleaning of leaves and other debris from screen 5 and the inside of gutter assembly 1, gutter guard 9 can then be closed and re-sealed. Front portion 6 is pressed back against gutter assembly 1 and pressure sensitive adhesive strip 7 affixes it thereto.
FIG. 2 shows a from perspective of an installed gutter assembly utilizing a preferred form of rain gutter guard of the present invention. Gutter assembly 1 is mounted just below the edge of roof 8, in a conventional manner, such as by hooks fastened below the roofline, not shown. Leaves and debris collect on screen 5, as water passes into gutter assembly 1 to be drained off.
The embodiment of the gutter guard invention shown in FIGS. 3 and 4, generally designated 10, has a one-piece construction formed from a unitary strip of metallic or other material. Gutter guard 10 has edge portions 12 and 14 provided with upward score lines 16 along which edge portions are easily folded. Downward score lines 20 separate end portions 12 and 14 from central portion 18. Central portion 18 has a plurality of perforations 22 adapted to allow for the flow of rain water while preventing the passage of leaves and other debris. Gutter guard 10 has a top surface 24, a bottom surface 26, and a thickness controlled so that gutter guard 10 remains flexible but resists deformation due to the weight of foreign objects or of animals such as squirrels. Bottom surface 26 of gutter guard 10 is coated with pressure sensitive adhesive. The adhesive is optionally provided only on edge portions 12 and 14 but may be provided along the entire bottom surface 26 of gutter guard 10, including bottom surface 26 of central portion 18. The presence of pressure sensitive adhesive is an important and advantageous feature of the invention, as previously discussed.
Referring to FIG. 4, gutter guard 10 has a width w and may be provided in a variety of sizes. Width w is preferably approximately 6 inches for residential gutters, and gutter guard 10 may optionally be supplied in long, coiled lengths of predetermined length or of greater length to be cut to size upon installation. Score lines 16 in edge portions 12 and 14, and score lines 20 defining the boundary of edge portions 12 and 14, are located at distances d 1 and d 2 from the edges of gutter guard 10, respectively. Distance d 1 is preferably about half of distance d 2 , thereby bisecting edge portions 12 and 14. Distance d 1 is preferably about 5/16", and distance d 2 is preferably about 5/8" but these dimensions are not critical.
In FIG. 5, gutter guard 10 is shown mounted on gutter assembly 30 attached to a structure 32 having a wall 34 and a roof 36. Gutter assembly 30 has a ledge portion 38 and is provided with a standard cross-sectional shape to define an interior area 39. Bottom surface 26 of gutter guard 10, provided with pressure sensitive adhesive, is applied to ledge portion 38 to adhere edge portion 14 to gutter assembly 30. Edge portion 12 is folded along score line 16, and pressure sensitive adhesive on bottom surface 26 adheres edge portion 12 to gutter assembly wall 40.
In operation, edge portion 14 may be lifted from ledge 38 and gutter guard 10 may be flexed about score lines 16 and 20 to expose the interior 39 of gutter assembly 30. Accordingly, access is provided to the interior 39 so that debris in gutter assembly 30 can be removed. Subsequently, the pressure sensitive adhesive on bottom surface 26 of end portion 14 may be re-applied to ledge 38 of gutter assembly 30, thereby closing gutter guard 10. Gutter guard 10 can be mounted on standard residential or commercial gutters having various dimensions.
Installation of gutter guard 10 is possible whether roofing or roof flashing enters the gutter or not. When roofing or roof flashing enters the gutter, edge portion 12, which would otherwise be adhered to wall 40 of gutter assembly 30, is folded against itself along score line 16 and leaned against the roofing or roof flashing surface. In such an installation, edge portion 14 remains adhered to ledge 38, and edge portion 12 is lifted to flex gutter guard 10 about score lines 16 and 20 to provide access to interior region 39.
This simplified design provides the great benefit of increased accessibility and ease of cleaning, while reducing the cost and complexity of traditional gutter protection devices, which are secured with clamps, screws and other fasteners. A gutter guard constructed in accordance with the present invention also provides the great benefit of increased structural strength in addition to improving accessibility and ease of cleaning and reducing the cost of the gutter guard. This is achieved by attaching the gutter guard to the top of the gutter assembly and not within as in previous gutter guards. This increases the structural support of the guard so that it can withstand greater force, such as the weight of squirrels, for example.
Finally, a gutter guard according to this invention is easy and safe to install, replace and clean. Not only does the gutter guard minimize the time spent on ladders associated with cleaning and installing of conventional gutter screens, but the ease of handling reduces the occurrence of scratches and cuts.
Although the present invention has been described in a specific embodiment thereof, it is not limited thereto in spirit or in scope, as defined in the appended claims.
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A guard for the protection of rain gutters includes a solid back portion scored along a score line, which is bent to secure the guard to a gutter. A pivoting means lifts the gutter guard; a solid front portion is affixed with a pressure sensitive adhesive for securing to the gutter and is pivotable for allowing access therein. The guard has a middle portion having holes sized to allow the passage of water while substantially retaining solid materials.
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BACKGROUND OF THE INVENTION
The present invention relates to a locking manhole insert and more specifically to a locking manhole insert designed to be placed under an existing manhole cover for the security of any equipment which might be placed thereunder.
To monitor for unauthorized effluent pollutants, environmental monitoring equipment often is installed through manholes into sanitary sewer and stormsewer pipes. The monitoring equipment is typically left in a single location for an extended period of time (e.g. one week) and then removed for data extraction. Such equipment is generally well known in the environmental testing art.
Unfortunately such equipment sometimes is tampered with since it is left unattended by authorized personnel for many days. Tampering may be for the purpose of intentionally affecting (e.g. improving) the acquired data. Tampering may also occur by curious people who want to see what was placed in the hole. Obviously, any tampering is undesirable.
Applicant is not aware of any commercially available device for securing the testing equipment within the manhole. However, Applicant is aware that locking manhole covers are shown in the patent literature.
One such locking manhole cover is disclosed in U.S. Pat. No. 5,082,392, issued Jan. 21, 1992, to Marchese. The Marchese cover has radial locking arms mounted on the underside of an otherwise generally conventional manhole cover. These radial arms are retracted and extended by rotating an actuating disc that is accessible through a vent hole in the cover. A key is provided that extends through the vent hole and is used to rotate the disc.
A second locking manhole cover is disclosed in U.S. Pat. No. 4,964,755, issued on Oct. 23, 1990, to Lewis et al. The Lewis cover also has radial locking arms attached to an actuating disc that is mounted on the underside of an otherwise generally conventional manhole cover. The actuating disc is spring-biased upwardly toward the cover and has a series of locking pins that engage holes in the cover. The actuating disc is accessed through a vent in the cover using a special key. To turn the actuating disc, one must use the special key to force the plate downward, so as to disengage the locking pins from the cover, and rotate the disc.
Marchese and Lewis suffer from a series of shortcomings. First, both inventions are designed to be used in place of an existing manhole cover. Therefore, they must meet the structural requirements of a conventional manhole cover. This makes them expensive to fabricate and, as a result of their weight, burdensome to use. Second, both locking manhole covers require a special key to actuate the locking mechanism. This means that an individual who gains access to a single key can unlock and remove all covers. In this sense, the covers are not truly secure. Third, if the locking mechanism malfunctions, or the key is misplaced, it may be necessary to damage or destroy the locking cover in order to remove it from the manhole frame.
SUMMARY OF THE INVENTION
The aforementioned problems of manhole security are overcome by the present invention wherein a locking manhole insert is provided which may be installed underneath a conventional manhole cover to restrict access to any equipment which might be temporarily located within the manhole.
The manhole insert includes a plate-shaped body that fits within a conventional manhole frame. A series of locking radial arms are attached to an actuating disc mounted on the underside of the insert body. The body includes a peripheral lip and a floor that supports the insert within the manhole frame opening by resting upon the manhole frame support flange. The floor of the plate-shaped disc is recessed below the lip, defining a void. Portions of the locking and/or actuating mechanism are located within the void on the floor of the insert body and under the conventional manhole cover.
The rotating disc includes an actuating handle extending through the insert and accessible from the top of the manhole insert. The radial arms are retracted and extended by operating the handle. A fixed ear is secured to the insert floor. The handle is aligned with the fixed ear when the radial arms are in the extended position, enabling the handle to be padlocked to the fixed ear and prevent the radial arms from being retracted.
In a preferred embodiment, chains are mounted to the undersurface of the manhole insert. These chains can be used to suspend equipment, such as a pollution monitoring sampling unit, within the manhole opening. Once installed and locked, the manhole insert prevents access to the manhole opening and any equipment suspended therein.
The present insert is relatively simple and inexpensive to fabricate. The insert need not meet all the structural requirements of a conventional manhole cover, which is reinstalled over the insert.
A structure that permits the use of conventional padlocks enables a different lock for each manhole insert. Use of a conventional padlock is also less expensive than incorporating a key-lock mechanism into each manhole insert. Further, if the padlock key is lost or misplaced, the padlock can be cut rather than damaging or destroying the manhole insert.
These and other objects, advantages, and features of the present invention will be more fully understood and appreciated by reference to the detailed description of the preferred embodiment and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the present invention suspending a pollution monitoring unit;
FIG. 2 is a top view of a preferred embodiment of the present invention;
FIG. 3 is a bottom view of a preferred embodiment of the present invention; and
FIG. 4 is a sectional view of the present invention installed in a conventional manhole frame and suspending a pollution monitoring unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A locking manhole insert 1 constructed in accordance with the preferred embodiment of the present invention is generally illustrated in FIGS. 1 and 2, and includes a plate-shaped body 10 having a plurality of radial locking arms 18 attached to a rotating disc 20 concentrically mounted on the undersurface of the insert. When installed, the body fits underneath a conventional manhole cover to prevent unauthorized access. The body is easily installed and locked, and also unlocked and removed.
The plate-shaped body 10 includes a circular, planar floor 14, a circumferential wall 16, and a peripheral lip 12. The floor 14 is disc-shaped and has a diameter slightly smaller than the internal diameter of the support flange 62 in the manhole frame 60. The circumferential wall 16 extends axially upward from the outer edge of the floor 14. The lip 12 extends radially outward from the top of the circumferential wall 16 and has an external diameter substantially identical to the diameter of a conventional manhole cover 64. The floor defines an arcuate slot to receive the actuating handle as will be described. A fixed ear or lug 28 is secured, for example, by welding to the floor 14 adjacent one end of the slot 26. The ear defines a hole 34 for receiving a padlock 36. A fixed ring or eye 32 is fixedly secured to the top surface of the floor 14, for example, by welding (see FIG. 2). This ring 32 is used in installing and removing the plate-shaped insert 10. The circumferential wall 16 creates a space between the lip 12 and floor 14, so that the manhole cover 64 may be seated upon the lip 12 without interference from any elements that may extend above or lie upon the floor 14.
A pivoting actuating disc 20 with a diameter substantially smaller than the floor 14 is concentrically mounted to the underside of the plate-shaped body 10. One end of each of the locking radial arms 18 is pivotally attached to the rotating disc 20 in a radially symmetric manner. A fixed guide 22 is radially aligned with each locking radial arm 18 and is attached to the underside of the plate-shaped body 10. Each locking radial arm 18 slidably passes through its corresponding fixed guide 22. The fixed guide 22 provides a fixed point through which each locking radial arm 18 must pass when being retracted or extended.
An L-shaped actuating handle 24 is fixedly attached, for example, by welding to the rotating disc 20 (see FIG. 1). The long leg 38 of the handle 24 extends radially from the rotating disc 20. The short leg 40 of the handle 24 extends upward through the arc-shaped slot 26 in the floor 14 of the plate-shaped body 10 (see FIG. 3). The short leg 40 defines a hole 42 for receiving a padlock 36. The holes 34 and 42 are aligned to receive the padlock when the insert 1 is locked in position. The slot 26 defines the range of motion for the handle 24. The rotating disc 20 is rotated by moving the handle 24 back and forth along the arc-shaped slot 26. Rotating this disc 20 in turn retracts or extends the radial locking arms 18. The handle 24 abuts the fixed ear 28 when the radial arms 18 are in the extended position. When the handle 24 is secured to the fixed ear 28 the locking radial arms 18 can not be retracted.
As shown in FIG. 1, a plurality of fixed rings 44 are attached to the undersurface of the plate-shaped body 10 in a radially symmetric manner. A chain 30 is attached to each of these fixed rings 44 for use in suspending equipment, such as environmental monitors, below the plate-shaped body 10 (see FIGS. 3 and 4).
When a sampling device is to be placed in a manhole, the conventional manhole cover is removed, and the sampling unit 70 is suspended from the insert 1 on the chains 30. The unit 70 and insert with the locking arms 18 retracted are then lowered into the manhole 60, optionally using the suspension ring 32. Upon complete installation, the peripheral lip 12 sits upon the support flange 62 of the manhole frame 60. The floor 14 and circumferential wall 16 extend below the plane of the lip, and the sampling unit 70 is suspended below. To secure the plate-shaped body 10, the actuating handle is moved to the end of slot 26 adjacent the locking ear 28 to extend the locking radial arms 18. A padlock 36 is installed through the lug 28 and handle 24 to lock the arms in the extended position. Finally, the conventional manhole cover 64 is reinstalled on top of the plate-shaped body 10. As discussed above, the floor 14 is sufficiently recessed below the lip 12 to allow a manhole cover 64 to be seated upon the lip 12 above the padlock, actuating handle 24, and fixed ring 32. The process is reversed to remove the insert and sampling unit from the manhole.
The above description is that of a preferred embodiment of the invention. Various changes and alterations can be made without departing from the spirit and broader aspects of the invention as set forth in the appended claims, which are to be interpreted in accordance with the principles of patent law, including the doctrine of equivalents.
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A locking manhole insert to be placed under a conventional manhole cover to prevent unauthorized access to the manhole. The insert includes a plate-shaped disc with a plurality of locking radial arms mounted to its undersurface. The locking radial arms are securable in the extended position using a conventional padlock. The insert further includes apparatus for suspending equipment, such as pollution monitoring units, within the manhole opening.
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This patent document is a continuation of U.S. patent application Ser. No. 11/599,842, filed on Nov. 15, 2006 now U.S. Pat. No. 7,879,292, which claims priority to to Japanese Patent Application No. JP2005-330498 filed Nov. 15, 2005, all of which are hereby incorporated by reference in their entireties.
TECHNICAL FIELD
The present disclosure relates to an agitating device.
BACKGROUND
Sample analyzers include, for example, blood analyzers. Such sample analyzers aspirate a sample such as blood or the like collected in a sample container (collection tube), mix the aspirated sample with reagent, measure the mixed sample and analyse the measured sample to obtain analysis results.
The sample analyser comprises an agitating device that is used mix the sample in the sample container before the sample is aspirated by the sample analyzer.
For example, the sample agitating and aspirating device disclosed in Japanese Laid-Open Patent Publication No. 63-187158. This sample agitating and aspirating device grips a sample container held in a rack by means of hand, and repeats a reciprocating rotation movement of the hand gripping the sample container by a rotation drive cylinder. Thus, the sample within the sample container is vigorously agitated.
The hand is provided so as to be movable relative to the support member that is base of the sample agitating and aspirating device, and the hand removes the sample container from the rack and agitates the sample container.
The rotation drive cylinder that provides the rotational drive to agitate the hand is provided integratedly with the hand, and configured so as to move together with the hand within the device.
Therefore, a large drive force is required to move the hand via the rotation drive cylinder used for agitation. A large drive source is needed to obtain such a large drive force, thus enlarging the size of the apparatus.
SUMMARY
The scope of the present invention is defined solely by the appended claims, and is not affected to any degree by the statements within this summary.
In one embodiment, an agitating device for agitating a blood sample in a sample container is disclosed. The agitating device includes a base comprising a horizontally-supported shaft, a container holder including a first hand and a second hand, the first hand having a first hole at one end and a first hold portion at other end, the second hand having a second hole at one end and a second hold portion at other end, the first and second holes through which the shaft is inserted, the first and second hands being rotatable relative to the shaft and the first and second hold portions faced each other, and an agitation drive unit including a contact member for contacting the container holder and a drive source for reciprocating the contact member contacting the container holder between a lower position and an upper position.
In another embodiment, a blood sample analyzer for analyzing a blood sample in a sample container is disclosed. The blood sample analyzer includes a base comprising a horizontally-supported shaft, a container holder comprising first hand and second hand, the first hand including a first hole at one end and a first hold portion at other end, the second hand including a second hole at one end and a second hold portion at other end, the first and second holes through which the shaft is inserted, the first and second hands being rotatable relative to the shaft and the first and second hold portions faced each other, an agitation drive unit comprising a contact member for contacting the container holder and a drive source for reciprocating the contact member contacting the container holder between a lower position and an upper position, an aspirator comprising an aspiration tube and aspirating a blood sample contained in the agitated sample container, a measurement sample preparer comprising a chamber for preparing a measurement sample by mixing the aspirated blood sample and a reagent, and a measurement part measuring blood cells contained in the measurement sample.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a sample analyzer;
FIG. 2 is a perspective view of a manual placement-type sample analyzer (sample analyzer main body);
FIG. 3 is an exploded perspective view of a sample analyzer;
FIG. 4 is a perspective view of the internal mechanism of the manual placement-type sample analyzer;
FIG. 5 is an enlargement of the sample container acceptor moving unit of the manual placement-type sample analyzer;
FIG. 6 is a side view of the sample container positioner;
FIG. 7 is a function block diagram of the sample analyzer;
FIG. 8 is a perspective view of the internal mechanism of the sample container supplier;
FIG. 9 is a perspective view of the movable base;
FIG. 10 is a top view of the moving unit of the sample container supplier;
FIG. 11 is a perspective view showing the container holder in the closed condition;
FIG. 12 is a perspective view showing the container holder in the open condition;
FIG. 13 is a perspective view showing the container holder agitation operation;
FIG. 14 is a side view showing the regulating state in which the container holder is fixed non-rotatably to the apparatus base, and the state in which the regulation is released via contact with the contact member;
FIG. 15 is a side view showing the container holder agitation operation;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiments of the present invention are described hereinafter.
FIG. 1 shows a blood analyzer as an example of a sample analyzer 1 . The sample analyzer 1 measures a blood sample contained in a sample container (collection tube) 2 , and the measurement result is analyzed by a computer 7 (omitted from FIG. 1 ).
The sample analyzer 1 is provided with a sample analyzer main body apparatus (blood analyzer main body apparatus) 3 with the function of measuring the sample blood, and a sample container supplier (sampler) 4 that automatically supplies a plurality of sample containers to the sample analyzer main body 3 .
As shown in FIG. 2 , the sample analyzer main body 3 is originally configured as a manual placement-type sample analyzer 3 a that measures a manually placed sample container 2 .
The sample analyzer 1 has a sample container supplier 4 subsequently joined to a manual placement-type sample analyzer 3 a, as shown in FIG. 3 , and the two devices 3 a and 4 are integrated so as to be separable, thus configuring a sample analyzer with a detachable sampler attachment. As a result, the sample analyzer 1 not only allows manual placement of sample containers 2 , but also automatically supplies sample containers 2 .
Moreover, the two devices 3 a and 4 may be integrated after initial assembly of the devices during the manufacturing process.
Sample Analyzer Main Body 3 (Manual Placement-type Sample Analyzer 3 a )
FIGS. 2 and 4 show the manual placement-type sample analyzer 3 a (sample analyzer main body 3 ). The manual-placement-type sample analyzer 3 a is mainly configured by an internal mechanism 301 having a measuring unit for measuring samples and the like, and a casing 302 that houses the internal mechanism unit 301 .
The casing 302 is provided with a casing body 302 a (refer to FIG. 3 ) that has an open front (one surface), and a front casing 302 b mounted on the casing body 302 a so as to obstruct the front opening of the casing body 302 a. When the sample container supplier 4 is installed on the sample analyzer main body 3 a, the front casing 302 b is removed (refer to FIG. 3 ).
An opening 304 is formed in the bottom right area of the front casing 302 b, such that a sample container acceptor 310 , in which a sample container 2 is manually set, can move forward from inside the casing 302 to the front of the casing 302 (refer to FIG. 2 ).
The internal mechanism 301 is provided with a sample container acceptor 310 and a mover 320 that moves the sample container acceptor 310 .
The sample container acceptor 310 is provided with a mounting base 312 that has a holding orifice 311 (refer to FIG. 6 ) for holding a tube-like sample container collection tube in an upright and approximately vertical state. The holding orifice 311 is open at the top, and the hole extends vertically (perpendicular direction). Therefore, setting and replacing a sample container 2 on the sample container acceptor 310 is accomplished by setting and removing the sample container 2 in a vertical direction (perpendicular direction).
Moreover, the holding orifice 311 has a relatively large diameter to allow the insertion of sample containers of various tube diameters.
The mover 320 is configured so as to move the mounting base 312 in front-to-back directions. As shown in FIG. 5 , the mover 320 is provided with a slider 321 that is movable in forward and backward directions and on the leading end of which is mounted the mounting base 312 , a guide 322 that guides the forward and backward movement of the slider 321 , and a motor 323 that functions as the drive unit that drives the slider 321 .
When the motor 323 rotates, the rotational movement is transmitted to the guide 322 side via a belt 324 . This rotational movement is converted to a linear movement by a rotation-to-linear movement conversion mechanism not shown in the drawing that is built into the guide 322 , such that the slider 321 is moved in forward and backward directions.
Moreover, since the slider 321 is provided so as to move horizontally, a sample container 2 set in an approximately vertical state on the sample receiver 320 can be moved horizontally while maintaining the vertical condition of the sample container.
When the slider 321 is moved forward, the sample container acceptor 310 projects forward from the opening 304 , as shown in FIG. 2 , such that a sample container 2 can be set in the holding orifice 311 . Furthermore, the position of the sample container acceptor 310 shown in FIG. 2 is referred to as the manual sample container receiving position. When the slider 321 is moved backward, the sample container acceptor 310 is housed within the apparatus, as shown in FIG. 4 .
A cover 324 used to close the opening 304 is rotatably provided on the end of the slider 321 (refer to FIG. 2 ). A spring not shown in the drawing exerts a force so as to incline the cover 324 to the outer side at a predetermined angle. When the slider 321 is retracted, the cover 324 is moved from the state shown in FIG. 2 in an upward direction to close the opening 304 , and when the slider 321 advances, the cover 324 is moved forward and downward to the state shown in FIG. 2 .
A measurement start button 305 is provided on the front of the casing 302 . When the start button 305 is pressed after the sample container 2 has been inserted in the holding orifice 311 of the mounting base 312 , the slider 321 is retracted, and the sample container 2 (sample receiver 310 ) is positioned at the aspirating position (the position shown in FIG. 4 ) within the apparatus 3 . Thus, in the manual placement-type sample analyzer 3 a, the sample container acceptor 310 moves between the manual sample container receiving position and the aspirating position.
An aspirator 330 is provided within the apparatus 3 to aspirate the sample within the sample container 2 that is disposed at the aspirating position. The aspirator 330 is provided with an aspiration tube 331 that is moved downward (vertically downward direction) and pierces the stopper 2 a that seals the sample container 2 , then aspirates the sample within the sample container. The aspirator 330 is further provided with a horizontal drive mechanism for moving the aspiration tube 331 horizontally within the apparatus 3 , and a vertical drive mechanism for moving the aspiration tube 331 vertically.
The holding orifice 311 of the sample container acceptor 310 is formed relatively large so as to allow the insertion of sample containers of various diameters as previously mentioned. Therefore, there is a possibility that the sample container 2 accommodated in the holding orifice 311 may be somewhat inclined and eccentrically positioned and leaning within the holding orifice 311 . There is concern that the inclination, eccentricity and leaning of the sample container may hinder the aspiration tube 331 as it advances within the sample container 2 .
In the present embodiment, a positioning part 340 is provided to position the sample container 2 so as to prevent the sample container from leaning at the aspirating position.
As shown in FIGS. 5 and 6 , the positioning part 340 is configured by a stationary positioner 341 provided at a fixed position within the apparatus 3 , and a movable positioner 342 provided on the sample container acceptor 310 side, so as to fix the position of a sample container by holding the sample container 2 between both positioners 341 and 342 .
The movable positioner 342 is provided at the top of the mounting base 312 , and abuts the front side of a sample container 2 inserted in the holding orifice 311 . When the sample container acceptor 310 is retracted to the aspirating position, the back side of the sample container 2 abuts the stationary positioner 341 , and the sample container 2 is gripped from the front and back by the stationary positioner 341 and the movable positioner 342 . Thus, the sample container 2 is held stable and stationary, and ensures reliable aspiration of the sample.
The sample (the blood sample)aspirated by the aspirator 330 is mixed with reagent and transported to the measuring unit. For this measuring process, the internal mechanism 301 of the apparatus 3 is provided with a measurement sample preparing unit configured by a reagent containers containing reagent, reagent supply pump, reagent supply path, and mixing chamber for mixing the sample and reagent, and further provided with a controller 301 a for controlling the mechanism 301 , and a measuring unit for performing measurements related to red blood cells, white blood cells and platelets in the sample prepared by the measurement sample preparing unit (refer to FIG. 7 ).
Furthermore, the controller is connected to a computer 7 that performs analysis processing of the measurement results, operations of the apparatus and the like, sends measurement result data to the computer, and receives operation instructions from the computer 7 .
When the sample container supplier 4 is installed in the apparatus 3 , the controller 301 a controls the sample container supplier 4 .
Sample Container Supplier (Agitating Apparatus) 4
When a rack 5 holding a plurality of sample containers 2 is set, the sample container supplier 4 shows in FIGS. 1 , 3 , and 8 automatically removes one sample container 2 from the rack 5 , agitates the sample container 2 , and supplies the agitated sample container 2 to the sample analyzer 3 .
The sample container supplier 4 , which functions as an agitating apparatus, is provided with an internal mechanism 401 for agitating and supplying a sample container, and a casing 402 as an apparatus base within which the internal mechanism 401 is installed. FIG. 8 shows the bottom surface 402 a and rear surface 402 b of the casing 402 that remain when the casing 402 has been removed. FIG. 8 also shows the sample container sample container acceptor 310 and moving part 320 of the sample analyzer main body 3 to facilitate understanding.
As shown in FIG. 3 , when the sample container supplier 4 is installed in the manual placement-type sample analyzer 3 a (sample analyzer main body 3 ), the front casing 302 b of the apparatus 3 is removed and the sample container supplier 4 is inserted in the front (one side) of the apparatus 3 . Furthermore, a mounting plate 6 spans bottom surfaces of both the apparatuses 3 and 4 and is affixed to each by screw or the like, such that both apparatuses 3 and 4 are rigidly coupled.
When the apparatuses 3 and 4 are combined, connective wiring and tubing are required between the apparatuses 3 and 4 . For example, the apparatuses 3 and 4 are connected by a power cable for supplying electric power to the electric motor provided in the sample container supplier 4 , control signal line allowing the same electric motor to be controlled by the controller 301 a of the apparatus 3 , air tube for supplying air to the air cylinder provided in the apparatus 4 , sensor signal lines for transmitting signals from sensors provided in the apparatus 4 to the controller 301 a of the apparatus 3 and the like.
Furthermore, the controller 301 a of the apparatus 3 is switchable from a setting for controlling the operation in the manual mode by the apparatus 3 , to a setting to control the operation in both the manual mode and the automatic mode.
Rack Holder 410
The bottom surface 402 a of the casing (apparatus base) 402 is provided with the rack holder 410 in which the rack 5 is set. The rack holder 410 is capable of holding two (multiple) racks 5 equally spaced in front and back. More specifically, arranged on the casing bottom surface 402 a of the rack holder 410 are concavities 411 whose lengths extend laterally and are disposed at equal spacing at front and back. A rack sensor (not shown in the drawing) for detecting the presence of the rack 5 in the rack holder 410 is provided on the casing 402 , such that automatic operation for supplying a sample container cannot be performed when a rack 5 is not disposed in the rack holder 410 .
An opening 403 is formed on the front surface, right side surface and top surface of the casing 402 . Furthermore, an openable cover 404 is mounted on the casing 402 to open and close the opening 403 . As shown in FIG. 1 , when the cover 404 is open, it is possible to set the rack 5 in the rack holder 410 within the casing 402 .
Moreover, although the cover 404 is closed during the sample container automatic supplying operation, the cover 404 is formed of a transparent or semi transparent material to allow visual monitoring of the interior through the cover 404 .
Sample Container Supplying Unit 420
The sample container supplier 4 is provided with a sample container supplying unit 420 as one mechanism configuring the internal mechanism 401 , and which removes the sample container 2 from the rack 5 in the rack holder 410 , agitates the sample container 2 , and moves the sample container 2 to the sample analyzer main body 3 side.
The sample container supplying unit 420 is provided with a movable base 440 (refer to FIG. 9 ) having a hand-like holder 430 for holding the sample container 2 , and a moving unit 450 (refer to FIG. 10 ) that moves the movable base 440 within the apparatus casing (apparatus base) 402 .
Moving Base 440
As shown in FIG. 9 , the moving base 440 is provided with a base body 441 , a forward-and-back moving base 442 that is movable in forward-and-backward directions (Y direction in FIG. 9 ) relative to the base body 441 , and an elevator base 443 that is movable in vertical directions (Z direction in FIG. 9 ) relative to the forward-and-back movable base 442 . The elevator base 443 is movable in forward-and-back and vertical directions as viewed from the base body 441 .
Furthermore, the holder 430 is mounted on the elevator base 443 .
An elevator drive unit (elevator cylinder) 445 that configures the elevator is mounted on the forward-and-back movable base 442 . The elevator base 443 is mounted on the leading end of a rod 445 a of the elevator cylinder 445 . Thus, the elevator base 443 and holder 430 can be raised and lowered relative to the forward-and-back movable base 442 via the extension and retraction of the elevator cylinder 445 .
Moving Unit 450
The moving unit 450 moves the holder 430 installed on the moving base 440 within the casing (apparatus base) 402 . More specifically, the moving unit 450 moves the movable base 440 laterally (X direction in FIG. 10 ), and moves the forward-and-back movable base 442 of the movable base in the forward-and-back directions (Y direction in FIG. 10 ) relative to the base body 441 .
As shown in FIG. 10 , the moving unit 450 is provided with a movement drive unit 451 configured by electric motors M 1 and M 2 , and a transmission mechanism 452 for transmitting the drive force of the movement drive unit to the movable base 440 side.
The first motor M 1 of the movement drive unit 451 is disposed on the left side of the interior of the casing 402 of the sample container supplier.
A first belt 454 configuring the transmission mechanism 452 is looped between a rotating shaft M 1 a of the first motor M 1 and a first pulley 453 disposed on the right side of the interior of the casing 402 of the sample container supplier. The first belt 454 extends in a lateral direction at a position at the rear of the interior of the casing 402 of the sample container supplier.
Moreover, the second motor M 2 of the movement drive unit 452 is disposed to the front of the first motor M 1 and at the left side of the interior of the casing 402 of the sample container supplier. A second belt 456 configuring the transmission mechanism 452 is looped between a rotating shaft M 2 a of the second motor M 2 and a second pulley 455 disposed on the right side of the interior of the casing 402 of the sample container supplier. The second belt 456 also extends in a lateral direction at a position on the front side of the first belt 454 and positioned at the rear of the interior of the casing 402 of the sample container supplier. Furthermore, the second belt 456 is also looped around a third pulley 457 provided on the base body 441 of the moving base 440 , and has a part 456 a that extends in the front-to-back direction so as to form an T-shape overall.
The base body 441 of the movable base 440 is mounted via a mounting stay 441 a on a part extending at the front side of the first belt 454 , such that when the first belt 454 is moved laterally via the rotation of the first motor M 1 , the base body 441 is pulled and the entire movable base 440 is moved laterally.
Furthermore, when the movable base 440 is moved laterally, the second motor M 2 also rotates to move the front-to-back movable base 442 forward and back.
The front-to-back movable base 442 of the movable base 440 is mounted via a mounting stay 442 a on the right side of the front-to-back extension 456 a of the second belt 456 , such that the front-to-back movable base 442 is moved in front-to-back directions relative to the base body 441 when the second motor M 2 is rotated while the rotation of the first motor M 1 is stopped.
According to this configuration, the holder 430 provided on the movable base 440 is movable in lateral directions (X direction) front-to-back directions (Y direction), and vertical directions (Z direction) within the apparatus casing 402 . That is, the holder 430 can be moved in three-dimensional directions (XYZ directions) via the holder moving mechanisms included in the moving unit 450 and elevator drive unit 445 .
Holder 430
As shown in FIGS. 11 and 12 , the holder 430 provided on the movable base 440 (elevator base 443 ) is configured by a pair of finger-like grabbers 431 and 432 that can open and close and has an overall hand-like configuration.
The grabbers 431 and 432 are provided so as to be rotatable on a shaft 433 provided on the elevator base 443 . The holder 430 is capable of performing an agitation operation, which is described later, by means of the grabbers 431 and 432 provided so as to be integratedly rotatable on the shaft 433 .
The grabbers 431 and 432 are provided with bases 431 a and 432 a that have holes through which the shaft 433 is inserted, and grabber bodies 431 c and 432 c that have grippers 431 b and 432 b extending from the bases 431 a and 432 a and grip the sample containers 2 by the ends thereof.
The grabber (fixed side grabber) 431 among the two grabbers is prevented from moving in the axial direction of the shaft 433 . Furthermore, the other grabber (movable side grabber) 432 is provided so as to be movable in the axial direction of the shaft 433 .
A spring 434 is provided between the grabbers 431 and 432 , and this spring exerts a force so as to force the movable grabber 432 to make contact with the fixed grabber 431 . That is, the grabbers 431 and 432 of the holder 430 are normally closed.
A shaft 435 also is inserted through the grabber bodies 431 c and 432 c of the grabbers 431 and 432 so as to guide the movement (opening and closing movement) of the movable grabber 432 .
Holder Grip Drive Unit 447
A holder grip drive unit (holder operating cylinder) 447 configured by an air cylinder is provided on the elevator base 443 of the movable base 440 to open the holder 430 , that is to move the movable grabber 432 relative to the fixed grabber 431 . A press plate 448 is mounted on the leading end of a rod 447 a of the holder opening/closing cylinder 447 to move the movable grabber 432 .
As shown in FIG. 11 , when the rod 447 a of the holder operating cylinder 447 is extended, the movable side grabber 432 is positioned on the fixed grabber 432 side by the spring 434 , such that the holder 430 is closed. When the rod 447 a is contracted and the holder 430 is closed, the press plate 448 is separated from the movable grabber 432 .
As shown in FIG. 12 , when the rod 447 a of the holder operating cylinder 447 is extended, the press plate 448 presses the base 432 a side of the movable grabber 432 , the movable grabber 432 is moved along the shafts 433 and 435 , and the holder opens. Thus, a condition 9 is obtained in which the sample container 2 is gripped.
In this condition, the sample container 2 is positioned between the grippers 43 lb and 432 b, and when the rod 447 a of the holder operating cylinder 447 is contracted as shown in FIG. 11 , the press plate 448 separates from the movable grabber 432 , and the movable grabber 432 is moved back by the spring 434 . Thus, the holder 430 closes, and the sample container 2 can be gripped by the holder 430 .
When the press plate 448 presses the movable grabber 432 and the holder 430 is open, the rotation of the grabbers 431 and 432 around the shaft 433 is regulated by contact friction between the press plate 448 and the movable grabber 432 (an operating regulating condition). When the press plate 448 presses the movable grabber 432 and the holder 430 is open, the rotation of the movable grabber 432 is regulated by pinching between a diameter expansion part 433 a mounted on the end of the movable grabber 432 and the press plate 448 . According to this pinching, the whole of the holder 430 is regulated.
When the holder 430 is closed, however, the press plate 448 and the diameter expansion part 433 a separate from the movable grabber 442 , and the rotation regulation of the grabbers 431 and 432 by the press plate 448 is released (an operating free condition).
Thus, the press plate 448 and the diameter expansion part 433 a function as the regulating part by regulating the rotation when the holder 430 is open and by releasing the regulating rotation when the holder 430 is closed.
Mixing Drive Unit 460
As shown in FIG. 13 , a mixing drive unit 460 is provided as an internal mechanism 401 of the apparatus 4 to generate a mixing drive force to mix a sample within the sample container 2 before the sample container 2 is supplied to the sample analyzer main body 3 .
The mixing drive unit 460 is configured by an electric motor, and the mixing drive unit 460 is fixedly provided at a position on one side (left side) of the rack holder 410 on the rear surface of the casing 402 .
Te sides (left side) of the rack holder 410 provided with the mixing drive unit 460 is near the retracted position (movement start position) of the movable base 440 (holder 430 ).
A contact member 461 is mounted on the rotating shaft 460 a of the motor 460 to contact the holder 430 (fixed grabber 431 ) and transmit the agitation drive force to the holder 430 .
As indicated by the solid line in FIG. 14 , the holder 430 normally (when set at the retracted position) hangs downward from the shaft 433 via its own weight.
The holder 430 is attracted by a permanent magnet 449 provided on the elevator base 443 (movable base 440 ) via metal shard (magnetic body) provided on the fixed grabber 431 of the holder 430 such that the holder 430 does not rotate around the shaft 433 at the hanging position.
When the movable base 440 returns to the retracted position via the moving unit 450 , the contact member 461 of the agitation drive unit 460 contacts the holder 430 as it hangs. When the contact member 461 comes into contact with the holder 430 through the movement of the movable base 440 , the holder 430 rotates slightly on the shaft 433 as indicated by the dashed line in FIG. 14 , such that the metal shard 436 and magnet 449 are released from the magnetic attraction condition.
Thus, the metal shard 436 and the magnet 449 regulate the rotation of the holder 430 about the shaft 433 and function as a regulating part for locking the holder 430 to the movable base 440 side; when the holder is at the retracted position, this regulation is released, and the holder 430 separates from the movable base 440 so as to freely rotate about the shaft 433 .
In the present embodiment, when the holder 430 is at the position other than the retracted position (the position above the rack holder 410 or the sample container acceptor 310 ), the rotation (the mixing operation) of the holder 430 is regulated by the regulation part comprising the metal shard 436 and the magnet 449 . When the holder 430 is open, the rotation (the mixing operation) of the holder 430 is regulated by the regulation part comprising the press plate 448 and the diameter expansion part 433 a.
When the holder 430 removes the container from the rack 5 of the rack holder 410 , returns the container 2 to the rack 5 of the rack holder, sets the container 2 to the sample container acceptor 310 and remove the container from the sample container acceptor 310 , it is prevented that the holder 430 freely moves along the pathway of the mixing operation.
The regulation or releasing is operated with the moving of the holder 430 and the opening/closing of the holder 430 . The apparatus is simple so as not to need the specific driving part to regulate or release the regulation.
When the holder 430 attains the retracted position and is in a rotatable (agitation operation) state and the motor 460 of the agitation drive unit 460 rotates in one direction, the contact member 461 raises the holder 430 in a lifting operation, as shown in FIG. 15 . As a result, the holder 430 is rotated upward and reaches the upper position. Furthermore, when the motor 460 rotates in the opposite direction and the contact member returns to the original position in a restoring operation, the holder 430 rotates downward under its own weight and returns to the lower position.
The agitation operation is accomplished by repeated forward and reverse rotation of the motor 460 , and the repeated raising and lowering of the holder 430 holding the sample container 2 . In the agitation operation the raising and lowering of the holder 430 is repeated approximately ten times. Since the agitation operation is performed when the sample container 2 is at the retracted position of the movable base 440 without the rack 5 , space is conserved.
During the agitation operation, the contact member 461 and the holder 430 alone need be in contact, such that a connective system is not required between the members 461 and 430 . Therefore, the agitation drive force can be received when the holder 430 is simply moved near the agitation drive unit 460 , and the agitation drive force can not be received when the holder 430 is moved away from the agitation drive unit 460 .
Receiver Unit 470 of the Sample Container Acceptor 310
As shown in FIGS. 1 and 3 , a receiving unit 470 is provided on the casing 402 of the sample container supplier to receive the arriving sample container acceptor 310 of the sample analyzer main body 3 . The receiving unit 470 is provided on the other side (right side) of the rack holder 410 in the lateral direction.
The receiving unit 470 has an opening 471 formed on the bottom right part of the rear surface 402 b of the casing 402 , and a concavity 472 that accommodates the sample container acceptor 310 that has moved forward and passed through the opening 471 from the sample analyzer main body 3 .
The sample container acceptor 310 can advance into the casing 402 of the sample container supplier even when a wall (casing rear surface 402 b ) separates the sample analyzer main body 3 and the sample supplier 4 via the provision of the opening 471 .
Furthermore, the position of the concavity 472 is the position at which the sample container 2 is supplied by the sample supplier 420 (sample container supplying position), and the sample container acceptor 310 can accept the sample container 2 by advancing the sample container acceptor 310 into the concavity 472 .
Sample Container 2 Manual Placement Mode (Manual Mode) in the Sample Analyzer 1
The sequence of the manual mode for setting a sample container 2 manually in the sample analyzer 1 having the previously described configuration is described below.
As shown in FIG. 8 , a sample container 2 containing a sample manually agitated beforehand is inserted in the holding orifice 11 of the sample acceptor 310 when the sample container acceptor 310 is moved forward from the sample analyzer main body 3 and received by the receiver 470 of the sample container supplier 4 . When the manual measurement start button 480 provided on the casing bottom surface 402 a of the sample container supplier 4 is pressed, the controller 301 a retracts the slider 321 . Then, a manually set sample container 2 (sample acceptor 310 ) is positioned at the aspirating position (position in FIG. 4 ) within the sample analyzer main body 3 .
The sample of the sample container 2 at the aspirating position is aspirated by the aspirator 330 , and measured by the measuring unit. Then the measurement results are analyzed by a computer not shown in the drawing.
The manual mode operation, and measurement and analysis processes after placement are basically identical to the sequence in the manually placement mode of the manual placement-type sample analyzer 3 a.
In the sample analyzer 1 with the installed sample container supplier 4 , the forward extension of the sample container acceptor 310 is greater than the manual placement-type sample analyzer 3 a without an installed sample container supplier 4 , such that the sample container acceptor 310 can be reliably advanced into the interior of the sample container supplier 4 . That is, the sample container supplying position of the sample analyzer 1 is positioned farther forward than the manual sample container setting position in the manual placement-type sample analyzer 3 a.
Moreover, the forward extension of the sample container acceptor 310 can be switched by the setting of the controller 301 a.
Sample Container 2 Automatic Supplying Operation (Automatic Mode) in Sample Analyzer 1
In the execution of the automatic mode, the rack 5 holding the sample container 2 is set in the rack holder 410 , and the cover 404 is closed on the sample container supplier 4 , as shown in FIG. 1 . he rack 5 holds the sample container 2 in an approximately upright vertical state.
Then, when the automatic measurement start button 490 is pressed, the sample container 2 is automatically supplied and the sample measured. Whether or not the cover 404 is closed is detected by a cover sensor not shown in the drawing; when the cover 404 is not closed, the automatic measurement can not start.
The automatic supply of the sample container 2 is controlled as follows by the controller 301 a. First, at the start of the automatic mode, the movable base 440 that has the holder 430 is at the movement start position (retracted position) shown in FIGS. 3 and 8 , and the operation starts from this position. The movable base 440 with the holder 430 is moved from the movement start position to the position of the sample container 2 to remove one of the two sample containers 2 in the rack 5 set in the rack holder 410 .
When the holder 430 is positioned above the sample container 2 to be removed, the holder 430 is opened and the holder 430 is lowered in this open state. After lowering, the holder 430 is closed and raised while gripping the sample container 2 , then returns to the movement start position (mixing position).
The space between the front and rear concavities 441 of the rack holder 410 is set to allow passage of the sample container 2 held by the holder 430 . Therefore, when the holder 430 is moved laterally above the rack holder 410 holding the sample container 2 , the sample container 2 held by the holder 430 can pass through the space between the sample containers 2 (front and rear space) in the rack 5 set in the front and back concavities 441 .
As a result, the holder 430 holding the sample container 2 can be lifted above the rack holder 410 without raising the held sample container 2 to as position higher than the sample container 2 in the rack 5 . That is, without raising the holder 430 very much, the holder 430 can be moved above the rack holder 410 while avoiding contact between the held sample container 2 and the sample container 2 in the rack 5 .
Thus, the raising height is very slight when moving the holder 430 (movable base 440 ), such that the operation can be performed quickly and the apparatus can be made more compactly (particularly in the height direction of the apparatus).
Moreover, a sample container sensor 500 is provided to detect whether or not the holder 430 holds a sample container 2 when the holder 430 (movable base 440 ) holding the sample container 2 returns to the movement start position. If the holder 430 holds a sample container 2 , the mixing operation proceeds. When the holder 430 does not hold a sample container 2 , the same operation as described above is performed to remove a sample container 2 from the other position of the rack 5 .
As shown in FIG. 13 , during the mixing operation, the mixing drive unit 460 is rotated to vertically rotate the contact holder 430 to mix the sample within the sample container 2 .
When the mixing operation ends, the holder 430 returns to the condition of hanging in a perpendicular direction as shown in FIG. 1 .
The mixing position need not to be identical with the retracted position, the mixing position may be near the retracted position.
Then, the holder 430 (movable base 440 ) holding the sample container 2 holds the sample container 2 in a near vertical state, crosses above the rack holder 410 , and moves to a position above the sample container acceptor 310 (receiver 470 ) astride the rack holder 410 .
Then, the holder 430 is lowered, and the sample container 2 is inserted in the sample container receiver 310 . Thus, the sample container 2 is set in the sample container receiver 310 in a near vertical upright state. Thereafter, the holder 430 opens, separates from the sample container 2 , and is lifted.
Then, the slider 321 is retracted and the information recording area (barcode) 2 b adhered to the sample container 2 is read by a reading unit (barcode reader) not shown in the drawing, and the sample container 2 (sample acceptor 310 ) is positioned at the aspirating position (position shown in FIG. 4 ) within the sample analyzer main body 3 .
The sample of the sample container 2 at the aspirating position is aspirated by the aspirator 330 , and measured by the measuring unit. Then the measurement results are analyzed by a computer not shown in the drawing.
When the sample has been aspirated from the sample container 2 , the slider 321 advances and the sample container acceptor 310 is again positioned at the receiver 470 .
The holder 430 is again lowered to collect the aspirated sample container 2 , and the sample container 2 in the sample container acceptor 310 is gripped and lifted. Then, the holder 430 moves to the position of the rack 5 , and the sample container 2 is returned to the rack 5 .
The holder 430 (movable base 440 ) returns to the movement start position after the aspirated sample container 5 has been returned to the rack 5 .
Thereafter, the same automatic supplying measurement and analysis are performed for the other sample container in the rack 5 .
The present invention is not limited to the above embodiment and may be variously modified.
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An agitating device for agitating a blood sample in a sample container is disclosed. The agitating device includes a base comprising a horizontally-supported shaft, a container holder including a first hand and a second hand, the first hand having a first hole at one end and a first hold portion at other end, the second hand having a second hole at one end and a second hold portion at other end, the first and second holes through which the shaft is inserted, the first and second hands being rotatable relative to the shaft and the first and second hold portions faced each other, and an agitation drive unit including a contact member for contacting the container holder and a drive source for reciprocating the contact member contacting the container holder between a lower position and an upper position.
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BACKGROUND OF THE INVENTION
The invention relates to a dehumidifying device for the dehumidification of a cavity, preferably the space between the glass sheets of a window.
For the dehumidification of a cavity, e.g. a room it is known to let the air to said room circulate through a hygroscopic agent, e.g. silica gel. Likewise, it is known that such a hygroscopic agent will gradually become water saturated and will have to be replaced or regenerated.
This is not a problem when dealing with dehumidication of rather large rooms such as a laboratory or part thereof. However, in dealing with an inaccessible cavity or a cavity where at least one of the dimensions is very limited, e.g. the space between the two glass sheets of a double glazing, it can be very difficult or impossible to perform replacement or regeneration of the moisture absorbing agent.
Furthermore, it is known that numerous technical solutions have for many years been proposed or used for keeping the intermediary space in a double glazing free from humidity. For various reasons, these different solutions work most frequently unsatisfactorily.
An important reason is that very often use is made of a hermetic seal designed for remaining tight during the whole lifetime of the window.
This seal cannot be repaired and even a microscopic puncture will spoil the properties of the window. This makes heavy demands on performing the sealing and the insulating power of the double glazing is greatly impaired along the seal.
Another reason is that the manufacturing itself of such windows presupposes a moisture-free atmosphere in the production hall or, at least, that it is dry air which is retained between the two glass sheets at the moment they are hermetically joined together which makes the manufacturing process difficult.
A third reason is to be found in ageing phenomena occurring in said agents, whereby the intended sealing often is only short-lived and from the moment where a leakage has occurred in the double glazing unit the penetrating moisture will result in the well-known phenomena: misting, accumulation of condensed water in the lower part of the window, etc.
SUMMARY OF THE INVENTION
It is an object of the present invention to remedy the stated disadvantages and in view thereof a dehumidifying device according to the invention is characterised in that it comprises a cell so arranged as to dissociate the water molecules from said space by application of external energy.
The advantage of such a design is that the means used to keep the two glass sheets together need no longer be arranged so as to keep both dust and moisture away and it is sufficient to let said means be efficient as dust barrier. The cell can be made to work immediately, i.e. already when assembling the glazing unit and even if a leakage should occur in the unit the cell will effectively prevent misting and thus extend the lifetime of the unit. The water is dissociated by electrolysis and oxygen and hydrogen will be drained off to the atmosphere, whereby the electrolyte is concentrated and its hygroscopic effect is maintained.
For a better understanding of the mode of operation of such a cell reference is made to an article: "Photocatalytic Decomposition of Water at Semiconductor Electrodes" by H. P. Maruska and A. K. Ghosh in Solar Energy, Vol. 20, page 443 to 458, Pergamon Press, 1978.
A particular advantage of the dehumidifying device according to the invention is that its simple design allows it to be placed in already existing windows or in windows manufactured in the usual way, e.g. by mounting it on one of the sheets after having simply made a hole adapted to the cell in said sheet. The dehumidifying device necessitates thus no other modification in existing constructions.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further explained hereinafter with reference to the accompanying schematical drawing in which
FIG. 1 shows an embodiment of a dehumidifying device according to the invention, especially for use in a tilting window, and
FIG. 2 another embodiment of a dehumidifying device according to the invention.
DETAILED DESCRIPTION
FIG. 1 shows a part of a window, preferably a tilting window, with two essentially parallel glass sheets 1 and 2, separated from one another by an air space 3. The drawing neither shows the window frame nor the pivot hinges or the means for securing the two glass sheets together.
In one of the glass sheets, e.g. the glass sheet 2 which is assumed to be the external glass sheet, provision is made of a preferably circular opening 4 in which the dehumidifying device according to the invention is located.
This dehumidifying device is shaped as a cartridge comprising a glass container 5 surrounded by a plastic jacket 6 which is inserted, e.g. pushed into or firmly glued to the opening 4, its external flange 7 covering the edge of the opening 4.
In the embodiment shown, the glass container 5 is in the form of a cylinder of circular cross-section in relation to axis 0--0, for which reason the plastic jacket 6 is also shaped as a cylinder. By means of a partition 8 essentially perpendicular to the axis 0--0, the glass container 5 is divided up into two compartments 5a and 5b forming vessels which communicate with one another through a glass tube 9 running parallel to the axis 0--0 in the lower part of the partition 8.
As shown in FIG. 1, the side wall of the two compartments which is located nearest the axis 0--0 ends at a certain distance from the partition 8, thus forming an opening or pipe stub 10 which connects one compartment 5a with the air space 3 between the glass sheets 1 and 2, and an opening or pipe stub 11 which connects the other compartment 5b with the atmosphere through an interchangeable filter plug 12 of, e.g., plastic material fitted with a dust filter 13 and inserted in the glass container.
An electrode 14 is provided on the inside of the end wall of the container 5 facing the atmosphere and a second electrode 15 is provided on the inside of the opposite end wall of the container. The two compartments 5a and 5b of the container 5 contain granulated material as shown by references 5c and 5d. Said granulated material is saturated with a hygroscopic electrolyte and reference 16 designates the electrolyte meniscus in one compartment 5a. The electrolyte may, e.g., be concentrated sulphuric acid H 2 SO 4 .
By conveniently dimensioning the glass container 5, the pipe stubs 10 and 11, by suitably locating and dimensioning the glass tube 9 and by choosing a convenient quantity of electrolyte, the window and with it the dehumidifying device may be placed in any position, without liquid leaking out from the container. The purpose of the granulated material is to prevent splashes due to sudden changes in the position of the window or blow-off due to sudden variations of pressure in the air space 3 between the glass sheets 1 and 2.
The inside of the anode 14 is provided with a layer 17 of capillary material which by capillarity absorbs the electrolyte and distributes it over the parts of the electrode which are not immersed in the electrolyte.
As previously mentioned, the dehumidifying device functions by electrolysis of water. Aqueous vapor which is present in the space 3 or originates from outside air diffuses slowly toward the electrolyte and is absorbed therein. When the window cools down, a low pressure appears in the intermediary space 3 and air from outside is drawn in through the filter plug which retains any dust particle from said air. Air is drawn in through the communicating compartments which then work as a trap, whereby the air is dried by passing through the hygroscopic agent. This reduces the moisture of the air which penetrates inside the window, while the water content of the electrolyte increases correspondingly.
When the window is heated either from inside the room or due to exposition to sunlight the pressure in the intermediary space 3 increases, whereby air is expelled throught the dehumidifying device and any water present in said air is absorbed by the electrolyte and dissociated.
For dissociation of the quantity of water present in the electrolyte, electrolysis may be performed. This reaction necessitates that a potential of at least 1.23 V be applied between the two electrodes and in order to obtain a current of fairly convenient magnitude, potentials of 1.6 to 1.8 V will be necessary. It is possible to reduce the necessary potential, which, e.g., can be obtained by means of a battery, by using an anode of, e.g., TiO 2 , which subjected to illumination produces oxygen, and a cathode of, e.g., Pt which produces hydrogen.
Another possibility of avoiding the need of bias is to use an anode of SrTiO 3 which allows photoelectrolysis without bias.
A further possibility of producing the potential for the dissociation phenomenon is based on the use of an external photocell as shown by reference 18, said photocell being connected to the electrodes 14 and 15 via connections 19 and 20.
It should be noted here that in certain circumstances where the intensity of illumination on said photocell would reach an insufficient level, e.g. due to poor illumination or to particular climatic conditions, the energy gained from such a photocell of relatively limited size may be too low. In such case, it is advantageous to use the whole surface or at least part of the whole surface of the outer glass sheet 2 as a support for the photocell layer, said layer (not shown) being then via conductors (not shown) printed on the glass sheet connected with the respective electrodes of the electrolysis cell in the cartridge.
FIG. 2 shows another embodiment of a dehumidifying device according to the invention. In analogy with FIG. 1, neither the window frame nor the hinges or the means for securing the two glass sheets together are shown in FIG. 2.
In one glass sheet, e.g. glass sheet 22, which is assumed to be the external glass sheet, a preferably circular opening 24 has been made in which the dehumidifying cartridge is inserted.
This dehumidifying device comprises a glass container 25 which e.g. is shaped as a circular cylinder around the axis 0--0. This container is maintained in the opening 24 in the glass sheet 22 by means of a sleeve 26 of plastic or elastomer, shaped with a cylindrical part 27 to be inserted in the opening 24 and with an external annular flange 28 to be located against the outer face of the glass sheet 22 around the opening and with an internal annular flange 29 surrounding the central opening 30 of the sleeve and forming a supporting edge for the glass container 25.
At the innermost end of the sleeve 26, the cylindrical part 27 is shaped with a flange 31 which extends radially inwards and surrounds a central opening 32 for the glass container. As shown in FIG. 2, an annular space is provided between the cylindrical side wall of the container 25 and the cylindrical part 27 of the sleeve. Prior to inserting the container in its sleeve said annular space is filled with dust filtering material as shown at 33.
Holes 34 in the internal flange 29 of the sleeve establish connection between the filter space and the atmosphere.
In the cylindrical wall of the container 25 there is at least one hole 35 through which the inside of the container communicates with the annular filter space 33, and at least one hole 36 through which the inside of the container communicates with the intermediate space 23 between the glass sheets 21 and 22.
The container 25 is provided with an electrode 37 on or near the end wall facing the opening 30 in the sleeve and a second electrode 38, e.g., on the cylindrical side wall. The container contains electrolyte in the form of granulated material impregnated with acid, e.g. H 2 SO 4 , or of a gel containing a convenient quantity of acid. The electrode 37 receives sunlight directly. If said electrode is made of, e.g., SrTiO 3 or other suitable material having similar semi-conductor properties or combination of such materials, the quantity of water present in the electrolyte dissociates into oxygen and hydrogen.
The outer surface of the cylindrical part 27 of the sleeve is shaped with annular ribs 39 ensuring fixation of the sleeve in the opening 24, both during and after insertion of the sleeve. It has to be noted that the sleeve should be shaped and dimensioned in relation to the glass sheet and to the container so that there is tight fitting at all the places where the sleeve is in contact with the glass or the container.
It should be noted that in the above it is assumed that the container 5 (FIG. 1) or 25 (FIG. 2) is made of glass. However, it may also be made of other material, e.g., plastic, provided that said material lets light pass through to the anode 37 or that the anode 37 is located on the outside of the container, directly accessible to sunlight.
It will be understood that the dehumidifying cartridge as shown in FIG. 2 may also be combined with a photocell layer on the container 25 itself or on at least a part of the surface of the outer glass sheet 22 in the same way as previously explained in relation to the embodiment according to FIG. 1.
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For the dehumidification of a cavity preferably the intermediary space (3) between the glass sheets (1, 2) of a window, the dehumidifying device comprises a cell (5, 6, 7) shaped as a cartridge to be inserted in an opening in one of the glass sheets and so arranged as to absorb and by electrolysis to dissociate the water molecules from said cavity (3) by application of external energy. (FIG. 1).
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/426,688, filed Nov. 15, 2002.
FIELD OF THE INVENTION
The invention is directed generally to motor vehicles, and more particularly, to oil tanks usable with motor vehicles.
BACKGROUND
A conventional motorcycle includes a frame and is supported by front and rear wheels. A motorcycle also includes a motor that is often positioned in a cavity that is centrally located within the frame of the motorcycle. The cavity is formed by the supports forming the frame and is located beneath a seat for supporting a rider. Components necessary for operation of the motorcycle are typically positioned in the cavity and may be attached to the engine, mounting brackets, or the frame itself proximate to the cavity. In addition, an oil tank is often attached to the frame directly beneath the seat that supports a rider. The cavity in which a motor is mounted often does not include a housing or other structure. Rather, the cavity is open. As a result, the engine and related components are susceptible to being covered with corrosive and destructive elements, such as oil, salt, sand, water and other materials, commonly found on a roadway. Also, by positioning the components of the motorcycle in the cavity adequate areas for storage are not available.
Thus, a need exists for an alternative configuration for a motorcycle so that components of the motorcycle are protected from elements found on a roadway and adequate storage is provided.
SUMMARY OF THE INVENTION
The invention is directed to a fender for a motor vehicle. The fender may be a rear fender configured to be positioned proximate to a rear wheel of a motor vehicle. In other embodiments, the fender may be configured to be placed proximate to other wheels of motor vehicles, such as front wheels. The fender is formed from a body that is configured to be placed in close proximity with a rear wheel of the motor vehicle to limit the amount of material thrown by the rear wheel onto the rider or the motor vehicle, or both. The fender may also include a housing attached to the body and forming a cavity for containing a fluid. The housing may include one or more orifices for receiving or releasing a fluid, or both. The body of the fender may be curved around the axis about which the rear wheel rotates so that a first end of the body of the fender is positioned proximate to an uppermost position of the rear wheel of the motorcycle and a second end of the body is positioned proximate to a rear portion of the rear wheel where the rear wheel contacts a ground surface. The body of the fender may also be curved so that a first edge of the body of the fender is positioned generally parallel to a first side of a rear wheel and a second edge of the body of the fender is positioned generally parallel to a second side of the rear wheel, wherein the first side of the rear wheel is generally opposite to the second side of the rear wheel.
In one embodiment, the fender is configured to be coupled to a motorcycle proximate to a rear wheel, and the cavity in the fender may contain oil, thereby eliminating the need to couple an oil tank to the motorcycle proximate to the engine. By incorporating the oil tank in the fender, space under the seat of the motorcycle is opened. Engine components that are susceptible to failure from destructive materials typically present on a roadway may be positioned under the seat, thereby at least partially protecting the components from the elements.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate preferred embodiments of the presently disclosed invention(s) and, together with the description, disclose the principles of the invention(s). These several illustrative figures include the following:
FIG. 1 is a side view of a motorcycle according to the invention;
FIG. 2 is a rear perspective view of the motorcycle of FIG. 1 according to the invention;
FIG. 3 is a side perspective view of the fender;
FIG. 4 is a bottom view according to the invention; and
FIG. 5 is a cross-section of the fender taken at 5 — 5 in FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1–5 show a fender 10 of this invention. Fender 10 may be configured to be a fender; however, fender 10 is not limited to a rear fender, but may also be a front fender usable with a front wheel or a fender for another type of wheel. Fender 10 generally is formed from a body 12 and a housing 30 that forms a cavity 32 for containing fluids. Fender 10 may be configured to be placed proximate to a rear tire of a motor vehicle 40 . Motor vehicle 40 may be any motor vehicle. In one embodiment, fender 10 may be configured to be placed proximate to a rear tire of a motorcycle. Fender 10 may be formed from a body 12 configured to be placed in close proximity with a rear wheel of a motorcycle 40 to protect a rider and motorcycle 40 from materials kicked up by the rear wheel from a roadway surface. Body 12 may curved, as shown in FIG. 1 , to cover a portion rear wheel 14 so that a first end 16 of body 12 is positioned proximate to an uppermost position 18 of a rear wheel 14 of the motorcycle and a second end 20 of body 12 is positioned proximate to a portion of the rear wheel 14 where the rear wheel 14 contacts a ground surface. In this position, body 12 is curved around axis 15 . Body 12 is not limited to this configuration. Rather, body 12 may be longer or shorter than body 12 shown in FIG. 1 . In addition, body 12 may be a combination of one or more curved or straight edges.
Body 12 may also be curved so that a first edge 22 of body 12 is positioned generally parallel to a first side 24 of rear wheel 14 of the motorcycle, and a second edge 26 of body 12 is positioned generally parallel to a second side 28 of rear wheel 14 . First side 24 of rear wheel 14 is generally opposite to second side 28 of rear wheel 14 . In another embodiment, body 12 may have a generally flat cross-section or other configuration.
Fender 10 may also include a housing 30 attached to body 12 and forming a cavity 32 for containing a fluid, such as, but not limited to oil, water, engine coolant, and other fluids. Cavity 32 may be configured to have various capacities, such as, but not limited to about one cup to about one gallon or more. Housing 30 is not limited to a simple cavity 32 . Instead, housing 30 may form two or more cavities. Housing 30 may be integrally formed together with body 12 or may be formed separately and coupled to body 12 . In one embodiment, housing 30 is positioned on an outside surface 34 of body 12 . However, housing 30 may be positioned on another surface of body 12 . Housing 30 may have any configuration that does not interfere with operation of the motor vehicle to which housing 30 may be attached. Housing 30 may include one or more brackets 36 enabling housing 30 to be attached to a motor vehicle. Bracket 36 may have any configuration.
Housing 30 also includes a one or more orifices 38 for receiving or releasing a fluid, or both. More specifically, housing 30 may have a single orifice 38 for receiving and releasing a fluid, or housing 30 may have one or more inlets 38 for receiving a fluid into cavity 32 or may have one or more outlets 38 for releasing a fluid from cavity 32 . Housing 30 may also have an orifice 38 used solely for draining oil from cavity 32 . A valve or other device may be coupled to orifice 38 for controlling the release of fluids from cavity 32 . Housing 30 may also include a fill cap 39 for receiving a fluid.
The components of fender 10 may be formed from any resilient material, such as, but not limited to, aluminum, steel, stainless steel, galvanized steel, titanium, composites, plastics, any combination of these materials or other materials. Each component may be formed from the same material. Alternatively, the components may be formed from different materials.
Fender 10 may be releasably or permanently coupled to a motor vehicle. For instance, fender 10 may be releasably coupled to a motor vehicle using nuts and bolts, quick connect mechanisms, cable, or other such devices. Fender 10 may be permanently coupled to a motor vehicle using any type of weld compatible with the material forming fender 10 or other permanent coupling mechanism. Fender 10 may or may not be painted and may or may not have a finished surface. Fender 10 may be painted using one or more colors and may include decals or other appearance enhancing items.
In one embodiment, fender 10 is coupled to a motorcycle 40 , as shown in FIGS. 1 and 2 , and cavity 32 is configured to function as an oil tank. However, cavity 32 may contain other materials as needed. Motorcycle 40 is composed of front and rear wheels, 42 and 14 respectively, that support a frame 44 . Positioning an oil tank in fender 10 increases the amount of open space near the engine of the motorcycle. In most conventional motorcycles, the oil tank 32 is positioned directly beneath the seat. However, incorporating the oil tank 32 in fender 10 allows electronic components to be positioned in the space typically occupied by an oil tank. This configuration allows for these components to be secured under the seat and out of the elements (sun, rain, salt spray, etc.), thereby providing for a more secure and reliable system.
The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of this invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of this invention.
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A fender for a motor vehicle, such as a motorcycle, having a tank for containing fluids, such as oil. The fender limits the amount of materials thrown by a rear wheel of the motor vehicle onto a rider and provides a reservoir for fluids used by the engine. The fender also increases the amount of free space located under the seat and proximate to an engine of the motor vehicle, thereby enabling engine components to be placed under the seat in a more protected position.
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This invention is a Continuation-In-Part to U.S. Application Ser. No. 08/237,900 entitled Hydrogen Enriched Natural Gas as a Clean Motor Fuel filed on May 4, 1994.
This invention relates to mobile vehicle fuels, and in particular to a hydrogen and natural gas mixture used as a fuel for combustion engines and a lean burn throttle control algorithm to optimize a vehicle emissions and power. This invention was funded in part under contract no. DCA 92SE20061505026 from the Florida Energy Office.
BACKGROUND AND PRIOR ART
Due to the world's depleting reserves of fossil fuels such as oil, there exists a need for alternative fuel vehicles(AFV's). The Energy Policy Act (EPACT) signed by President Bush in 1992 requires that states and the federal government take steps to reduce energy use and to shift to other sources of energy, including the addition of alternative fuel vehicles(AFV's) to federal and state fleets. Individual states such as California and New York have instituted goals of near-zero emission standards for percentages of new vehicles sold within those states in the near future. Thus, the need exists for alternative fuels.
Natural gas has long been considered an excellent alternative fuel since it is considered much cleaner than other fossil fuels such as oil, and its reserves are much larger than crude oil. Natural gas which is primarily composed of methane and combinations of Carbon Dioxide, Nitrogen, Ethane, Propane, Iso-Butane, N-Butane, Iso Pentane, N-Pentane, and Hexanes Plus, is a renewable energy source since anaerobic bacterial eventually will convert all plants into methane type gas. Natural gas has an extremely high octane number, approximately 130, thus allowing higher compression ratios and broad flammability limits.
A problem with using natural gas is reduced power output when compared to gasoline, due mostly to the loss in volumetric efficiency with gaseous fuels, as well as the lack of the infrastructure for fueling natural gas vehicles. Another problem area is the emissions produced by these natural gas vehicles. Although, the emissions are potentially less than that of gasoline vehicles, these vehicles generally require some types of emissions controls such as exhaust gas recirculation(EGR), positive crankcase ventilation(PCV), and/or unique three-way catalyst. A still another problem with using natural gas vehicles is the slow flame speed which requires that the fuel be ignited substantially before top dead center (BTDC). In general, most internal combustion engines running on gasoline operate with a spark advance of approximately 35 degrees BTDC where as the same engine operating on natural gas will require an approximate advance of 50 degrees BTDC. The slower burn rate of the fuel results in reduced thermal efficiency and poor burn characteristics.
Proposed alternative fuels utilizing hydrogen and fossil fuels have also been used with resulting problems. In an article entitled Houseman et al., "A Two-Charge Engine Concept: Hydrogen Enrichment" SAE Paper #741169 (1974), research was conducted at the Jet Propulsion Laboratory. The researchers ran a V-8 internal combustion engine on a mixture of gasoline and hydrogen. The addition of hydrogen allowed the engine to be operated much leaner than was possible on gasoline alone. The result of this research was that NO X emissions were reduced below the 1977 EPA standard of 0.4 gm per mile. The article states that "At an equivalence ratio of 0.53, very low NO X and CO were produced and engine thermal efficiency was substantially increased over stock gasoline configurations. The article mentions that in order to "operate a vehicle on fuel mixtures of gasoline and hydrogen, an onboard source of hydrogen is required. Onboard storage of hydrogen, either as a compressed gas, as a liquid at cryogenic temperature, or as a hydride is not a practical solution today. Direct generation of hydrogen from gasoline in an onboard reactor was selected as the best solution to the problem." The main problem with this device was that the reactor described has not been adopted due to the complexity of the device.
The articles by MacDonald, J. S.,entitled "Evaluation of the Hydrogen Supplemented Fuel Concept with an Experimental Multicylinder Engine" Automotive Engineering Congress and Exposition, SAE Paper #760101 (1976), and by Parks , F. B., entitled " A Single-Cylinder Engine Study of Hydrogen-Rich Fuels" Automotive Engineering Congress and Exposition, SAE Paper #760099 (1976) were by authors from General Motors that also investigated the use of hydrogen-enriched gasoline. Reflecting on Houseman et al.'s work, MacDonald states that, "while this approach (hydrogen reactor) as been shown to be feasible, it does have its limitations. A problem is the maximum theoretical yield of hydrogen per pound of fuel is about 14% by weight. Another problem is the hydrogen generator is at best only 80% efficient, so that any gasoline going to the generator represents an efficiency loss, which is a loss in fuel economy. For these reasons it is desirable to keep the quantity of hydrogen required for acceptable engine operation to a minimum. This article goes on to report that when 14.4% of the fuel mass was hydrogen the engine operated satisfactorily with an equivalence ratio of 0.52 and the NO X levels had dropped below the EPA mandated level of 0.4 gm per mile.
Several U.S. patents have incorporated similar concepts. For example, U.S. Pat. No. 4,376,097 to Emelock describes a hydrogen generator for motor vehicles. U.S. Pat. No. 4,508,064 to Watanabe describes a customized engine for burning hydrogen gas. U.S. Pat. No. 5,176,809 to Simuni describes a technique of producing and recycling hydrogen from exhaust gases.
Some research has been conducted for combining hydrogen and natural gas as a fuel mixture. Articles by Nagalingam et al. entitled: "Performance Study Using Natural Gas, Hydrogen-Supplemented Natural Gas and Hydrogen in AVL Research Engine", International Journal of Hydrogen Energy, Vol 8, No. 9, pp. 715-720, 1983; Fulton et al. entitled: "Hydrogen for Reducing Emissions from Alternative Fuel Vehicles" 1993 SAE Future Transportation Conference, SAE Paper from Alternative Fuel Vehicles" 1993 SAE Future Transportation Conference, SAE Paper #931813, (1993) and an article by Yusuf entitled: "In Cylinder Flame Front Growth Rate Measurement of Methane and Hydrogen Enriched Methane Fuel in a Spark Ignited Internal Combustion Engine, Unpublished Masters Theseis, University of Miami (1990) each disclosed such combinations of a fuel mixture. However, the mixtures were generally limited to 20% hydrogen and the rest generally methane.
U.S. Pat. No. 5,139,002 to Lynch et al., states that hydrogen enriched mixtures should only contain mixtures of up to levels of between "10 and 20%." See column 9, lines 49-60, and column 16, lines 14-21. At column 9, lines 37-60, Lynch et al. states that "Relatively few tests were necessary to rule out the 25% and 30% mixtures(of hydrogen) . . . "
Despite its clean burning characteristics, the utilization of hydrogen has had many problems as an alternative fuel. Primarily, the use of hydrogen in vehicles has been limited by the size, weight, complexity and cost of hydrogen storage options as well as the cost of hydrogen.
The controlling of air/fuel ratios and engine power has been limited in past applications. Generally, a spark ignition(SI) engine's power is controlled through a process called throttling. Throttling controls the volume of air that enters a combustion engine. The throttle system is formed from one or more throttle blades which are placed in the air inlet stream. During a "closed throttle" position also referred to as IDLE, the throttle blade closes off the air inlet and the only air entering the engine is leakage passing through the blades. Alternatively, the only air entering the engine can be air passing through a small hole in the throttle blade to provide a minimum amount of air to the engine. When the throttle is wide open, the throttle blade is parallel to the air stream and it presents a minimal air restriction to the incoming air. Most often the throttle blade is between full open and fully closed thus presenting a controlled restriction to the air passage.
Fuel in a spark ignition(SI) engine is generally introduced into the inlet air stream to provide the air fuel mixture for combustion. Various methods have been used for introducing the fuel into the air. For example, the carbureted SI engine is the most common method for automotive applications. Here, the carburetor controls the amount of fuel injected into the air stream by the fuel orifice size and the pressure drop across a venturi. To increase the amount of fuel to be injected given a constant pressure drop, the size of the jet was increased. With a fixed jet size, the amount of fuel entering the air stream remained virtually proportional to the pressure drop across the ventur. Thus, the pressure drop across the ventur was a function of throttle position.
An alternative known method of introducing fuel into the air stream is a fuel injector. The fuel injector can be located in a common plenum which feeds all of the cylinders on a multicylinder engine. At this location, the engine is said to be "throttle body injected." The injectors can alternatively be located in the intake runners feeding the individual runners. This type of injection is referred to as "port injection."
In both the throttle body and the port injection systems a sensor is needed to measure the amount of air entering the engine in order to control the injectors and produce a constant air/fuel ratio over the full range of throttle openings. Generally the output signal from a pressure sensor or a flow sensor is fed to a computer which uses the analog of the air flow from the sensor to control the length of time the injector is to be open and thus control the air/fuel ratio. Additional sensors have also been included to measure throttle position and exhaust oxygen content. Output from these sensors also can control the air/fuel ratio.
Power output of an engine has also been controlled strictly by the amount of fuel introduced into the combustion chamber just prior to ignition. In compression ignition(CI) engines also referred to as "Diesel Engines", the CI engine does not usually have a throttle. Air entering the engine is only restricted by the intake manifold design. Fuel is injected directly into the cylinder of the CI engine just prior to ignition. The ignition is caused by the high heat generated during the compression stroke.
Examples of the above prior art can be found in U.S. Pat. Nos.: 3,982,878 to Yamane et al.; 4,184,461 to Leung; 4,213,435 to Simko; 4,244,023 to Johnson; 4,406,261 to Ikeura 4,471,738 to Smojver; 4,512,304 to Snyder; and 4,730,590 to Sogawa.
Operating an engine at lean burn was attempted by U.S. Pat. No. 4,499,872 to Ward et al. However, the Ward system is restricted to an adiabatic engine design and requires elaborate structural components and connections such as a microwave generator in order to operate.
SUMMARY OF THE INVENTION
The first objective of the present invention is to provide a hydrogen and natural gas mixture that can extend the lean combustion limits of natural gas as a motor fuel.
The second object of this invention is to provide a hydrogen and natural gas mixture that substantially reduces the harmful exhaust emissions produced by conventional combustion engines.
The third object of this invention is to provide a hydrogen and natural gas mixture that can be used in existing gaseous vehicles without major modification and additions to those vehicles.
The fourth object of this invention is to provide a hydrogen and natural gas mixture that can meet long term federal and state emission requirements.
The fifth object of this invention is to provide a hydrogen and natural gas fuel mixture that optimizes the cost of the fuel against exhaust emissions.
The sixth object of this invention is to provide a hydrogen and natural gas fuel mixture that contains approximately 21 to 50% hydrogen and the rest natural gas such as methane.
The seventh object of this invention is to provide a computer controlled method of controlling the variable air/fuel ratio of a standard internal combustion engine in order to achieve lean burn.
The eighth object of this invention is to provide a throttle control to achieve lean burn in a standard internal combustion engine.
The ninth object of the invention is to provide a control to maintain the air fuel ratio to optimize power, efficiency and emissions as defined by the California Air Resources Board for an Ultra Low Emissions Vehicle and for a near Zero Emissions Vehicle from a closed blade throttle to a fully open blade throttle position.
The tenth object of this invention is to provide a system to increase the fuel to air ratio (φ) as a function of power demand after the engine throttle is fully open.
The eleventh object of this invention is to provide a method of determining the amount of fuel to air enrichment using a multi-criteria decision analysis algorithm optimized to minimize emissions while creating sufficient power to meet demand.
The twelfth object of this invention is to provide a method a method for adjusting the hydrogen and methane fuel mixture ratio based on engine power demands and emissions.
A preferred embodiment of the invention is to provide a hydrogen and natural gas fuel mixture where the percent of hydrogen is approximately twenty-one up to fifty percent of the mixture. The natural gas portion of the fuel can include constituents such as combinations of Methane, Carbon Dioxide, Nitrogen, Ethane, Propane, Iso-Butane, N-Butane, Iso Pentane, N-Pentane, and Hexanes Plus. Current internal combustion engines that are in mass production can take this alternative fuel without any substantial modifications to their systems. This alternative fuel is lean burning and emits emissions that are below current legal standards. Specific mixture ratios of utilizing the mixture ratios are disclosed for an internal combustion engine for a vehicle.
A computer algorithm is disclosed that determines the amount of fuel to air enrichment necessary to meet sufficient power demands of an internal combustion engine's throttle while minimizing emissions. The power demand is determined by a computer algorithm whose input is the throttle position sensor. The position, the velocity and the acceleration of the throttle pedal after the throttle blades are fully open will be measured and computed to determine minimum fuel enrichment. In addition to fuel enrichment the spark timing will be varied to optimize power enhancement while minimizing emissions. The system can be operated in an open loop configuration utilizing lookup tables that depend upon engine configuration. Various engine configurations included for the lookup tables can include but are not limited to cylinder size(4,6,8,10,12), cylinder displacement and head dimensions. Alternatively the system can be operated using exhaust gas emission monitoring on board the vehicle using sensors such as NO X , CO, CO 2 , O 2 , THC (Total hydrocarbon), NMOG(Nonmethane organic compounds). The system can use in-cylinder pressure transducers to measure engine power output as a feedback device to close the control loop with the throttle position sensor and algorithm or the system can be operated in the open loop configuration. In addition the in-cylinder pressure transducer can be utilized to measure cylinder misfire and modify the air fuel ratio in each cylinder of the engine further optimizing emission and power output. The fuel mixture of hydrogen and natural gas can be adjusted dynamically to the engine based on engine demand and emissions.
Further objects and advantages of this invention will be apparent from the following detailed description of a presently preferred embodiment which is illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGS.
FIG. 1 shows a graph of exhaust emissions for natural gas and 0% hydrogen mixtures in parts per million(PPM) vs. Equivalence Ratio.
FIG. 2 shows an enlarged sectional graph of FIG. 1 of exhaust emissions for natural gas and 0% hydrogen mixtures in parts per million(PPM) vs. Equivalence Ratio.
FIG. 3 shows a graph of exhaust emissions for natural gas and 0% hydrogen mixtures in grams per horse power hour(g/HpHr) vs. Equivalence ratio.
FIG. 4 shows an enlarged sectional graph of FIG. 3 of exhaust emissions for natural gas and 0% hydrogen mixtures in grams per horse power hour(g/HpHr) vs. Equivalence ratio.
FIG. 5 shows a graph of exhaust emissions for natural gas and 11% hydrogen mixtures in parts per million(PPM) vs. Equivalence Ratio.
FIG. 6 shows an enlarged sectional graph of FIG. 5 of exhaust emissions for natural gas and 11% hydrogen mixtures in parts per million(PPM) vs. Equivalence Ratio.
FIG. 7 shows a graph of exhaust emissions for natural gas and 10% hydrogen mixtures in grams per horse power hour(g/HpHr) vs. Equivalence ratio.
FIG. 8 shows an enlarged sectional graph of FIG. 7 of exhaust emissions for natural gas and 10% hydrogen mixtures in grams per horse power hour(g/HpHr) vs. Equivalence ratio.
FIG. 9 shows a graph of exhaust emissions for natural gas and 20% hydrogen mixtures in parts per million(PPM) vs. Equivalence Ratio.
FIG. 10 shows an enlarged sectional graph of FIG. 9 of exhaust emissions for natural gas and 20% hydrogen mixtures in parts per million(PPM) vs. Equivalence Ratio.
FIG. 11 shows a graph of exhaust emissions for natural gas and 20% hydrogen mixtures in grams per horse power hour(g/HpHr) vs. Equivalence ratio.
FIG. 12 shows an enlarged sectional graph of FIG. 11 of exhaust emissions for natural gas and 20% hydrogen mixtures in grams per horse power hour(g/HpHr) vs. Equivalence ratio.
FIG. 13 shows a graph of exhaust emissions for natural gas and 28% hydrogen mixtures in parts per million(PPM) vs. Equivalence Ratio.
FIG. 14 shows an enlarged sectional graph of FIG. 13 of exhaust emissions for natural gas and 28% hydrogen mixtures in parts per million(PPM) vs. Equivalence Ratio.
FIG. 15 shows a graph of exhaust emissions for natural gas and 30% hydrogen mixtures in grams per horse power hour(g/HpHr) vs. Equivalence ratio.
FIG. 16 shows an enlarged sectional graph of FIG. 15 of exhaust emissions for natural gas and 30% hydrogen mixtures in grams per horse power hour(g/HpHr) vs. Equivalence ratio.
FIG. 17 shows a graph of exhaust emissions for natural gas and 36% hydrogen mixtures in parts per million(PPM) vs. Equivalence Ratio.
FIG. 18 shows an enlarged sectional graph of FIG. 17 of exhaust emissions for natural gas and 36% hydrogen mixtures in parts per million(PPM) vs. Equivalence Ratio.
FIG. 19 shows a graph of exhaust emissions for natural gas and 40% hydrogen mixtures in grams per horse power hour(g/HpHr) vs. Equivalence ratio.
FIG. 20 shows an enlarged sectional graph of FIG. 19 of exhaust emissions for natural gas and 40% hydrogen mixtures in grams per horse power hour(g/HpHr) vs. Equivalence ratio.
FIG. 21A and 21B is a Flow chart showing a preferred operation of the throttle control invention.
FIG. 22 is a schematic diagram showing a preferred system control connections for using the throttle control invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Before explaining the disclosed embodiment of the present invention in detail it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
HYDROGEN ENRICHED NATURAL GAS FUELS
Tests were conducted with mixtures of hydrogen and natural gas. The fuels were mixed for the purpose of reducing emissions that are normally emitted by fossil fuels and to extend the lean combustion limit of natural gas by introducing hydrogen.
The engine used for these tests was a V-8, Chevrolet 350 which was rebuilt with the following specifications:
______________________________________Bore: 4.030" (0.030 over bore from standard)Stroke: 3.480"Pistons: Cast Aluminum, Flat top with 4 valve reliefsCam: StockCylinder heads: 76 ccValves: Intake 1.94" Exhaust 1.50"Compression Ratio: 9:1Intake Manifold: Aluminum Throttle BodyExhaust Manifold: 15/8" Steel pipe headersSpark Plugs: Autolite: 303 Gap: 0.035"Ignition: HEI with the vacuum spark advance removedWires: Carbon CoreCarburetor: Throttle body with Impco Gaseous fuel meter______________________________________
The dynamometer used in the tests was a Computer Controlled Super Flow 901 with a maximum torque specification of 1000 lb ft. The dynamometer was calibrated prior to the beginning of testing. In addition, the dynamometer was checked for calibration drift due to the heating of the strain gage and was re-zeroed between each pull.
For the emissions monitoring a NOVA Model Number 7550/B was used to measure CO, CO 2 , O 2 , NO, NO 2 , NO X . The instrument was modified by FSEC to output the results to an Analog to Digital Board mounted in an IBM-compatible 286 computer. The NOVA was calibrated using certified span gases. The NOVA was zeroed using room air and was spanned using 35 ppm certified NO 2 span gas, 1402 ppm N-Hexane (Hydrocarbon), 8.993% Carbon Monoxide and 17.490% Carbon Dioxide. The hydrocarbons measured in this testing were not speciated to determine the exact makeup of the total. It is generally known that approximately 80 to 90% of the total hydrocarbons are made up of methane hydrocarbons. The methane hydrocarbons are non photo-reactive and are generally not considered to be a significant pollutant.
The NO 2 span gas bottle contained a liner to prevent any reaction between the gas and the bottle. The instrument was checked for zero drift before and after each test. In addition, the span was checked before and after each test sequence. Data was only accepted when both zero and span repeated within the limits of the instrumentation.
The emissions pickup tube was mounted in the collector pipe 14 inches from the primary pipes. Only stainless steel and Teflon tubing was used for exhaust gas delivery.
The following engine and atmospheric condition and monitoring equipment was utilized during testing and collected by the dynamometer: Oil Pressure, Exhaust Gas Temperature, Water Temperature, RPM, Torque, Barometric Pressure, Humidity, Carburetor Air Temp, Air, and Oil Temperature. The mass air flow was measured using a 6"calibrated turbine which was attached to the carburetor using a 6"sheet metal elbow. The exhaust gas temperature of each cylinder was monitored using a K type thermocouple mounted in an aluminum plate which was bolted between the head and the exhaust header. The thermocouples were mounted to take the exhaust temperature reading in the center of the exhaust stream.
For fuel flow, the mixture of CNG and hydrogen was fed into a Micro Motion Mass Flow Sensor, Model CMF 025. The Micro Motion Sensor operates using the coriolis effect, which negates the need for turbines and bearings thus substantially increasing the accuracy and repeatability of the gas flow measurements. The sensor was calibrated by Micro Motion and has a certified accuracy of 0.44% at a flow rate of 25 lbs per hour.
Each of the test runs were conducted at 17 horsepower and 1700 rpm. The testing was conducted at this level to simulate a light-duty truck traveling along a level paved road at 55 mph.
Each of the five tests included a varying mixture level volumes of hydrogen with natural gas. The results of tests 1-5 are listed in tables 1-5 respectively.
__________________________________________________________________________TEST 1 0% HYDROGEN and 100% Natural Gas__________________________________________________________________________ FUEL CNG ETDCTEST A/F % EQUIV RPM HP MR TIMING TORQUE__________________________________________________________________________AAA-2 16.5 0 1.0424 1697 17 22 50 52.7AAA-1 16.6 0 10.361 1695 17.1 23 50 53.1AAA-3 16.8 0 1.0238 1698 16.8 22 50 52.9AAB-2 17 0 1.0118 1698 17 22 49 52.5AAB-3 17.2 0 1 1698 17 22 49 52.5AAB-1 17.3 0 0.9942 1698 17 22 49 52.7AAC-2 18.7 0 0.9198 1700 1639 22 51 52.1AAC-3 18.8 0 0.9149 1699 17 22 51 52.5AAC-1 19.1 0 0.9005 1700 17 22 51 52.5AAD-1 20.9 0 0.823 1697 16.8 22 51 52AAD-3 21.1 0 0.8152 1694 17.7 23 51 53.4AAD-2 21.3 0 0.8075 1698 17.2 23 51 53.1AAE-2 22.9 0 0.7511 1699 17.1 22 56 52.9AAE-3 23 0 0.7478 1700 17.3 23 58 53.5AAE-1 23.2 0 0.7414 1692 16.8 22 56 52.3AAF-1 23.9 0 0.7197 1669 15.5 20 56 47.9AAF-2 24.3 0 0.7078 1704 16.12 21 56 49.5AAF-3 24.4 0 0.7049 1704 15.7 21 56 48.5 AVE 0%__________________________________________________________________________ OIL H2O PPM PPM PERCENT A1 + A2 NOX HCTEST TEMP TEMP NOX HC O2 SCFM g/Hp/Hr g/Hp/Hr__________________________________________________________________________AAA-2 201 172 999 49.2 2.88 41.6 5.40 0.27AAA-1 202 172 999 48.8 2.88 42 5.41 0.26AAA-3 203 173 999 48.9 2..93 41.6 5.46 0.27AAB-2 205 172 999 47.6 3.37 42.6 5.52 0.26AAB-3 206 171 999 46.8 3.38 42.4 5.49 0.26AAB-1 206 173 999 46.7 9.98 42.5 5.50 0.26AAC-2 206 172 56.2 5.2 46.1 3.54 0.34AAC-3 205 173 603.8 58.7 5.19 46.3 3.60 0.34AAC-1 204 173 608.9 55.2 5.17 46.2 3.62 0.33AAD-1 204 172 182.3 69.5 6.64 50.5 1.20 0.46AAD-3 202 171 168.2 71.2 6.39 51.5 1.10 0.46AAD-2 203 172 183.5 68.4 6.64 51.9 1.21 0.45AAE-2 202 171 52.6 116.6 8.35 58.8 0.39 0.87AAE-3 202 172 115.5 8.34 59.2 0.38 0.86AAE-1 203 171 56.9 115.8 8.32 59 0.43 0.88AAF-1 199 172 32.1 184.4 9.21 82.6 0.28 1.61AAF-2 200 171 209.1 9.34 63.4 0.24 1.76AAF-3 199 171 26.4 211.4 9.33 83.2 0.23 1.84__________________________________________________________________________
In Table 1, at an equivalence ratio of 1 on the stoichiometric scale, the NO X was beyond the scale of the NOVA instrument. At an equivalence ratio of 0.8333 the NO X has fallen sharply, however, the hydrocarbons were beginning to rise sharply. This was an indication that the engine is at or near the lean limit of combustion. Although a continuous reduction in the equivalence ratio yielded a sharp reduction in NO X the engine misfired.
__________________________________________________________________________TEST 2 11% HYDROGEN AND 89% Natural Gas__________________________________________________________________________ FUEL ETDCTEST A/F % EQUIV RPM HP MR TIMING TORQUE__________________________________________________________________________ABA-2 14.2 10.7 1.2324 1700 17.0 22 35 52.7ABA-1 14.4 10.7 1.2153 1703 17 22 35 52.4ABA-3 14.5 10.7 1.2069 1896 17.1 23 35 53.1ABB-1 15.3 11.2 1.1438 1700 16.9 22 40 52.3ABB-2 15.5 11.3 1.129 1699 16.8 22 40 52ABB-3 15.6 11.5 1.1218 1699 17 22 40 52.4ABC-3 17.2 11.8 10.174 1700 17 22 40 52.4ABC-1 17.6 11.9 0.9943 1699 17.1 23 40 53ABC-2 17.6 11.8 0.9943 1700 17.1 22 40 52.7ABD-1 19.6 11.7 0.8929 1699 17.1 23 41 53ABD-2 19.6 11.6 0.8929 1697 17.1 22 41 52.9ABD-3 19.6 11.6 0.8929 1697 17.2 23 41 53.2ABE-2 20.6 11.6 0.8495 1701 17.2 23 44 53.1ABE-1 20.7 11.6 0.8454 1703 17.1 22 44 52.7ABE-3 20.9 11.6 0.8373 1700 17.1 22 44 52.7ABF-3 22.9 11.5 0.7642 1699 17.2 23 45 53.2ABF-1 23 11.5 0.7609 1701 16.9 22 45 52.1ABF-2 23.4 11.5 0.7479 1699 17.1 22 45 52.9ABG-2 25.9 11.5 0.6757 1701 17.1 22 55 52.7ABG-1 28 11.5 0.6731 1706 17.1 22 55 52.5ABG-3 26.3 11.5 0.6654 1706 17 22 55 52.3 AVE 11.4%__________________________________________________________________________ OIL H2O PPM PPM PERCENT A1 + A2 NOX HCTEST TEMP TEMP NOX HC O2 SCFM g/Hp/Hr g/Hp/Hr__________________________________________________________________________ABA-2 212 172 469.2 60.8 0.51 37.8 2.31 0.30ABA-1 211 172 454.9 61.1 0.5 38 2.26 0.3ABA-3 212 172 491.7 61.3 0.52 37.9 2.42 0.30ABB-1 212 174 999.5 49.4 1.28 38.1 5.00 0.25ABB-2 212 174 999.5 50.8 1.27 38.2 5.04 0.25ABB-3 213 174 999.5 48.7 1.31 38.3 4.99 0.24ABC-3 209 172 854.4 41.8 3.32 41.6 4.60 0.23ABC-1 209 174 867.2 41.6 3.41 41.8 4.66 0.22ABC-2 209 174 862.2 42.2 3.35 42.1 4.82 0.23ABD-1 208 173 254.6 52.1 5.48 46.6 1.52 0.31ABD-2 207 172 259.3 52.1 5.47 46 1.53 0.31ABD-3 207 171 259.4 51.9 5.48 46.5 1.53 0.31ABE-2 205 172 157.6 61.4 6.5 48.5 0.97 0.38ABE-1 207 171 168.8 61.5 6.44 48.8 10.5 0.38ABE-3 205 173 173.7 60.6 6.41 48.7 1.08 0.38ABF-3 203 171 46.1 76.1 8.02 55.3 0.32 0.53ABF-1 206 172 44.8 76.5 8.06 55.1 0.32 0.54ABF-2 205 171 43.4 77.2 8.05 55.5 0.31 0.54ABG-2 202 171 23.2 138.2 9.59 63.7 0.19 1.1ABG-1 204 171 23.4 142.6 9.65 63.9 0.19 1.15ABG-3 202 172 24.3 140.6 9.61 63.5 0.20 1.13__________________________________________________________________________
This test in Table 2 began at an equivalence ratio of 1.25. The NO X was approximately 450 ppm. The NO X climbed rapidly as the air to fuel mixture was leaned out. At an equivalence ratio of approximately 1.1 the NO X had risen beyond the instrument capability. At stoichiometric (an equivalence ratio of 1) the NO X is beginning to fall sharply and is reduced from that observed with no hydrogen added As this mixture is leaned out further, the NO X continues to fall significantly, and the hydrocarbons again began to rise sharply. However, the slope is less than that noted on pure natural gas.
Test 2 was terminated at an equivalence of 0.666. Although the engine did not appear to be at the lean limit, the hydrocarbons had risen beyond acceptable limits.
__________________________________________________________________________TEST 3. 20% HYDROGEN AND 80% Natural Gas__________________________________________________________________________ FUEL BTDCTEST A/F % EQUIV RPM HP ME TIMING TORQUE__________________________________________________________________________ACA-2 15 19.7 1.1833 1700 17 22 35 52.5ACA-1 15.1 19.5 1.1755 1702 17 22 35 52.4ACA-3 15.3 19.8 1.1601 1705 17 22 35 52.4ACB-2 17.7 19.8 1.0028 1699 17.2 23 39 53.2ACB-3 17.9 19.9 0.9916 1701 17.2 23 39 53ACB-1 18 19.8 0.9861 1698 17.3 23 39 53.4ACC-1 19.2 19.9 0.9245 1701 17 22 43 52.5ACC-3 19.4 20 0.9149 1700 17 22 43 52.4ACC-2 19.5 20 0.9103 1699 17 22 43 52.6ACD-2 20.7 19.9 0.8575 1696 17.1 22 45 52.9ACD-1 21.1 20 0.8412 1700 17.1 22 45 52.7ACD-3 21.1 20 0.8412 1699 17 22 45 52.4ACE-3 22.2 20 0.7995 1700 17 22 51 52.5ACE-2 22.7 20 0.7819 1699 17.1 23 51 53ACE-1 22.9 20 0.7751 1698 17 22 51 52.6ACF-2 24.8 20.1 0.7215 1697 17.1 22 55 52.9ACF-3 24.6 20 0.7215 1698 16.9 22 55 52.3ACF-1 25 20 0.71 1699 17 22 55 52.7ACG-2 26.1 20 0.6801 1699 17.1 22 59 52.9ACG-3 26.6 20 0.6673 1697 17 22 59 52.6ACG-I 27 20 0.6574 1669 17 22 59 52.7ACH-1 27.9 20 0.6382 1700 16 21 60+ 49.3ACH-2 28 20 0.6339 1709 16.5 22 60+ 50.6ACH-3 28.1 20 0.8317 1703 16.2 21 60+ 49.9 AVE 19.9%__________________________________________________________________________ OIL H2O PPM PPM PERCENT A1 + A2 NOX HCTEST TEMP TEMP NOX HC O2 SCFM g/Hp/Hr g/Hp/Hr__________________________________________________________________________ACA-2 212 172 827.5 52.7 0.81 37.5 4.05 0.26ACA-1 219 174 824.7 54.9 0.83 37.5 4.04 0.27ACA-3 212 174 827.6 53.3 0.82 37.6 4.06 0.28ACB-2 210 172 999.5 41.1 3.81 42.1 5.38 0.22ACB-3 210 172 999.5 41.8 3.68 42 5.36 0.22ACB-1 212 172 999.5 41.1 3.63 42.3 5.37 0.22ACC-1 210 173 775.1 47.3 4.86 44.8 4.47 0.27ACC-3 209 173 773.3 46.6 4.89 44.3 4.41 0.27ACC-2 210 173 802.7 46.9 4.84 44.7 4.82 0.27ACD-2 206 173 292.5 55.6 6.19 47.3 1.77 0.34ACD-1 207 172 300.7 55.6 6.16 47.3 1.81 0.34ACD-3 206 172 288.5 55.6 6.16 47.3 1.75 0.34ACE-3 206 173 180.9 66.5 7.42 50.3 1.22 0.43ACE-2 205 172 200.2 65.8 7.35 51 1.30 0.43ACE-1 206 171 200.7 65.8 7.34 50.9 1.31 0.43ACF-2 204 170 67.9 81.1 8.63 55.1 0.47 0.57ACF-3 203 171 66.8 81.7 8.68 55.2 0.47 0.58ACF-1 204 172 66.1 80.9 8.63 55.5 0.47 0.57ACG-2 202 171 34.9 96.3 9.49 60.2 0.27 0.73ACG-3 202 171 34.3 96.7 9.49 50.7 0.26 0.73ACG-1 203 172 35.1 96.9 9.48 59.9 0.27 0.74ACH-1 200 171 20.7 132.3 10.15 63.2 0.18 1.13ACH-2 201 171 20.6 137.9 10.15 64 0.17 1.15ACH-3 200 172 19.9 137.2 10.19 64.3 0.17 1.17__________________________________________________________________________
In Test 3 at stoichiometric, the NO X is again beyond the limit of the measurement instrumentation. At an equivalence ratio of 0.95 (slightly lean) the NO X falls sharply. The NO X continues to fall as the equivalence ratio is reduced to a value of 0.625, where the test was terminated. The test was terminated because the engine again appeared to be missing and was apparently beyond the drivable limits.
__________________________________________________________________________TEST 4. 28% HYDROGEN AND 72% Natural Gas__________________________________________________________________________ FUEL BTDCTEST A/F % EQUIV RPM HP ME TIMING TORQUE__________________________________________________________________________ADA-3 15.3 28.1 1.1791 1701 16.8 22 36 52ADA-2 15.4 28.2 1.1714 1700 16.9 22 36 52.1ADA-1 15.5 28 1.1639 1703 16.8 22 36 51.9ADB-3 16.6 28.1 1.0887 1699 17 22 38 52.6ADB-1 16.7 28.1 1.0802 1702 17 22 38 52.4ADB-2 16.7 28.2 1.0802 1702 17 22 38 52.5ADC-1 17.7 28 1.0192 1702 17.2 23 39 53.1ADC-3 17.7 28.1 1.0192 1703 17.1 22 39 52.6ADC-2 18 28.2 1.0022 1699 17.3 23 39 53.4ADD-2 19.1 28.2 0.9445 1702 16.9 22 39 52.3ADD-1 19.6 28.3 0.9204 1702 16.8 22 39 52ADD-3 19.7 28.2 0.9157 1703 17 22 39 52.4ADE-3 21.5 28.3 0.8391 1701 17 22 41 52.6ADE-1 21.7 28.4 0.8313 1700 17 22 41 52.6ADE-2 21.8 28.4 0.8275 1703 17.2 23 41 53ADF-2 23 28.5 0.7843 1703 17.1 22 50 52.6ADF-3 23.1 28.4 0.781 1702 17 22 50 52.6ADF-1 23.2 28.4 0.7776 1703 17.1 22 50 52.6ADG-2 24.8 28.5 0.7274 1700 17 22 52 52.5ADG-3 24.9 28.5 0.7245 1701 17.1 22 52 52.6ADG-1 25.2 28.5 0.7159 1703 17 22 52 52.3ADH-3 26.7 28.5 0.6757 1701 17.1 22 54 52.7ADH-2 26.8 28.4 0.6731 1701 17 22 54 52.6ADH-1 27.3 28.5 0.6608 1703 17.2 23 54 53ADI-1 28.3 28.5 0.6375 1701 17 22 58 52.6ADI-3 28.4 28.5 0.6352 1698 16.8 22 58 52.4ADI-2 28.7 28.5 0.6286 1699 17 22 58 52.5 AVE 28.3%__________________________________________________________________________ OIL H2O PPM PPM PERCENT A1 + A2 NOX HCTEST TEMP TEMP NOX HC O2 SCFM g/Hp/Hr g/Hp/Hr__________________________________________________________________________ADA-3 209 173 999 52.3 0.9 38 5.01 0.26ADA-2 209 172 999 52.7 0.89 37.8 4.95 0.26ADA-1 210 173 999 54.6 0.88 37.8 4.96 0.27ADB-3 209 172 999 34.7 2.06 39 5.06 0.18ADB-1 210 173 999 34.8 2.01 39.3 5.09 0.18ADB-2 211 171 999 34.6 2.04 39.3 5.09 0.18ADC-1 209 172 999 35.2 3.58 41.7 5.33 0.19ADC-3 209 174 999 36.8 3.38 41.7 5.36 0.20ADC-2 207 174 999 35.7 3.36 41.9 5.32 0.19ADD-2 207 173 584.8 40.6 5 44 3.33 0.23ADD-1 208 173 580.8 40.7 5.01 44.4 3.36 0.24ADD-3 207 171 573.3 41.7 5 44.7 3.30 0.24ADE-3 204 172 252.6 53 6.54 48.6 1.57 0.33ADE-1 203 171 256.1 53.2 6.57 48.6 1.59 0.33ADE-2 205 171 253.1 52.3 6.55 48.5 1.58 0.32ADF-2 202 171 208.4 62.6 7.53 51.2 1.36 0.41ADF-3 203 172 220.6 61.6 7.53 51.4 1.45 0.40ADF-1 202 172 211.8 61.1 7.52 51.6 1.39 0.40ADG-2 202 171 74.1 72.4 8.59 55.1 0.52 0.51ADG-3 200 171 75.5 71.4 8.58 54.7 0.52 0.49ADG-1 201 171 76.4 71.1 8.56 54.9 0.53 0.50ADH-3 198 171 26.9 82.5 9.54 60 0.20 0.63ADH-2 200 172 27.3 83.1 9.54 60.1 0.21 0.63ADH-1 199 171 27.3 83.1 9.55 60 0.21 0.63ADI-1 198 170 15.9 104.1 10.27 63.6 0.13 0.84ADI-3 197 171 16.7 104.2 10.27 63.8 0.14 0.85ADI-2 199 171 16.5 104.4 10.27 63.8 0.13 0.84__________________________________________________________________________
In Test 4, at stoichiometric, the NO X is again beyond the limit of the measurement instrumentation and remained beyond the limit of instrumentation at an equivalence ratio of 0.95. When the air to fuel ratio was leaned to an equivalence of 0.87, the NO X dropped sharply. The test was again terminated at an equivalence ratio of approximately 0.625 where the NO X was measured to be approximately 16.5 ppm. The engine was again observed to be missing although in cylinder pressure readings were not taken to confirm this fact. Notice that the hydrocarbons were found to be 104 ppm.
__________________________________________________________________________TEST 5 36% HYDROGEN AND 64% Natural Gas__________________________________________________________________________ FUEL ETDCTEST A/F % EQUIV RPM HP MR TIMING TORQUE__________________________________________________________________________AEA-1 16 35.9 1.1475 1704 16.9 22 35 52AEA-3 16 38 1.1475 1699 17.1 23 35 53AEA-2 16.1 36 1.1404 1704 16.6 22 35 51.3AEB-2 16.1 36 1.0144 1204 17 22 37 52.4AEB-1 18.5 36.1 0.9924 1701 17 22 37 52.4AEB-1 18.5 35.9 0.9871 1703 17 22 37 52.5AEC-3 20 36 0.918 1703 17 22 38 52.4AEC-1 20.3 35.9 0.9044 1706 16.9 22 38 52AEC-2 20.5 35.9 0.8958 1705 17.1 22 38 52.8AED-3 22 36 0.8345 1704 17 22 43 52.5AED-1 22.1 35.9 0.8303 1702 17 22 43 52.4AED-3 22.2 35.9 0.827 1703 17 22 43 52.4AEE-3 23.2 36 0.7914 1705 17 22 44 52.5AEE-2 23.3 36 0.788 1705 17.1 22 44 52.6AEE-1 23.4 35.9 0.7846 1702 17 22 44 52.6AEG-3 25 35.9 0.7344 1702 17 22 49 52.4AEG-2 25.2 36 0.7286 1703 17.1 22 49 52.6AEG-1 25.5 35.9 0.72 1702 17 22 49 52.5AEH-1 29.5 35.9 0.6224 1707 17 22 50 52.1AEH-2 29.5 35.9 0.6224 1704 16.8 22 50 51.9AEH-3 29.5 36 0.6224 1703 17.2 22 50 52.9 AVE 36.0%__________________________________________________________________________ OIL H2O PPM PPM PERCENT A1 + A2 NOX HCTEST TEMP TEMP NOX HC O2 SCFM g/Hp/Hr g/Hp/Hr__________________________________________________________________________AEA-1 213 174 999 40.8 1.16 38 4.97 0.20AEA-3 213 173 999 41.1 1.13 38.3 4.95 0.20AEA-2 211 174 999 42.8 1.15 37.9 5.04 0.12AEB-2 207 174 999 32.8 3..71 41.9 5.41 0.16AEB-1 208 174 999 32.1 3.7 41.8 5.39 0.17AEB-3 207 173 999 33.1 3.71 42.1 5.43 0.18AEC-3 206 172 475.3 39.9 5.41 45.4 2.77 0.23AEC-1 206 173 493.3 39.5 5.39 45.5 2.90 0.23AEC-2 205 172 491.5 38.5 5.38 45.5 2.85 0.22AED-3 203 173 385.1 50.8 6.7 48.9 2.41 0.32AED-1 203 172 387.9 50.1 6.69 48.7 2.42 0.31AED-3 204 172 395.5 50.1 6.68 48.8 2.47 0.31AEE-3 201 171 204.1 58.4 7.53 51.1 1.33 0.38AEE-2 203 172 206.7 58.2 7..54 51.2 1.34 038AEE-1 203 173 202.6 58.4 7.58 51 1.32 0.38AEG-3 200 172 78.8 68 8.82 54.9 0.55 0.48AEG-2 200 170 77.7 67.4 8.62 54.8 0.54 0.47AEG-1 202 172 76.9 68.4 8.85 54.9 0.54 0.48AEH-1 199 170 12.4 105.5 10.63 64.8 0.10 0.87AEH-2 198 172 11.7 104.1 10.64 65 0.10 0.87AEH-3 199 172 11.9 102.7 10.6 64.9 0.10 0.83__________________________________________________________________________
In Test 5at stoichiometric, the NO X , levels were beyond the measurement limit of the instrumentation. The NO X levels dropped sharply at an equivalence ratio of 0.91. The NO X levels continue to fall to the termination of the test at approximately 0.625 equivalence ratio. The NO X has a low value of approximately 12 ppm. The hydrocarbons have a maximum value of 105 ppm. This is approximately the same as the hydrocarbons measured during the 30% hydrogen testing. The test was terminated before there was a sharp rise in the hydrocarbons thus indicating that the roughness was not being caused by running the engine beyond the lean limit.
SUMMARY OF TESTS 1-5
The purpose of TESTS 1 through 5 was to determine if the lean limit of Natural Gas can he extended by introducing Hydrogen, H 2 . The hypothesis used was that the leaner the engine could be run without going into lean misfire, the lower the NO X would be while only incurring moderate increases in the Hydro Carbons, HCs. HCs were not considered to be a significant problem since HCs can be reduced using catalysts.
FIGS. 1 through 20 show partial maps of the NO X and hydrocarbon emissions at various levels of hydrogen in Natural Gas and at various equivalence ratios.
Both 28% hydrogen and 36% hydrogen mixtures yielded very low NO X levels a to 0.625 equivalence ratio. See FIGS. 13-20. The extremely low NO X levels of 28 ppm (0.21 gm/hp hr) and 12 ppm((0.10 gm/hp hr) respectively were unexpected. Recall that all of the emissions readings were taken at the exhaust manifold outlet. There were no emission control equipment on the tested engine and there was no catalytic converter. The levels of NO X at 28% and 36% hydrogen mixtures were substantially below the strictest air quality standards. For example, current air quality standards in Japan require NO X emissions to be below 200 ppm. This standard is extremely difficult to meet and has never been met without substantial emissions control equipment on the engine, based on the prior art known to the inventors.
Referring back to FIGS. 2 and 4 for 0% Hydrogen. Although at an equivalence ratio of 0.75 the NO X level fell significantly the hydrocarbons increased at approximately the same rate thus indicating an unstable operating condition. This same result can be noted in FIGS. 6 and 8 (11% Hydrogen) and in FIGS. 10 and 12 (20% Hydrogen). However, the lean limit extends from approximately 0.75 equivalence ratio at 0% hydrogen to 0.67 equivalence ratio at 20% hydrogen. It is not feasible to operate the engine at these lean limits since a very small change in the air fuel ratio will make a very significant increase in the NO X levels or a very significant increase in the hydrocarbon levels. When the hydrogen concentration was extended to 28% there is no longer a point where the hydrocarbons abruptly increase as was seen at all lower levels of hydrogen thus making lean burn a viable option. This same result was noted at concentrations of 36% hydrogen as seen in FIGS. 17 and 18.
The test results demonstrate that extremely low levels of NO X are possible with acceptably moderate increases in unburned hydrocarbons using 28 % and 36% hydrogen supplementation. Previous research conducted at 20% hydrogen did not indicate a significant enough reduction to consider the mixture of hydrogen and natural gas as a viable solution to the problem of producing extremely low NO X levels of 20% and below. The significant reduction in NO X was realized when the hydrogen level was raised to approximately 30% and the engine was run nearer the lean limit. In addition, the lean limit of combustion was significantly extended by the increased levels of hydrogen. The NO X levels reported are an order of magnitude below the strictest current requirements. This level of NO X was achieved without a catalytic converter or other emissions reducing hardware on the engine.
The tests and related data demonstrate that levels up to approximately 50% Hydrogen can be used with combustion engines. Over 50% Hydrogen gas in the mixture could create possible problems related to storage and safety. However, the specific mixture amounts of between approximately 21 and 50% Hydrogen, can be further narrowed down by engine size(4,6,8 cylinders) and regulatory concerns.
While natural gas has been referred to as including primarily methane, natural gas can include other components is much smaller amounts. Besides primarily containing methane, natural gas can include Carbon Dioxide. Nitrogen, Ethane, Propane, Iso-Butane, N-Butane, Iso Pentane, N-Pentane, and Hexanes Plus.
While the tested engine did not use a catalytic converter, one could be added. The hydrocarbon levels at 28% and 36% hydrogen at an equivalence ratio of 0.625 were both approximately 104 ppm(0.84 gm/hp hr). Since approximately 15% of the hydrocarbons are photo reactive the total reactive hydrocarbons are approximately 16 ppm (0.13 gm/hp hr.). This level of hydrocarbon emissions is extremely low and there is the potential of reducing the total hydrocarbons to near zero through the use of a catalytic converter.
Mixtures of hydrogen and natural gas can be mixed by known methods such as but not limited to sonic mixing, or merely injecting hydrogen into natural gas, or injecting natural gas into hydrogen.
While the alternative fuel mixture in this invention has been successfully used with existing combustion engines, modifications on existing engines can be accomplished in order to enhance engine performance such as horsepower. For example, the alternative fuel disclosed herein can be used in combustion engines include but are not limited to turbocharging, engine settings(ignition, sparkplugs), camshafts, intake manifold and cylinder head modifications, compression ratios, and injection system and combinations thereof.
While the invention has been described as being used for mobile vehicles such as an eight(8) cylinder automobiles, the invention would have applicability to various other size engines such as four(4), six(6), and twelve(12) cylinder mobile engines.
Furthermore, the disclosed invention can be used with other size engines such as but not limited to lawnmower engines, trucks, vans, aircraft and trains.
VARIABLE AIR/FUEL RATIO THROTTLE CONTROL
This portion of the invention covers a variable air/fuel ratio control that optimizes emissions and power output for lean burn applications. FIG. 21A and 21B is a Flow chart showing a preferred operation of the throttle control invention. FIG. 22 is a schematic diagram showing a preferred system control connections for using the throttle control invention. Before discussing these Figures, a background for this invention will now be discussed.
Test results have indicated that Spark Ignition(SI) engines can operate at an equivalence ratio of approximately 0.5 with approximately 35% by volume hydrogen in methane. The emissions during this test were NO X of approximately 8 ppm and HC or approximately 845 ppm. This test was conducted on the engine previously discussed. Maximum engine horsepower was 93 at an equivalence ratio of approximately 0.625 while maximum horsepower was 24 at an equivalence ratio of 0.5. Thus, the optimum equivalence ratio is a function of desired emissions, and horsepower. Varying the equivalence ratio dynamically will provide a vehicle with needed horsepower while minimizing the emissions from the vehicle. The optimum equivalence ratio is thus a function of the percentage of hydrogen enrichment, selected NO X (Noxious Oxide) and HC (Hydro Carbon) levels, engine design configuration(cylinder size, cylinder displacement, head dimensions, and the like) as well as desired power output
A system optimized for these parameters(hydrogen enrichment, NO X , HC, engine design) will produce less power than could be produced if the engine were operated approximately at stoichiometric. With this system, the emission levels of NO X , and controlled HC's will be on the order of approximately 25 ppm or less. In addition the CO output will be on the order of approximately 1% of less. These levels of emission would qualify the vehicle for ULVE(Ultra Low Vehicle Emission) status as established by the California Air Resources Board(CARB). The system for introducing fuel and air into the engine can utilize either a carburetion system or a fuel injection system as described previously in the background section of the invention. However, the prior art systems are still limited because additional power would be required for severe grade climbing, expressway merging and passing. In the prior art systems a wide open throttle could still cause the engine to not produce sufficient power for these extreme conditions. In the subject invention, the air/fuel ratio can be shifted during the wide open throttle toward stoichiometric. Thus, in the instant invention, the air/fuel ratio is shifted toward stoichiometric as a function of the instantaneous power demand.
The novel throttle control can use a "carburetor" or "fuel injection" system. For a carbureted system, a secondary demand regulator system can be operated in parallel with the standard demand regulator system. The standard demand regulator system can be adjusted to maintain an optimal air/fuel ratio. When the throttle blades in the primary system are wide open the secondary system is activated. The secondary system supplies additional fuel to the system as a function of the system demand and the throttle pedal position.
FIG. 21A and 21B is a Flow chart showing a preferred operation of the throttle control invention. In the injection system, the standard electronic control unit(ECU) such as the control unit 10 of U.S. Pat. No. 4,730,590 to Sagawa, which is incorporated by reference, can be programed to implement the algorithm. Referring to FIG. 21, From Start, step 110 is to calculate engine speed(rpm) N, mass air flow Q, and mass fuel flow F f . Step 120 is to calculate throttle position T p , velocity of throttle position d T p /dt, and acceleration of throttle position d 2 T p /dt 2 . Step 130 is calculate current emissions. Step 140 is calculate desired air fuel ratio AF d which is a function of acceptable emission levels, desired vehicle speed and acceleration values computed above. Step 150 is to calculate actual air fuel AF a which is calculated from Q and F f . Step 160 is to calculate in-cylinder pressure C pr , average in-cylinder pressure C pr , standard deviation of in-cylinder pressure σC pr and Z value equal to ##EQU1## Step 200 of FIG. 21A goes to the top of FIG. 21B. Step 210 is to calculate δ which is equal to the desired air fuel, AF d minus actual air fuel, AF a . Step 220 holds if δ=0 and Z<1.0 at box 222 there is is no change go to step 100. If δ=0 and Z>1.0 there is more cylinder pressure variation than is normally expected. Go to step 224 to increase Pw, the pulse width of the injector which will increase fuel, and set an engine alarm, 226 which can be a warning dashboard light that the engine is malfunctioning and that the driver should check the engine. If δ<0, go to step 232 and increase Pw which will increase fuel to the engine and then go to step 100. If δ is not <0 go to step 240 and check Z. If Z <1 go to step 242 and reduce the amount of fuel to the engine, lower Pw, and then go to step 100. If Z is not <1 go to step 250 reduce Pw and set engine alarm 260 that engine is malfunctioning and then go to step 100.
FIG. 22 is a schematic diagram showing a preferred system of the control connections for using the throttle control algorithm of FIGS. 21A and 21B with the internal combustion engine 10 in a mobile vehicle. Air is inducted through the intake manifold 1 and the volume can be measured by sensor 2 whose output is sent to control unit 14 a computer that runs the algorithm flow chart depicted previously in FIGS. 21A and 21B. The position of the throttle blade can be determined by sensor 3. Sensor 3 can be configured such that when the throttle blade is fully open(parallel to intake air) the additional travel of the throttle can occur to indicate an operator(drivers) desire for increased power. Component 4 can be the fuel injector whose Pw pulse width is controlled by control unit 14. As the pulse width to injector 4 is increased, the air fuel ratio (φ) can be increased. Component 5 is the mass fuel flow sensor which also provides input for control unit 14. Component 6 is the emission sensor which can monitor NO X , CO, CO 2 , THC, NMOG and O 2 passing into muffler 12. Sensor 7 is the engine 10 temperature sensor. Sensor 8 is the crank angle sensor used to determine engine 10 speed and which of the cylinder(s) is being fired. Sensor 9 is the in-cylinder pressure transducer for engine 10. For each cylinder of the engine, there is a separate in-cylinder transducer 9. Control unit 14 can also control the fuel passing into injector 4 by fuel supply 16. The fuel supply 16 can store a high pressure mixture of natural gas(CH 4 ) and hydrogen(H 2 ) in a mixture as that described in relation to the discussion of FIGS. 1-20 previously. Alternatively, fuel supply 16 can store separate containers of natural gas(i.e. CH 4 ) and hydrogen(H 2 ). For example, CH 4 can be stored in one high pressure cylinder. For separate storage, hydrogen, H 2 , can be stored either in a high pressure cylinder, in a hydride, or in a cryogenic form. Furthermore, the separately stored hydrogen could be generated on board the vehicle through a reforming process of CH 4 . When stored separately, the ratio of CH 4 and H 2 can be varied dynamically and controlled by control unit 14 as a function of output emissions and engine power.
The algorithm in our invention will maintain the air/fuel ratio at the optimum for emission while the engine power is under the control of the throttle. Experimentation indicates that many internal combustion engines will operate best at approximately φ=approximately 0.625. This however needs to be individually determined for each different engine configuration.
The entire system is under the control of the driver. The transition from the fixed air/fuel ratio to the variable air/fuel ratio can be automatic where the driver is unaware of the change. Alternatively, the system can require additional force on the throttle pedal to alert the driver that the vehicle is now being operated in less than the optimal range.
Although the control algorithm embodiment and schematic has been described for use with a hydrogen gaseous fuel, the invention would have applicability to other types of mobile vehicle fuels that can support an extreme lean burn condition.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.
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A hydrogen and natural gas fuel mixture for internal combustion engines is provided for vehicle engines such as those used in standard production engines for automobiles, trains and lawn mowers. The gaseous fuel for operating a vehicle combustion engines includes approximately 21 to 50% Hydrogen and the rest natural gas constituents such as combinations of Methane, Carbon Dioxide, Nitrogen, Ethane, Propane, Iso-Butane, N-Butane, Iso Pentane, N-Pentane, and Hexanes Plus. A fuel mixture of approximately 28 to 36 percent Hydrogen and a air fuel equivalence ratio of approximately 0.625 is an extreme lean burn condition that yields hydrocarbon emission levels of less than approximately 104 ppm(0.84 hm/hp hr.). Current internal combustion engines that are in mass production can take this alternative fuel without any substantial modifications to their systems. This alternative fuel is lean burning and emits emissions that are below current legal standards. The novel fuel mixture can be used in internal combustion engines for automobiles, lawnmowers, and trains. A control system for allowing the internal combustion engines to operate at extreme lean burn conditions is also provided for use with both a carburetor and fuel injection system. For a carburetor system, a secondary demand regulator system can kick in when a throttle is wide open and will allow additional fuel to pass through the system to meet instantaneous power demands such that occur when full throttle depression is insufficient for severe grade climbing, expressway merging, passing and the like. The fuel injection system can also be programed with a control algorithm that will select air fuel ratios. The computer control can increase fuel with respect to air when the throttle reaches a selected point of travel. The computer control can also dynamically change the hydrogen and natural gas fuel mixture ratio dynamically while the vehicle is being operated based on engine power demands and emissions.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a divisional of U.S. Ser. No. 07/737,883, filed Jul. 25, 1991, now U.S. Pat. No. 5,204,468; which is a continuation of U.S. Ser. No. 569,779, filed Aug. 21, 1990, now abandoned and which in turn is a continuation of U.S. Ser. No. 440,086, filed Nov. 22, 1989, now abandoned, which in turn is a continuation-in-part of U.S. Ser. No. 320,975, filed Mar. 9, 1989, now U.S. Pat. No. 4,966,904 and which, in turn, is a divisional application of U.S. Ser. No. 173,376, filed Mar. 25, 1988, now U.S. Pat. No. 4,876,261.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a compound of the formula (I) or its salt and a process for producing the compounds; The compounds have the effect to dilate neophrovascular tracts; ##STR3## wherein represents the formula ##STR4## (wherein R 4 is a hydrogen atom or lower alkylsulfonyl); R 1 is hydrogen, lower alkyl, hydroxyl, halogen, amino, or lower acylamino;
R 2 is hydrogen, lower alkyl, hydroxyl, amino, or lower alkylsulfonylamino;
R 3 is hydrogen, lower alkyl, or hydroxyl;
R is hydrogen or halogen;
with the proviso that when R 1 is hydroxyl, there is no case that all of R 2 , R 3 and R are hydrogens, and further with the proviso that when R is hydrogen, A excludes ##STR5## or a salt thereof. (The above definitions in the formula (I) and groups are interpreted to be the same, hereinafter.) The compounds act directly upon dopamine receptor present in renal vascular tracts, and are used as nephrovascular dilators.
This invention relates to amino-substituted tetrahydroisoquinoline derivatives represented by the following general formula (I), ##STR6## or salts thereof, which are compounds useful as medicines; to a process for preparing the same; and to medicines containing the same as active ingredient.
2. Description of the Related Art
The kidney is an important organ which participates in maintaining homeostasis of the cirulatory system. If blood circulation insufficiency occurs in this organ for some causes, renal functions will lower to break up homeostasis of the circulatory system, thus inducing, maintaining or aggravating diseases of circulatory organs, such as hypertension and cardiac insufficiency.
Vasodilators and diuretics have been used for the treatment of these diseases, but no vasodilator is so far known which has a positive effect to dilate renal vascular tracts. It is also known that conventional diuretics tend to upset the balance among electrolytes. Dopamine shows diuretic and nephrovascular dilating effects, but also has unfavorable effects (vasoconstricting and heart-rate increasing effects). In addition, it cannot be orally administered and its effect is not well maintained. Thus, there is no drug presently available which is suited for clinical use.
SUMMARY OF THE INVENTION
Under the circumstances, we have tried to develop new compounds which act directly upon dopamine receptor present in renal vascular tracts, and which can be orally administered and maintain the effect over long periods. This invention was accomplished on the basis of the result of such studies.
Thus, this invention relates to compounds represented by the general formula (I) and salts thereof, to a process for preparing the same, and to nephrovascular dilators containing the same as active ingredient.
The compounds of this invention have an asymmetric carbon atom at 4-position of the tetrahydroisoquinoline ring, and all the optical isomers based on this asymmetric carbon and mixtures thereof are included in this invention.
Compounds (I) are capable of forming salts, of which pharmacologically acceptable ones are also included in this invention. These are inorganic salts, such as hydrochlorides, hydrobromides, sulfates, phosphates and nitrates; and organic salts, such as maleates, fumarates, benzoates, ascorbates, methanesulfonates and tartrates.
DETAILED DESCRIPTION OF THE INVENTION
In the definitions of the formula (I) compounds, "lower alkyl" means C 1 to C 5 straight or branched chain alkyl, and the examples of "lower alkyl" are methyl, ethyl, propyl, iso-propyl, butyl, iso-butyl, sec-butyl, pentyl, etc. "Lower acyl" means C 1 to C 6 straight or branched chain acyl, and the examples of "lower acyl" are formyl, acetyl, propionyl, butyryl, iso-butyryl, valeryl, iso-valeryl, pivaloyl, hexanoyl, etc. The examples of "halogen" are fluorine, chlorine, bromine or iodine. The compounds of this invention have an asymmetric carbon atoms at 4-position of the tetrahydroisoquinoline ring, and, as the case may be, in lower alkyl and/or lower acyl, and all the optical isomers based on this asymmetric carbon and mixtures thereof are included in this invention.
Compounds (I) of this invention may be prepared by the methods described below.
Method 1 ##STR7## (wherein R 6 and R 7 are hydroxyl groups which may optionally be protected; and R 5 is hydrogen atom or a protective group for the nitrogen atom; A' is 2-(or 3-)thienyl, or other monovelent A group.
This method comprises cyclization of a compound represented by the general formula (II), followed by removal of the protective groups when required. As examples of the protective groups for hydroxyls in the starting material (II), may be mentioned linear or branched lower alkyls such as methyl, ethyl, isopropyl and tert-butyl, and aralkyls such as benzyl and phenethyl. As the protective group for the nitrogen atom, may be used linear or branched lower alkyls such as methyl, ethyl, isopropyl and tert-butyl, aralkyls such as benzyl and phenethyl, and substituted or unsubstituted acyl groups such as acetyl and trifluoroacetyl. The above other monovelent A means ##STR8##
Compounds (I) can be prepared by subjecting a compound represented by the general formula (II) to intramolecular cyclization by the action of a cyclizing agent capable of forming carbonium ion from the alcoholic hydroxyl in compound (II), such as hydrochloric acid, sulfuric acid, sulfuric acid in trifluoroacetic acid, polyphosphoric acid, esters of polyphosphoric acid, methanesulfonic acid in dichloromethane, hydrogen bromide, and Lewis acids (e.g., boron trifluoride, aluminum chloride and stannic chloride).
There is no specific limitation upon the reaction temperature; the reaction is carried out under ice cooling or under reflux condition, with the reaction time being properly set in each case depending on other factors.
When the reaction product thus obtained contains protective groups, these are removed by catalytic reduction (e.g., catalytic hydrogenation) or by treatment with boron tribromide, hydrobromic acid, aluminum chloride, trimethylsilyl iodide or hydroiodic acid. The protective group on the nitrogen atom may be removed simultaneously with the protective groups on hydroxyl groups, or in a separate step (for example, by treatment with cyanogen bromide, hydrochloric acid or ammonia water, hydrogenation in the presence of a catalyst, or other suitable methods).
Method 2 ##STR9##
Compounds (I) of this invention can be prepared by reduction of a nitro compound represented by the general formula (III), followed by removal of the protective groups when required.
This reduction may be effected by the use of a sulfur compound, such as sodium sulfate, sodium hydrosulfide, sodium dithionite and ammonium sulfide; by catalytic reduction in the presence of platinum, platinum black, palladium-carbon (Pt-C) or Raney nickel, or by reduction using a metal hydride such as lithium aluminum hydride. Any solvents inert to the reaction may be used, including alcohols such as methanol, ethanol and isopropanol, tetrahydrofuran, diethyl ether, dioxane, benzene and toluene. The reaction is carried out at a temperature properly set depending on the type of reducing agent used (under ice cooling or at elevated temperatures). The protective groups of the nitrogen atom and hydroxyl groups can be simultaneously removed in this reducing step if the reaction is conducted under proper conditions.
The compounds (I) of this invention thus formed are isolated and purified in the form of free amine or a salt thereof by commonly employed techniques, for example, extraction, crystallization, recrystallization and various types of chromatography.
(PREPARATIVE METHODS)
Compounds (I) of this invention may be prepared by the methods described below.
Method 1' ##STR10## (wherein R is hydrogen atom or a halogen atom; R 1' and R 4' are each hydrogen atom or a protective group for the nitrogen atoms; and R 2' and R 3' are each hydroxyl group which may optionally be protected).
This method comprises cyclization of a compound represented by the general formula (II), followed by removal of the protective groups when required. As examples of the protective groups for hydroxyls in the starting material (II), may be mentioned linear or branched lower alkyls of 1 to 5 carbon atoms such as methyl, ethyl, isopropyl and tertbutyl, and aralkyls such as benzyl and phenetyl. As the protective groups for the nitrogen atoms, may be used tri(lower)alkylsilyl groups such as trimethylsilyl; acyl groups, such as formyl, acetyl, propionyl, trifluoroacetyl, tert-butoxycarbonyl, methoxyacetyl, methoxypropionyl and benzyloxycarbonyl; and aralkyls such as benzyl and benzyhydryl.
Compounds (I) of this invention can be prepared by subjecting a compound represented by the general formula (II) to intramolecular cyclization by the action of a cyclizing agent capable of forming carbonium ion from the alcoholic hydroxyl in compound (II), such as hydrochloric acid, sulfuric acid, sulfuric acid in trifluoroacetic acid, polyphosphoric acid, esters of polyphosphoric acid, methanesulfonic acid in dichloromethane, hydrobromic acid, hydrogen fluoride, and Lewis acids (e.g., boron trifluoride, aluminum chloride and stannic chloride).
There is no specific limitation upon the reaction temperature; the reaction is carried out under ice cooling or under reflux condition, with the reaction time being properly set in each case depending on other factors.
When the reaction product thus obtained contains protective groups, these are removed by catalytic reduction (e.g., catalytic hydrogenation) or by treatment with boron tribromide, hydrobromic acid, aluminum chloride, trimethylsilyl iodide or hydroiodic acid. The protective groups on the nitrogen atoms may be removed simultaneously with the protective groups on hydroxyl groups, or in a separate step (for example, by treatment with cyanogen bromide, hydrochloric acid or ammonia water, hydrogenation in the presence of a catalyst, or other suitable methods).
Method 3 ##STR11##
Compounds (I) of this invention can be prepared by reduction of a carbonyl compound represented by the general formula (III), followed by removal of the protective groups when required. The carbonyl compounds (III) used in this reaction may be obtained by subjecting an alcohol represented by the following general formula (IV) ##STR12## to intramolecular cyclization by the action of a cyclizing agent, such as hydrochloric acid, sulfuric acid, sulfuric acid in trifluoroacetic acid, polyphosphoric acid, esters of polyphosphoric acid, methanesulfonic acid in dichloromethane, hydrobromic acid, hydrogen fluoride, and Lewis acids (e.g., boron trifluoride, aluminum chloride and stannic chloride).
A carbonyl compound (III) thus obtained is treated with a reducing agent, such as borane, diborane, lithium aluminum hydride, sodium borohydride plus propionic acid, aluminum hydride diisobutyl and aluminum hydride bis(2-methoxyethoxy)sodium, and the protective groups are removed as required, giving a compound (I) of this invention. Any solvents inert to the reaction may be used, for example, tetrahydrofuran, diethyl ether, benzene and dioxane. The reaction is carried out at a temperature properly set depending on the type of reducing agent used (under ice cooling or at elevated temperatures). The protective groups can be removed by the methods described in Method 1.
The compounds (I) of this invention thus formed are isolated and purified in the form of free amine or a salt thereof by commonly employed techniques, for example, extraction, crystallization, recrystallization and various types of chromatography.
Compounds (I) of this invention and salts thereof are efficiently absorbed when administered orally because of the high liposolubility, and are effective for treating diseases of circulatory organs, such as renal insufficiency, cardiac insufficiency and hypertension.
Compounds (I) of this invention and salts thereof are efficiently absorbed when administered orally and are effective for treating diseases of circulatory organs, such as renal insufficiency, cardiac insufficiency and hypertension. In the treatment of hypertension, in particular, these compounds are expected to provide an etiologically effective medicine unlike conventional symptomatic drugs.
Compounds (I) of this invention and salts thereof have the effect to dilate nephrovascular tracts, and this action is exerted through dopamine receptor. Therefore, these compounds also have the effect to dilate vascular tracts of other organs, and directly act upon renal tubules, thus showing diuretic effect. In addition, these compounds are expected to be effective for the prevention of oliguria during and after operation and for the treatment of visceral hyperfunction, edemas, arterioscrelosis and blood coagulation.
These pharmacological effects were confirmed by the test described below.
(Test Method)
Male and female mongrel dogs weighing 11 to 16 Kg were subjected to anesthesia with pentobarbital (30 mg/Kg i.v.), and artificial respiration was started by means of a cannula inserted into the trachea of each dog. During the whole course of test, pentobarbital was continuously administered (3 to 5 mg/Kg/hr) into the vein of right forelimb to maintain a constant anesthetic condition. A cannula for drug administration was inserted into the vein of right thigh. The systemic blood pressure was measured by means of a pressure transducer, with a cannula inserted into the artery of right thigh. The heart rate was measured using a cardiotachometer driven by pulse waveform.
Incision was made form the flank to the posterior wall of the peritoneum to expose the kidney, a probe was set to the renal artery, and the rate of renal blood flow was measured with an electromagnetic blood flowmeter. After setting the probe, an injection needle for drug administration connected to a polyethylene tube was inserted at the origin of the renal artery.
Each of the compounds tested was quickly injected in the form of a 0.2 ml solution, followed by continuous injection of physiological saline (0.5 ml/min) to ensure its rapid spreading in the renal artery.
All the test values are expressed as percentage change in the rate of blood flow, with the value immediately before administration taken as 100%.
Administration of the compounds of this invention to the renal artery of dogs put under anesthesia at doses of 0.3 to 100 μg showed increases in the rate of blood flow proportional to the amounts administered, with an increase of about 35% being observed at the highest dose. And, some compounds at doses of 0.3-30 μg showed increases with an increase of about 40% being observed at the highest dose (30 μg).
Preparations containing, as active ingredient, at least one of the compounds (I) and salts thereof of this invention may be manufactured in the form of tablets, powder, beadlets, granules, capsules, pills, injections, suppositories, ointment or poultices by using carriers, excipients and other commonly employed additives, and are orally (including sublingual application) or parenterally administered.
The suitable daily dose of the compounds of this invention should be determined with consideration given to the physical conditions, body weight, age, sex and other factors of particular patients, but is normally 50 to 1000 mg for adults (given all at a time or subdivided in several doses).
Reference Example A ##STR13##
m-Nitrobenzaldehyde (1.8 g) was added to a suspension of α-(aminomethyl-3,4-dimethoxybenzyl alcohol hydrochloride in 25 ml methanol, triethylamine (2.8 ml) was further added dropwise at room temperature with stirring, and the resulting solution was heated under reflux for 30 minutes. After cooling, sodium borohydride (1.45 g) was added in small portions with stirring under ice cooling, and the mixture was sitrred at room temperature for one hour and concentrated. The residue was treated with chloroform and water, and the chloroform layer was collected, washed with water and dried over anhydrous sodium sulfate. The solvent was distilled off, and the residue was recrystallized from ether/n-hexane, affording 3.3 g of pure α-[(3-nitrobenzylamino)methyl]-3,4-dimethoxybenzyl alcohol, m.p. 105°-107° C.
Reference Example B ##STR14##
To a solution of 3.3 g α-[(3-nitrobenzylamino)methyl]-3,4-dimethoxybenzyl alcohol obtained in Reference Example 1 in 50 ml methanol, was added 0.6 g Raney nickel, and the mixture was subjected to hydrogenation at room temperature. After confirming complete absorption of hydrogen gas, the reaction mixture was filtered, the filtrate was concentrated, and the residue was recrystallized from ethyl acetate.
Reference Example 1 ##STR15##
α-[[(4-methoxybenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol (m.p. 110°-112° C.)
Reference Example 2 ##STR16##
α-[[(3-methoxybenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol (m.p. 115°-116° C.)
Reference Example 3 ##STR17##
α-[[(3-methylbenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol.
Reference Example 4 ##STR18##
α-[[(4-methylbenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol.
Reference Example 5 ##STR19##
α-[[(2-methylbenzyl)amino]methyl]-3,4-dimethoxybenzylalcohol (m.p. 103°-104° C.)
Reference Example 6 ##STR20##
1.0 g of α-(aminomethyl)-3,4-dimethoxybenzyl alcohol hydrochloride was suspended in 5 ml of methanol, and after adding thereto 0.85 g of 2,3-dimethoxybenzaldehyde, 0.63 ml of triethylamine was added dropwise to the mixture while stirring at room temperature. The mixture was heated under reflux for 30 minutes, and 0.24 g of sodium boron hydride was added slowly to the mixture while stirring under ice cooling. After the foaming stopped, the mixture was concentrated. The residue was subjected to a separating procedure with chloroform and water, the chloroform layer was collected, washed with water, and dried over anhydrous sodium sulfate. The solvent was distilled off, and the residue was recrystallized from ethyl acetate-n-hexane, giving 1.07 g of α-[[(2,3-dimethoxybenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol, m.p. 96°-97° C.
Reference Example 7 ##STR21##
(1) To 1.56 g of 3-methoxy-2-methylbenzoic acid, was added 2.03 g of thionyl chloride, and the mixture was heated under reflux for 30 minutes. The reaction solution was concentrated, and subjected to azeotropic distillation with toluene 2 times. The residue was dissolved in 8 ml of toluene, and the solution was added dropwise to a mixture of 2.0 g of α-(aminomethyl)-3,4-dimethoxybenzyl alcohol hydrochloride and 1.52 ml of pyridine and 20 ml of isopropyl alcohol under ice cooling while stirring. The temperature of the mixture was reverted to room temperature, and after 30 minutes, the reaction solution was concentrated. The residue was dissolved in ethyl acetate, washed with 1N aquesous HCl, saturated aqueous NaHCO 3 solution, and water, successively, and dried over anhydrous sodium sulfate. The solvent was distilled off, and the residue was recrystallized from ethyl acetate-n-hexane, giving 2.41 g of α-[N(3-methoxy-4-methylbenzoyl)amidomethyl]-3,4-dimethoxybenzyl alcohol, m.p. 106°-109° C. (2) 1.02 g of α-[N--(3-methoxy-4-methylbenzoyl)amidomethyl]-3,4-dimethoxybenzyl alcohol was dissolved in 10 ml of tetrahydrofuran, and 1M boran-tetrahydrofuran solution (10.8 ml) was added dropwise to the mixture under an argon gas stream under ice cooling. The mixture was heated under reflux for 2.5 hours, and after ice cooling, 0.44 ml of methanol was added dropwise, and the mixture was heated under reflux for 30 minutes. The mixture was cooled with ice, and after adding thereto 0.9 ml of conc. hydrochloric acid, the mixture was heated under reflux for 30 minutes, and concentrated. The residue was dissolved in water, washed with ehter twice, and basified, and extracted with chloroform twice. The chloroform layers were collected, washed with water, and dried over anhydrous sodium sulfate. The solvent was distilled off, and the residue was recrystallized from chloroform-n-hexane, giving 560 mg of α-[[(3-methoxy-2-methylbenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol, m.p. 135°-136° C.
Reference Example 8 ##STR22## α-[[(3-methoxy-2-nitrobenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol (m.p. 92°-94° C.)
Reference Example 9 ##STR23## 4-(3,4-dimethoxyphenyl)-7-methoxy-8-nitro-1,2,3,4-tetrahydroisoquinoline.
Reference Example 10 ##STR24## 2-Benzyl-4(3,4-dimethoxyphenyl)-7-methoxy-8-nitro-1,2,3,4-tetrahydroisoquinoline (m.p. 118°-119° C.)
Reference Example 11 ##STR25## 2-Benzyl-4-(3,4-dihydroxyphenyl)-7-hydroxy-8-nitro-1,2,3,4-tetrahydroisoquinoline hydrobromide (m.p. above 180° C. (decomposition))
Reference Example 12 ##STR26## α-(cyano)-6-fluoro-3,4-dimethoxybenzyl alcohol.
Reference Example 13 ##STR27## α-(aminomethyl)-6-fluoro-3,4-dimethoxybenzyl alcohol hydrochloride (m.p. 223°-226° C.)
Reference Example 14 ##STR28## α-[[(2,3-dimethoxybenzylamino]methyl]-6-fluoro-3,4dimethoxybenzyl alcohol (m.p. 110°-112° C.)
Reference Example 15 ##STR29## α-[[(3-methoxy-2-nitrobenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol (m.p. 92°-94° C.)
Reference Example 16 ##STR30## 4-(3,4-dimethoxyphenyl)-7-methoxy-8-nitro-1,2,3,4-tetrahydroisoquinoline.
Reference Example 17 ##STR31##2-benzyl-4-(3,4-dimethoxyphenyl)-7-methoxy-8-nitro-1,2,3,4-tetrahydroisoquinoline (m.p. 118°-119° C.)
Reference Example 18 ##STR32## 8-amino-2-benzyl-7-methoxy-4-(3,4-dimethxoyphenyl)-1,2,3,4-tetrahydroisoquinoline (m.p. 142°-143° C.)
Reference Example 19 ##STR33## α-(cyano)-6-fluoro-3,4-dimethoxybenzyl alcohol (m.p. 112°-114° C.)
Reference Example 20 ##STR34## α-(aminomethyl)-6-fluoro-3,4-dimethoxybenzyl alcohol hydrochloride (m.p. 223°-226° C.)
Reference Example 21 ##STR35## α-[(benzylamino)methyl]-6-fluoro-3,4-dimethoxybenzyl alcohol (m.p. 80°-82.5° C.)
Reference Example 22 ##STR36## α-[[(2-thenyl)amino]methyl]-6-fluoro-3,4-dimethoxybenzyl alcohol (m.p. 79°-83° C.)
Reference Example 23 ##STR37## α-[[(3-thenyl)amino]methyl]-6-fluoro-3,4-dimethoxybenzyl alcohol (a syrupy matter)
Reference Example 24 ##STR38## α-(cyano)-6-fluoro-3,4-dimethoxybenzyl alcohol (m.p. 112°-114° C.)
Reference Example 25 ##STR39## α-(aminomethyl)-6-fluoro-3,4-dimethoxybenzyl alcohol (m.p. 223°-226° C.)
Reference Example 26 ##STR40##α-[[[(2-acetamido-4-thiazolyl)methyl]amino]methyl]-6-fluoro-3,4-dimethoxybenzyl alcohol (m.p. 173°-175° C.)
Reference Example 27 ##STR41## α-[[[(2-acetamido-4-thiazolyl)methyl]amino]methyl]-3,4-dimethoxybenzyl alcohol (m.p. 204°-206° C.)
Reference Example 28 ##STR42## α-[(3-nitrobenzylamino)methyl]-3,4-dimethoxybenzyl alcohol (m.p. 105°-107° C.)
Reference Example 29 ##STR43## α-[(3-aminobenzylamino)methyl]-3,4-dimethoxybenzyl alcohol (m.p. 84°-86° C.)
(The above Reference Examples compounds were prepared by conventinal manners.) ##STR44##
(1) α-[[(4-methoxybenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol (950 mg) was dissolved in 7.2 ml of trifluoroacetic acid, and after adding thereto 0.22 ml of conc. sulfuric acid under cie dooling, the reaction was allowed to react for 45 minutes. The reaction solution was concentrated, and subjected to azeotropic distillation with toluene 2 times. After adding chloroform, the mixture was basified by addition of 28% aqueous ammonia under ice cooling. By a separating procedure, the chloroform layer was collected, washed with water, and dried over anhydrous sodium sulfate. The solvent was distilled off, and the residue obtained was subjected to silica gel column chromatography (chlroform-methanol-28% aqueous ammonia=15:1:0.1), giving 790 mg of 6-methoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline as oily matter.
(2) To 790 mg of 6-methoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline, was added 16 ml of 48% hydrobromic acid, and the mixture was heated under reflux for 3 hours under an argon stream. The reaction solution was cooled, and precipitates which separated out were collected by filtration, giving 630 mg of 6-hydroxy-4-(3,4-dihydroxyphenyl)-1,2,3,4-tetrahydroisoquinoline hydrobromide.
______________________________________Elemental analysis (as C.sub.15 H.sub.16 NO.sub.3 Br) C(%) H(%) N(%) Br(%)______________________________________Cacld. 53.27 4.77 4.14 23.63Found 53.16 4.70 4.16 23.35______________________________________
Melting point: above 250° C.
Mass spectrum (FAB) 258 (M + =1)
NMR spectrum (d 6 -DMSO, internal standard TMS) δ(ppm) 3.24 (1H, d), 3.49 (1H, dd), 6.23 (1H, d), 6.59 (1H, s) 6.74 (1H, s), 6.76 (1H, d) 7.40 (1H, d)
EXAMPLE 2 ##STR45##
(1) 17.5 ml of α-[[(3-methoxybenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol was dissolved in 17.5 ml of trifluoroacetic acid, and after adding thereto 0.54 ml of conc. sulfuric acid under ice cooling, the reaction was allowed to react for 60 minutes. The reaction solution was concentrated, and was subjected to azeotropic distillation with toluene 2 times. After adding chloroform, the mixture was basified by addition of 28% aqueous ammonia under ice cooling. By a separating procedure, the chloroform layer was collected, washed with water once, and dried over anhydrous sodium sulfate. The solvent was distilled off, and the residue was subjected to silica gel colum chromatography (chloroform-methanol-28% aqueous ammonia=15:1:0.1), a material of Rf being 0.47 and 0.35 [Kiesel gel 60F 254 plate; chloroform-methanol-28% aqueous ammonia(15:1:0.1)] was obtained. The material of Rf being 0.47 is 5-methoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline (m.p. 118°-118° C., recrystallized from chloroform-n-hexane) (680 mg), and the material of Rf being 0.35 is 7-methoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline (m.p. 119°-120° C., ethyl acetate-n-hexane recrystallization) (670 mg ).
(2) 640 mg of 7-methoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline was dissolved in 13 ml of 48% aqueous hydrogen bromide, and the mixture was heated under reflux under an argon gas stream for 3 hours. The reaction solution was cooled, and crystals which separated out were collected, affording 580 mg of 7-hydroxy-4-(3,4-dihydroxyphenyl)-1,2,3,4-tetrahydroisoquinoline hydrobromide.
______________________________________Elemental analysis (as C.sub.15 H.sub.16 NO.sub.3 Br.1/5 H.sub.2 O) C(%) H(%) N(%) Br(%)______________________________________Cacld. 52.71 4.84 4.10 23.38Found 52.66 4.79 4.07 23.63______________________________________
Melting point: above 220° C. (decomposition)
Mass spectrum (FAB) 258 (M + =1)
NMR spectrum (d 6 -DMSO, internal standard TMS) δ(ppm):3.22 (1H, d), 3.48 (1H, dd), 4.60 (1H, dd), 6,58 (1H, s), 6.64 (1H, s), 6.67 (1H, d)
EXAMPLE 3 ##STR46##
(1) 1.8 g of α-[[(3-methylbenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol was dissolved in 13.5 ml of trifluoroacetic acid, and after adding thereto 0.41 ml of conc. sulfuric acid under ice cooling, the mixture was allowed to react for 40 minutes. The reaction solution was concentrated, and subjected to azeotropic distillation with chloroform 2 times, and after adding chloroform, the mixture was basified by addition of 28% aqueous ammonia. By a separating procedure, the chloroform layer was collected, washed with water once, and dried over anhydrous sodium sulfate. The solvent was distilled off, and the residue was subjected to silica gel column chromatography (chloroform-methanol-28% aqueous ammonia (15:1:0.1); a material of Rf being 0.46 [Kiesel gel 60F 254 plate, chloroform-methanol-28% aqueous ammonia (15:1:0.1)] was collected, recrystallized from chloroform-n-hexane, and recrystallized from the same solvent system several times, giving 870 mg of 4- (3,4-dimethoxyphenyl)-7-methyl-1,2,3,4-tetrahydroisoquinoline, m.p. 129°-131° C.
(2) 850 mg of 4-(3,4-dimethoxyphenyl)-7-methyl-1,2,3,4-tetrahydroisoquinoline was dissolved in 17 ml of 48% hydrobromic acid, and the mixture was heated under reflux under an argon gas stream for 3 hours. The reaction solution was cooled, and the crystals obtained were collected by filtration, giving 620 mg of 4-(3,4-dihydroxyphenyl)-7-methyl-1,2,3,4-tetrahydroisoquinoline hydrobromide.
Melting point; 192°-195° C.
______________________________________Elemental analysis (as C.sub.15 H.sub.16 NO.sub.3 Br) C(%) H(%) N(%) Br(%)______________________________________Cacld. 57.16 5.40 4.17 23.76Found 57.21 5.29 4.03 23.83______________________________________
Mass spectrum (FAB) 256 (M + =1)
NMR spectrum (d 6 -DMSO, internal standatd TMS) δ(ppm): 2.27 (3H, s), 3.26 (1H, dd), 3.59 (1H, dd) 6.48 (1H, dd), 6.55 (1H, s), 6.72 (1H, dx2), 7.02 (1H, d), 7.08 (1H, s)
EXAMPLE 4 ##STR47##
530 mg of α-[[(4-methylbenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol was dissolved in 4 ml of trifluoroacetic acid, and after adding thereto 0.12 ml of conc. sulfuric acid under ice cooling, the mixture was allowed to react for 30 minutes. The reaction solution was concentrated, and subjected to azeotropic distillation with toluene 2 times. After adding chloroform, the mixture was basified by addition of 28% aqueous ammonia. By a separating procedure, the chlorofrom layer was collected, was washed with water once, and dried over anhydrous sodium sulfate. The solvent was distilled off, and the residue was recrystallized from ethyl acetate-n-hexane, giving 490 of 4(3,4-dimethoxyphenyl)-6-methyl-1,2,3,4-tetrahydroisoquinoline (melting point: 94°-96° C.).
(2) To 450 mg of 4-(4,5-dimethoxyphenyl)-6-methyl-1,2,3,4-tetrahydroisoquinoline, was added 9 ml of 48% hydrobromic acid, and the mixture was heated under reflux under an argon gas stream for 3 hours. The reaction solution was cooled, and the crystals which separated out were collected by filtration, giving 390 mg of 4-(3,4-dihydroxyphenyl)-6-methyl-1,2,3,4-tetrahydroisoquinoline hydrobromide.
Melting point above 250° C. (decomposition)
______________________________________Elemental analysis (as C.sub.15 H.sub.16 NO.sub.3 Br) C(%) H(%) N(%) Br(%)______________________________________Cacld. 57.16 5.40 4.17 23.76Found 56.95 5.44 4.02 24.06______________________________________
Mass spectrum (EI) 255 (M + )
NMR spectrum (d 6 -DMSO, internal standard TMS) δ(ppm): 2.20 (3H, s), 3.28 (1H, dd), 3.64 (1H, dd), 6.50 (1H, dd), 6.56 (1H, dd), 6.56 (1H, s), 6.64 (1H, s), 6.75 (1H, d), 7.04 (1H, dd), 7.18 (1H, d)
EXAMPLE 5 ##STR48##
(1) 900 mg of α-[[(2-methoxybenzylamino]methyl]-3,4-dimethoxybenzyl alcohol was dissolved in 7 ml of trifluoroacetic acid, and after adding thereto 0.21 ml of conc. sulfuric acid under ice cooling, the mixture was allowed to react for 60 minutes. The reaction solution was concentrated, and subjected to zzeotropic distillation 3 times, and after adding chloroform, the mixture was basified by addtion of 28% aqueous ammonia. By a separating procedure, the chloroform layer was collected, washed with water, and dried over anhydrous sodium sulfate. The solvent was distilled off, and the residue obtained was recrystallized from ethyl acetate-n-hexane, giving 440 mg of 4-(3,4-dimethoxyphenyl)-8-methyl-1,2,3,4-tetrahydroisoquinoline, m.p. 86°-88° C.
(2) To 420 mg of 4-(3,4-dimethoxyphenyl)-8-methyl-1,2,3,4-tetrahydroisoquinoline, was added 48% hydrobromic acid, and the mixture was heated under reflux for 3 hours. After about 10 minutes, the crystals becomes to be separated out. The reaction mixture was cooled, and the crystals were collected by filtration, giving 420 mg of 4-(3,4-dihydroxyphenyl)-8-methyl-1,2,3,4-tetrahydroisoquinoline hydrobromide.
Melting point: above 250° C. (decomposition)
______________________________________Elemental analysis (as C.sub.15 H.sub.16 NO.sub.3 Br) C(%) H(%) N(%) Br(%)______________________________________Cacld. 57.16 5.40 4.17 23.76Found 57.04 5.43 4.17 23.73______________________________________
Mass spectrum (FAB) 256 (M + =L)
NMR spectrum (d 6 -DMSO, internal standard TMS) δ(ppm): 2.28 (3H, s), 3.60 (1H, dd), 6.50 (1H, dd), 6.80 (1H, s), 6.65 (1H, d), 6.76 (1H, d), 7.12 (1H, d)
EXAMPLE 6 ##STR49##
(1) 1.0 g of α-[[2,3-dimethoxybenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol was dissolved in 7.5 ml of trifluoroacetic acid, and after adding thereto 0,23 ml of conc. sulfuric acid under ice cooling, the mixture was allowed to react for 30 minutes. The reaction solution was concentrated, and subjected to azeotropic distillation with toluene 2 times. After adding to the mixture chloroform, the mixture was basified by addition of 28% aqueous ammonia under ice cooling. After separaating procedure, the chloroform layer was collected, washed with water, and dried over anhydrous magnesium sulfate. The solvent was distilled off, and the residue thus obtained was recrystallized from chloroform-n-hexane, affording 750 mg of 7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline, m.p. 109°-110° C.
(2) To 700 mg of 7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline, was added 14 ml of 48% hydrobromic acid, and the mixture was heated under reflux for 3 hours under an argon gas stream. The reaction mixture was cooled, and the crystals which separated ount were collected by filtration, giving 540 mg of 7,8-dihydroxy-4-(3,4-dihydroxyphenyl)-1,2,3,4-tetrahydroisoquinoline hydrobromide.
______________________________________Elemental analysis (as C.sub.15 H.sub.16 NO.sub.4 Br) C(%) H(%) N(%) Br(%)______________________________________Cacld. 50.87 4.55 3.95 22.56Found 51.02 4.33 3.96 22.82______________________________________
Melting point: above 230° C. (decomposition)
Mass spectrum (FAB) 274 (M + +1)
NMR spectrum (d 6 -DMSO; internal standard: TMS) δ(ppm) 3.24 (1H, m), 3.52 (1H, m), 6.08 (1H, d), 6.48 (1H, dd), 6.58 (1H, s), 6.68 (1H, d), 6.76 (1H, d),
EXAMPLE 7
510 mg of α-[[(3-methoxy-2-methylbenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol was dissolved in 3.8 ml of trifluoroacetic acid, 0.12 ml of conc. sulfuric acid was added dropwise under ice cooling, and the mixture was allowed to react for 30 minutes. The reaction solution was concentrated, and subjected to azeotropic distillation with toluene 2 times. The residue was dissolved in chloroform, and basified by addition of 28% aqueous ammonia. The chloroform layter was collected, washed with water, and dried over anhydrous magnesium sulfate. The solvent was distilled off, and the residue was recrystallized from ethyl acetate-n-hexane, giving 430 mg of 7-methoxy-4-(3,4-dimethoxyphenyl)-8-methyl-1,2,3,4-tetrahydroisoquinoline, m.p. 128°-129° C.
(2) To 410 mg of 7-methoxy-4-(3,4-dimethoxyphenyl)-8-methyl-1,2,3,4-tetrahydroisoquinoline, was added 8.2 ml of 48% hydrobromic acid, and the mixture was heated under reflux under an argon gas stream for 3 hours. The reaction mixture was cooled, and the crystals which separated out were collected by filtration, giving 410 mg of 7-hydroxy-4-(3,4-dihydroxyphenyl)-8-methyl-1,2,3,4-tetrahydroisoquinoline hydrobromide.
______________________________________Elemental analysis (as C.sub.16 H.sub.18 NO.sub.3 Br) C(%) H(%) N(%) Br(%)______________________________________Cacld. 54.56 5.15 3.98 22.69Found 54.34 5.10 3.95 22.58______________________________________
Melting point: 250° C.
Mass spectrum (FAB) 272 (M + +1)
NMR spectrum (d 6 -DMSO, internal standard TMS) δ(ppm): 2.05 (1H, s), 3.35 (total 3H), 6,46 (total 3H, 2.72 (total 3H, dx2) ##STR50##
EXAMPLE 8 ##STR51##
700 mg of 2-benzyl-4-(3,4-dihydroxyphenyl)-7-hydroxy-8-nitro-1,2,3,4-tetrahydroisoquinoline hydrobromide was dissolved in 14 ml of ethanol, and by adding thereto 0.07 g of 10% paradium-carbon, hydrogenation reaction was performed at 40° C. The reaction was over, the reaction mixture was filtered, and concentrated. The residue obtained was changed to precipitates by treatment with chloroform, the precipitates were collected by filtration, and dried, affording 590 mg of 8-amino-4-(3,4-dihydroxyphenyl)-7-hydroxy-1,2,3,4-tetrahydroisoquinoline hydrobromide.
______________________________________Elemental analysis (as C.sub.15 H.sub.17 N.sub.2 O.sub.3 Br) C(%) H(%) N(%) Br(%)______________________________________Cacld. 51.01 4.85 7.93 22.62Found 50.72 4.53 7.91 22.43______________________________________
Mass spectrum (FAB) 273 (M + +1)
NMR spectrum (d 6 -DMSO, internal standard TMS) δ(ppm): 5.96 (1H, d), 6.46 (1H, dd), 6.53 (1H, s), 6.60 (1H, d), 6.76 (1H, d)
EXAMPLE 9 ##STR52##
(1) 1.03 g of 2-benzyl-4-(3,4-dihydroxyphenyl)-7-hydroxy-8-nitro-1,2,3,4-tetrahydroisoquinoline hydrobromide was suspended in 20 ml of ethanol, and after adding thereto 1 ml of Raney nickel, hydrogenation reaction was performed at 40° C. The hydrogenation reaction was over, the reaction mixture was filtered, and concentrated, affording 0.88 g of 8-amino-2-benzyl-4-(3,4-dihydroxyphenyl)-7-hydroxy-1,2,3,4-tetrahydroisoquinoline hydrobromide.
(2) To a solution of 0.25 ml of formic acid in 10 ml of chloroform, was added under ice cooling 0.88 g of 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide, and then after 15 minutes, was added dropwise 5 ml of a solution of 8-amino-2-benzyl-4-(3,4-dihydroxyphenyl)-7-hydroxy-1,2,3,4-tetrahydroisoquinoline hydrobromide (0.88 g) in dimethylformamide. The temperature of the reaction mixture was reverted to room temperature, and the reaction was performed for further 30 minutes. The reaction mixture was concentrated, and the residue obtained was changed to precipitates by addition of standard buffer solution (x5). The precipitates were collected by filtration, and washed perfectly with water, affording 450 mg of 2-benzyl-4-(3,4-dihydroxyphenyl)-8-formylamido-7-hydroxy-1,2,3,4-tetrahydroisoquinoline.
(3) 450 mg of 2-benzyl-4-(3,4-dihydroxyphenyl)-8-formamido-7-hydroxy-1,2,3,4-tetrahydroisoquinoline was dissolved in 9 ml of ethanol, and after adding thereto 0.86 of 2N hydrochloric acid 0.05 g of 10% paradium-carbon, hydrogenation reaction was performed at room temperature. The hydrogenation reaction was over, the reaction mixture was filtered, and concentrated. The residue was changed to precipitates with treatment of isopropyl alcohol and acetonitrile, and the precipitates was collected by filtration, affording 320 mg of 4-(3,4-dihyroxyphenyl)-8-formamido-7-hydroxy-1,2,3,4-tetrahydroisoquinoline hydrochloride.
______________________________________Elemental analysis (as C.sub.16 H.sub.17 N.sub.2 O.sub.4 Cl) C(%) H(%) N(%) Cl(%)______________________________________Cacld. 57.06 5.09 8.32 10.53Found 56.78 4.82 8.20 10.72______________________________________
Mass spectrum (FAB) 301 (M + +1)
NMR spectrum (d 6 -DMSO, internal standard TMS) δ(ppm): 6.56 (1H, s), 6.66 (1H, d), 6.80 (1H, d), 6.90 (1H, d), 8,28 (1H, d),
EXAMPLE 10 ##STR53##
(1) α-[[(2,3-dimethoxybenzyl)amino]methyl]-6-fluoro-3,4-dimethoxybenzyl alcohol (1.0 g) was dissolved in 7 ml of trifluoroacetic acid, and after adding thereto under ice cooling, conc. sulfuric acid (0.25 ml), the mixture was stirred for 40 minutes. 0.72 g of sodium acetate was added to the reaction mixture, and the mixture was concentrated. To the residue was added chloroform and water, and the mixture was basified by addition of conc. aqueous ammonia under ice cooling. After separating procedure, the chloroform layter was collected, washed with saturated aqueous NaCl solution, and drioed over anhydrous sodium sulfate. The solvent was distilled off, 0.94 g of 4-(6-fluoro-3,4-dimethoxyphenyl)-7,8-dimethoxy-1,2,3,4-tetrahydroisoquinoline was obtained as a syrupy matter.
(2) 0.90 g of 4-(6-fluoro-3,4-dimethoxyphenyl)-7,8-dimethoxy-1,2,3,4-tetrahydroisoquinoline was dissolved in 25 ml of dichloromethane; and to the mixture was added dropwise 1M boron tribromide-dichloromethane solution (27 ml) under an argon gas stream, at internal temperature of -30° to -60° C. under cooling while stirring. The mixture was stirred for 3 hours at room temperature and 7.0 ml of methanol was added to the mixture under cooling with dry ice-methanol bath, dropwise. The mixture was stirred for 30 minutes at room temperature, the crystals which separated out was collected, giving 0.75 g of 4-(6-fluoro-3,4-dihydroxyphenyl)-7,8-dihydroxy-1,2,3,4-tetrahydroisoquinoline hydrobromide.
______________________________________Elemental analysis (as C.sub.15 H.sub.15 NO.sub.2 FBr)C(%) H(%) N(%) F(%) Br(%)______________________________________Cacld. 48.41 4.06 3.76 5.10 21.47Found 48.14 4.12 3.66 4.82 21.30______________________________________
Melting point: above 238° C. (decomposition)
Mass spectrum (FAB) 292 (M + +1)
NMR spectrum (d 6 -DMSO, interanl standard TMS) δ(ppm): 5.44 (1H, m), 7.12 (1H, d,), 7.43 (1H, d), 7.62 (1H, d), 7.72 (1H, d)
EXAMPLE 11 ##STR54##
2.02 g of 8-amino-2-benzyl-7-methoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline was dissolved in 20% hydrochloric acid; and to the solution was added dropwise a solution of 0.38 g of sodium nitrite in 1.9 ml of water, under cooling. To the mixture was added dropwise a solution of 0.55 g of cuprous chloride in 11 ml of 20% hydrochloric acid. After the reaction was over, 4.84 g of sodium hydroxide was added to the mixture, and the mixture was extracted with chloroform 2 times. The chloroform layer was collected, washed with water, and dried over anhydrous magnesium sulfate, the solvent was distilled off, and the residue was recrystallized from ethanol, giving 1.23 g of 2-benzyl-8-chloro-7-methoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline, m.p. 88°-91° C. ##STR55##
1.13 g of 2-benzyl-8-chloro-7-methoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline was dissolved in 28 ml of ethanol, and after adding thereto 0.22 ml of 12 N hydrochloric acid, hydrogenation reaction was performed by addition of 0.1 g of 10%-paradium-carbon. After the hydrogenation reaction was over, the reaction solution was filtered, and concentrated. The residue was dissolved in chloroform, washed with saturated aqueous sodium hydrogen carbonate solution and water, and dried over anhydrous magnesium sulfate. The solvent was distilled off, and the residue was recrystallized from ethyl acetate-n-hexane, giving 580 mg of 8-chloro-7-methoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline, m.p. 130°-132° C. ##STR56##
To 540 mg of 8-chloro-7-methoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline, was added 11 ml of 48% hydrobromic acid, and the mixture was heated under reflux for 3 hours under an argon gas stream. After cooling, the crystals which separated out were collected by filtration, and 520 mg of 8-chloro-7-hydroxy-4-(3,4-dihydroxyphenyl)-1,2,3,4-tetrahydroisoquinoline hydrobromide was obtained.
______________________________________Elemental analysis (as C.sub.15 H.sub.15 ClNO.sub.3 Br) C(%) H(%) N(%)______________________________________Cacld. 48.35 4.06 3.76Found 48.32 4.05 3.75______________________________________
Melting point: above 260° C. (decomposition)
Mass spectrum (FAB) 292 (M + +1)
NMR spectrum (d 6 -DMSO, internal standard TMS) δppm: 4.22 (1H, dd), 6.48 (1H, dd), 6.56 (1H, s), 6.62 (1H, d), 6.75 (1H, d), 6.92 (1H, d)
EXAMPLE 12 ##STR57##
(1) α-[(benzylamino)methyl]-6-fluoro-3,4-dimethoxybenzyl alcohol (1.25 g) was dissolved in 8.75 ml of trifluoroacetic acid, and after adding thereto 0.37 ml of conc. sulfuric acid under ice-cooling, the mixture was stirred for 70 minutes. Then, 1.07 g of sodium acetate was added to the mixture, and the reaction mixture was concentrated. To the residue, was added chloroform and water, and the mixture was basified by addition of conc. aqueous ammonia under ice-cooling. By a separating procedure, the chloroform layer was collected, washed with saturated aquous NaCl solution, and dried over anhydrous sodium sulfate. The solvent was removed by distillation, giving 1.18 g of 4-(6-fluoro-3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline as a syrupy matter.
(2) 1.15 g of 4-(6-fluoro-3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline was dissolved in 30 ml of dichloromethane, 26.4 ml of 1M boron tribromide-dichloromethane solution was added to the solution under an argon gas stream under stirring under cooling at the internal temperature of -20° to -30° C. The mixture was stirred for 3 hours at room temperature, and then, 7.0 ml of methanol was added dropwise under cooling in dry ice-methanol bath. The mixture was stirred for 30 minutes at room temperature, the crystals which separated out were collected by filtration, affording 1.0 g of 4-(6-fluoro-3,4-dihydroxyphenyl)-1,2,3,4-tetrahydroisoquinoline hydrobromide.
______________________________________Elemental analysis (as C.sub.15 H.sub.15 NO.sub.2 FBr)C(%) H(%) N(%) F(%) Br(%)______________________________________Cacld. 52.96 4,44 4.12 5.58 23.49Found 52.98 4.50 4.14 5.62 23.49______________________________________
EXAMPLE 13 ##STR58##
A mixture of 0.66 g of α-[[(2-thenyl)amino]methyl]-6-fluoro-3,4-dimethoxybenzyl alcohol and 10 ml of polyphosphoric acid was stirred for 3.5 hours at 60° C. The reaction solution was poured into ice water, and the mixture was basified by addition of 25 ml of conc. aqueous ammonia. The mixture was extracted with chloroform, and the chloroform layer was washed with water, and dried over anhydrous magnesium sulfate. The solvent was distilled off, and 0.66 g of 4-(6-fluoro-3,4-dimethoxyphenyl)-4,5,6,7-tetrahydrothieno[2,3-c]-pyridine was obtained as a syrupy matter.
(2) 0.65 g of 4-(6-fluoro-3,4-dimethoxyphenyl)-4,5,6,7-tetrahydrothieno[2,3-c]pyridine was dissolved in 14 ml of dichloromethane; and to the mixture was added 1M boron tribromide-dichloromethane solution (12 ml) dropwise under an argon gas stream, while cooling -30°--60° C. (internal temperature) while stirring. The mixture was stirred for 2 hours at room temperature, and 20 ml of methanol was added dropwise thereto under ice cooling. The solvent was distilled off, and the residue obtained was crystallized by using a mixture of methanol and chloroform (1:8). The crystals were collected by filtration, and recrystallized from ethanol, giving 0.29 g of 4-(6-fluoro-3,4-dihydroxyphenyl)-4,5,6,7-tetrahydrothieno[2,3-c]pyridine hydrobromide.
______________________________________Elemental analysis (as C.sub.13 H.sub.13 NO.sub.2 BrFS)C(%) H(%) N(%) Br(%) F(%) S(%)______________________________________Cacld. 45.10 3.78 4.05 23.08 5.49 9.26Found 44.95 3.82 3.99 25.04 5.58 9.29______________________________________
Melting point: above 237° C. (decomposition)
Mass spectrum (FAB) 266 (M + +1)
NMR spectrum (d 6 -DMSO, internal standard TMS) δ(ppm): 3.0-3.9 (2H), 4.2-4.8 (3H, 6,42 (1H, d), 6.55 (1H, d), 6.62 (1H, d), 7.47 (1H, d), 8.85 (1H, S), 9.0-10.0 (3H)
EXAMPLE 14 ##STR59##
(1) 1.16 g of α-[[(3-thenyl)amino]methyl]-6-fluoro-3,4-dimethoxybenzyl alcohol was dissolved in 11 ml of trifluoroacetic acid, and after adding thereto 0.31 ml of conc. sulfuric acid under ice cooling, the mixture was stirred for 4 hours. The reaction solution was concentrated, and chloroform and water were added to the residue. The mixture was basified by addition of 10 ml of conc. aqueous ammonia under ice cooling. The chloroform layer was collected after a separating procedure, washed with water, and dried over anhydrous magnesium sulfate. The solvent was distilled off, and the residue was recrystallized form ethanol, affording 0.76 g of 7-(6-fluoro-3,4-dimethoxyphenyl)-4,5,6,7-tetrahydrothieno[3,2-c]pyridine, m.p. 108°-111° C.
(2) 0.62 g of 7-(6-fluoro-3,4-dimethoxyphenyl)-4,5,6,7-tetrahydrothieno[3,2-c]pyridine (obtained above) was dissolved in 13 ml of dichloromethane; and to the mixture was added dropwise 12 ml of 1M boron tribromide-dichloromethane solution under an argon gas stream at -30°--60° C. (internal temperature) under cooling while stirring. The mixture was stirred for 2 hours at room temperature, and to the mixture was added dropwise 20 ml of methanol under ice cooling. The solment was distilled off, and the residue was recrystallized from ethanol, affording 0.30 g of 7-(6-fluoro-3,4-hydroxyphenyl)-4,5,6,7-tetrahydrothieno[3,2-c]pyridine hydrobromide.
______________________________________Elemental analysis (as C.sub.13 H.sub.13 NO.sub.2 BrFS)C(%) H(%) N(%) Br(%) F(%) S(%)______________________________________Cacld. 45.10 3.78 4.05 23.08 5.49 9.26Found 44.97 3.78 4.01 23.21 5.46 9,34______________________________________
Melting point: above 266° C. (decomposition)
Mass spectrum (FAB) 266 (M + +1) NMR spectrum (d 6 -DMSO, internal standard TMS) δ(ppm): 3.0-3.9 (2H), 4.31 (2H, s), 4.4-4.9 (1H), 6.58 (1H, d), 6.62 (1H, d), 6.98 (1H, d), 7.49 (1H, d), 8.90 (1H, s), 9.0-10.0 (3H)
Reference Example 1' ##STR60##
Zinc iodide (0.98 g) was added to a solution of 6-fluoro-3,4-dimethoxybenzaldehyde (5.2 g) in 55 ml tetrahydrofuran, trimethylsilyl-nitrile (4.92 ml) was further added dropwise with stirring under ice cooling in an argon gas atmosphere, and stirring under ice cooling was continued for two hours. The resulting mixture was then stirred at room temperature for four hours, 4.11 ml methanol was added under ice cooling, and the solvents were distilled off. To the residue, were added 50 ml methanol and 0.65 g citric acid, and the mixture was stirred overnight at room temperature and concentrated. The residue was treated with chloroform and water, and the chloroform layer was collected and dried over anhydrous magnesium sulfate. The solvent was distilled off, and the residue was recrystallized from chloroform/n-hexane, affording 3.28 g of pure α-(cyano)-6-fluoro-3,4-dimethoxybenzyl alcohol, m.p. 112°-114° C.
Reference Example 2' ##STR61##
To a suspension of 3.24 g α-(cyano)-6-fluoro-3,4-dimethoxybenzyl alcohol obtained in Reference Example 1 in 20 ml tetrahydrofuran, was added dropwise 33 ml of 1M solution of borane in tetrahydrofuran with stirring in a methanol/ice bath under an argon gas atmosphere, and the resulting solution was heated under reflux for three hours. After cooling the reaction mixture in an ice bath, methanol was added until gas evolution was no longer observed, the resulting solution was stirred at room temperature for one hour, and hydrogen chloride gas was introduced until the pH fell below 1. The crystals which separated out were collected, affording 3.34 g of α-(aminomethyl)-6-fluoro-3,4-dimethoxybenzyl alcohol hydrochloride, m.p. 223°-226° C.
Reference Example 3' ##STR62##
α-(Aminomethyl)-6-fluoro-3,4-dimethoxybenzyl alcohol hydrochloride (1.35 g) obtained in Reference Example 2 and 2-acetamido-4-formyl-thiazole (1.0 g) were suspended in 6.75 ml methanol, and 0.78 ml triethylamine was added dropwise to this suspension with stirring. The resulting solution was heated under reflux for 30 minutes, and 0.30 g sodium borohydride was added in small portions with stirring under ice cooling. The crystals which separated out were collected by filtration, washed with water and methanol in that order and vaccum-dried, giving 1.22 g of α-[[[(2-acetamido-4-thiazolyl)methyl]amino]methyl]-6-fluoro-3,4-dimethoxybenzyl alcohol, m.p. 173°-175° C.
Reference Example 4' ##STR63##
α-(Aminomethyl)-3,4-dimethoxybenzyl alcohol hydrochloride (2.88 g) and 2-acetamido-4-formyl-thiazole (2.1 g) were suspended in 14 ml methanol, and 1.8 ml triethylamine was added dropwise to this suspension with stirring. The resulting solution was heated under reflux for 30 minutes, and 0.70 g sodium borohydride was added in small portions with stirring under ice cooling. The crystals which separated out were collected by filtration, washed with water and methanol in that order and vaccum-dried, giving 3.55 g of α-[[[(2-acetamido-4-thiazolyl)methyl]amino]methyl]-3,4-dimethoxybenzyl alcohol, m.p. 204°-206° C.
EXAMPLE 15 ##STR64##
(1) A solution of 1.50 g α-[[[(2-acetamido-4-thiazolyl)methyl]amino]methyl]-6-fluoro-3,4-dimethoxybenzyl alcohol obtained in Reference Example 3 in 30 ml 6N-HCl was held at 60° C. overnight, the reaction mixture was cooled, and the crystals which separated out were collected by filtration, dissolved in 7.5 ml water and basified by addition of saturated solution of sodium bicarbonate. The crystals which separated out were collected by filtration, washed with a small amount of acetonitrile and vacuum-dried, affording 590 mg of 2-amino-7-(6-fluoro-3,4-dimethoxyphenyl)-4,5,6,7-tetrahydrothiazolo[4,5-c]pyridine, m.p.>240° C. (dec.).
(2) 2-Amino-7-(6-fluoro-3,4-dimethoxyphenyl)-4,5,6,7-tetrahydrothiazolo[4,5-c]pyridine (590 mg) obtained above was dissolved in 12 ml of 48% hydrobromic acid, and the solution was heated under reflux for three hours. The crystals which separated out were collected by filtration, affording 750 mg of 2-amino-7-(6-fluoro-3,4-dimethoxyphenyl)-4,5,6,7-tetrahydrothiazolo[4,5-c]pyridine dihydrobromide.
______________________________________(i) Elemental analysis (as C.sub.12 H.sub.14 N.sub.3 O.sub.2 SBr.sub.2F):C(%) H(%) N(%) S(%) Br(%) F(%)______________________________________Calcd. 32.53 3.18 9.48 7.24 36.06 4.29Found 32.26 3.23 9.39 7.37 35.90 4.13______________________________________
(ii) Melting point: >240° C. (dec.)
(iii) Mass spectrometry (FAB): 282 (M 30 +1)
(iv) NMR spectrum (d 6 -DMSO; internal standard: TMS): (ppm) 4.25 (br-s), 2H), 4.56 (m, 1H) 6.63 (d, 1H), 6.65 (d, 1H)
EXAMPLE 16 ##STR65##
(1) A solution of 1.72 g α-[[[(2-acetamido-4-thiazolyl)methyl]amino]methl]-3,4-dimethoxybenzyl alcohol obtained in Reference Example 4 in 34 ml 6N-HCl was held at 60° C. overnight, the reaction mixture was cooled, and the crystals which separated out were collected by filtration, dissolved in 8.5 ml water and basified by addition of saturated solution of sodium bicarbonate. The crystals which separated out were collected by filtration, washed with a small amount of acetonitrile and vacuum-dried, affording 510 mg of 2-amino-7-(3,4-dimethoxyphenyl)-4,5,6,7-tetrahydrothiazolo[4,5-c]pyridine, m.p.>240° C. (dec.).
(2) 2-Amino-4-(3,4-dimethoxyphenyl)-4,5,6,7-tetrahydrothiazolo[4,5-c]pyridine (480 mg) obtained above was dissolved in 9.6 ml of 48% hydrobromic acid, and the solution was heated under reflux for three hours. The reaction mixture was cooled, the crystals which separated out were collected by filtration, affording 620 mg of 2-amino-7-(3,4-dihydroxyphenyl)-4,5,6,7-tetrahydrothiazolo[4,5-c]pyridine dihydrobromide monohydrate.
______________________________________(i) Elemental analysis (as C.sub.12 H.sub.15 N.sub.3 O.sub.2 SBr):C(%) H(%) N(%) S(%) Br(%)______________________________________Calcd. 32.52 3.87 9.48 7.24 36.06Found 32.27 3.71 9.43 7.25 36.34______________________________________
(ii) Melting point: >250° C. (dec.)
(iii) Mass spectrometry (FAB): 264 (M + +1)
(iv) NMR spectrum (d 6 -DMSO; internal standard: TMS): (ppm) 6.56 (dd, 1H), 6.68 (d, 1H) 6.76 (d, 1H)
(Prescription)
A mixture of 100 mg of the compound obtained in Example 6 or 7 (free base), 200 mg of crystalline lactose and 2 mg of magnesium stearate is filled in a capsule by the usual method, and is orally administered four times a day to a patient requiring dilation of renal vascular tracts.
EXAMPLE 17 ##STR66##
(1) A solution of 2.8 g α-[(3-aminobenzylamino)methyl]-3,4-dimethoxybenzyl alcohol obtained in Reference Example 2 in 15 ml 6N-HCl was held at 60° C. overnight with stirring, and the reaction mixture was stirred under ice cooling for one hour. The crystals which separated out were collected by filtration, chloroform and water were added, and 10% aqueous solution of caustic soda was further added under ice cooling until the aqueous layer became alkaline. The mixture was stirred well, and the chlorofrm layer was collected, washed with saturated aqueous solution of sodium chloride and dried over anhydrous sodium sulfate. The solvent was distilled off, and the residue was recrystallized from ethyl acetate/n-hexane, affording 1.5 g of pure 7-amino-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline, m.p. 157°-159° C.
(2) To a solution of 1.5 g 7-amino-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline obtained above in 50 ml dichloromethane, was added dropwise 1M solution of boron tribromide in dichloromethane (25 ml) under an argon gas stream while maintaining the internal temperature at -20° C. The reaction mixture was stirred at room temperature for three hours and then cooled to -20° C. once again, and 7 ml methanol was added dropwise at that temperature. The crystals which separated out were collected by filtration and recrystallized from ethanol, giving 1 g of pure 7-amino-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline dihydrobromide.
______________________________________(i) Elemental analysis (as C.sub.15 H.sub.18 N.sub.2 O.sub.2): C(%) H(%) N(%) Br(%)______________________________________Calcd. 43.09 4.34 6.70 38.22Found 43.36 4.59 6.50 37.89______________________________________
(ii) Melting point: 194°-196° C. (dec.)
(iii) Mass spectrometry (FAB): 257 (M + +1)
(iv) NMR spectrum (d 6 -DMSO; internal standards: TMS): δ(ppm) 6.56 (s, 2H), 6.72 (d, 1H), 6.92 (d, 1H), 7.12 (s, 2H)
(Prescription)
A mixture of 100 mg of the compound obtained in Example 18 (free base), 200 mg of crystalline lactose and 2 mg of magnesium stearate is filled in a capsule by the usual method, and is orally administered four time a day to a patient requiring dilation of renal vascular tracts.
Reference Example
To a suspension of 22.5 g of methanesulfonylamidobenzoic acid in 648 ml of dichloromethane, was added 24, 37 g of 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride with stirring under ice-cooling, and stirring under ice-cooling was continued for 50 minutes. To the resulting mixture was added a suspension of 24.37 g of α-(aminomethyl)-3,4-dimethoxybenzyl alcohol hydrochloride and 15.14 ml of N-methylmorpholine in 100 ml of dichloromethane in small portions, and stirring under ice-cooling was continued for 5 hours. To the resulting mixture was added 1N HCl (300 ml), and the dichloromethane layer was separated. The separated solution was washed once with each of 1N HCl and saturated aqueous NaCl solution, and dried over anhydrous magnesium sulfate. The solvent was distilled off, and 32.71 g of α-[N-(3-methanesulfonylamidobenzolyl)amidomethyl]-3,4-dimethoxybenzyl alcohol was obtained as foamy matter.
Reference Example
32.7 g of α-[N-(3-methanesulfonylamidobenzolyl)amidomethyl]-3,4-dimethoxybenzyl alcohol was dissolved in 250 ml of tetrahydrofurane. To the resulting solution was added 298 ml of 1M borane-tetrahydrofurane dropwise below -30° C. The temperature of the resulting solution was raised to room temperature, and the solution was heated under reflux for 2.5 hours. To the resulting solution was added 24.9 ml of conc. hydrochloric acid dropwise and the solution was stirred for 30 minutes at room temperature. The solvent was distilled off; and to the residue obtained were added water and chloroform. The resulting mixture was basified with conc. aqueous ammonia, and extracted thrice with chloroform. The chloroform layers were combined, washed with saturated aqueous NaCl solution, and dried over anhydrous magnesium sulfate. The solvent was distilled off, and the residue thus obtained was subjected to silica gel column chromatography (chloroform-methanol-28% aqueous ammonia=20:1:0.1˜10:1:0.1), and a material of Rf being 0.12 [Kiesel gel 60F 254 p plate); chloroform-methanol-28% aqueous ammonia (20:1:0.1)] was collected, and crystallized from chloroform-n-hexane, affording 12.73 g of α-[[(3-methanesulfonylamidobenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol, m.p. 98°-100° C.
EXAMPLE 18
(1) 12.7 g of α-[[(3-methanesulfonylamidobenzyl)amino]methyl]-3,4-dimethoxybenzyl alcohol was dissolved in 250 ml of 6N hydrochloric acid, the mixture was allowed to react under an argon gas stream at 60°-65° C. for 3 hours. To the cooled reaction mixture were added chloroform, ice and conc. aqueous ammonia; and the mixture was extracted with 5% methanol-chloroform under basic condition. The organic layer was washed with saturated aqueous NaCl solution, and dried over anhydrous magnesium sulfate. The solvent was distilled off, and the residue thus obtained was subjected to silica gel column chromatography (chlroform-methanol-28% aqueous ammonia=20:1:0.1˜10:1:0.1), and a material of Rf being 0.14 [Kiesel gel 60F 254 plate; chloroform-methanol-28% aqueous ammonia=20:1:0.1) was collected, and crystallized from chloroform-ether, affording 5.94 g of 4-(3,4-dimethoxyphenyl)-7-methanesulfonylamido-1,2,3,4-tetrahydroisoquinoline, m.p. 220°-222° C.
(2) 4.0 g of 4-(3,4-dimethoxyphenyl)-7-methanesulfonylamido-1,2,3,4-tetrahydroisoquinoline was suspended in 40 ml of dichloromethane, and after adding thereto 2.08 ml of acetic anhydride under an argon gas stream at room temperature, the mixture was allowed to react for 1 hour. To the reaction solution were added water, ice and conc. aqueous ammonia, the mixture was extracted with dichloromethane under basic condition; and the extract was washed with 1N hydrochloric acid and water, each once, and dried over anhydrous magnesium sulfate. The solvent was distilled off, and 4.46 g of 2-acetyl-4-(3,4-dimethoxyphenyl)-7-methanesulfonylamido-1,2,3,4-tetrahydroisoquinoline was obtained a a syrupy matter.
(3) 4,46 g of 2-acetyl-4-(3,4-dimethoxyphenyl)-7-methanesulfonylamido-1,2,3,4-tetrahydroisoquinoline (obtained at (2) above) was dissolved in 50 ml of dichlromethane; and to the solution was added 66.2 ml of 1M borane-3Br dichloromethane solution dropwise under cooling below -28° C. under an argon gas stream. The mixture was allowed to react for 2.5 hours, and after adding dropwise 13.96 ml of methanol below -40° C., the temperature of the reaction solution was raised upto room temperature. About 30 ml of methanol was added to the solution, and the solvent was distilled off. 50 ml of toluene was added to the residue obtained, and the solvent was distilled off again, and after adding to the residue water and ethyl acetate, the mixture was extracted with ethyl acetate. The extract was washed with water and saturated aqueous NaCl solution each once, and dried over anhydrous magnesium sulfate. The solvent was distilled off, and 4.13 g of 2-acetyl-4-(3,4-dihydroxyphenyl)- 7-methanesulfonylamido-1,2,3,4-tetrahydroisoquinoline was obtained, m.p. 125°-127° C.
(4) 1.7 g of 2-acetyl-4-(3,4-dihydroxyphenyl)-7-methanesulfonylamido-1,2,3,4-tetrahydroisoquinoline obtained at (3) above was dissolved in 17 ml of ethanol and 17 ml of 2N hydrochloric acid, and the mixture was heated under reflux under an argon gas stream for 8.5 hours. The solvent was distilled off, and after adding water and ethyl acetate, the aqueous layer was separated with a separating funnel. The aqueous layer was washed with ethyl acetate 5 times, and concentrated. To the residue was added 30 ml of ethanol, and concentrating procedures was conducted 3 times, and after drying, 1.12 g of 4-(3,4-dihydroxyphenyl)-7-methanesulfonylamido-1,2,3,4-tetrahydroisoquinoline HCl salt was obtained a foamy matter.
______________________________________Elemental analysis (as C.sub.16 H.sub.18 N.sub.2 O.sub.4 SCl.1/3H.sub.2O)C(%) H(%) N(%) S(%) Cl(%)______________________________________Calcd. 50.99 5.26 7.43 8.50 9.40Found 51.20 5.31 7.29 8.73 9.63______________________________________
Mass spectrometry (FAB): 335 (M+1)
NMR spectrum (d 6 -DMSO; internal standard: TMS) δ (ppm) 3.02 (3H, s), 3.1-3.7 (2H, m), 4.24 (1H, m), 3.35 (2H, br-s), 6.4-7.2 (6H, m)
Reference Example 32
(1) 12.0 g of 3-ethanesulfonylamidobenzoic aicd was suspended in 360 ml of dichloromethane, and after adding thereto under ice cooling while stirring 12.04 g of 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride, the mixture was stirred for 30 minutes. To the mixture was added a suspension of 12.23 g of α-(aminomethyl)-3,4-dimethoxybenzyl alcohol hydrochloride and 7.48 ml of N-methylmorpholine in 60 ml of dichloromethane, slowly. The mixture was stirred overnight under ice cooling. After adding 1N hydrochloric acid (200 ml), the dichloromethane layer was collected, washed with 1N hydrochloric acid and saturated aqueous NaCl solution each once, and dried over anhdyrous magnesium sulfate. The solvent was distilled off, giving 20.35 g of α-[N-(3-ethanesulfonylamidobenzoyl)amidomethyl]-3,4-dimethoxybenzyl alcohol as a foamy matter.
(2) 20.0 g of α-[N-(3-ethanesulfonylamidobenzoyl)amidomethyl]-3,4-dimethoxybenzyl alcohol was dissolved in 150 ml of tetrahydrofuran; and to the mixture was added dropwise 1M borane-tetrahydrofuran solution (176 ml) below -20° C. The temperature of the solution was raised gradually to room temperature, and the mixture was heated under reflux for 2.5 hours. To the mixture was added 7.13 ml of methanol under cooling with methanol-ice bath, and the mixture was heated under reflux for 30 minutes. To the solution was added 14.7 ml of conchydrochloric acid under cooling with methanol-ice bath dropwise, and the mixture was stirred at room temperature for 30 minutes, and the solvent was distilled off. To the residue was added water and chloroform, and the mixture was basified with conc. aqueous ammonia, and extracted with choroform 3 times. The chloroform layer was collected, washed with saturated aqueous NaCl solution, and dried over anhydrous magnesium sulfate. The solvent was distilled off, and the residue was subjected to column chromatography (chloroform-methanol-28% aqueous ammonia=20:1:0.1-10:1:0.1), and a materia of Rf being 0.13 [Kiesel gel 60F 254 plate, chloroform-methanol-28% aqueous ammonia=20:1:0.1) was collected, giving 13.81 g of alpha-[[(3-ethanesulfonylamidobenzyl)amino]methyl]-,4-dimethoxybenzyl-alcohol.
EXAMPLE 19
1.0 g of 2-acetyl-4-(3,4-dihydroxyphenyl)-7-ethanesulfonylamido-1,2,3,4-tetrahydroisoquinoline was dissolved in 10 ml of ethanol and 10 ml of 2N hydrochloric acid, and the mixture was heated udner reflux overnight. The solvent was distilled off, and after adding water and ethyl acetate, the aqueous layer was collected, washed with ethyl acetate twice, and concentrated. To the residue was added 30 ml of ethanol, and the concentration procedures were repeated 3 times. The residue was crystallized from isopropanol, giving 0.90 g of 4-(3,4-dihydroxyphenyl)-7-ethanesulfonylamido-1,2,3,4-tetrahydroisoquinoline.1-isopropanol.1-HCl salt. Melting point: 161°-162° C.
______________________________________Elemental analysis (as C.sub.17 H.sub.21 N.sub.2 O.sub.4 SCl.C.sub.3H.sub.7 OH)C(%) H(%) N(%) S(%) Cl(%)______________________________________Calcd. 53.98 6.57 6.30 7.21 7.97Found 53.74 6.50 6.25 7.29 8.17______________________________________
Mass spectrum (FAB) 349 (M+1),
NMR spectrum (d 6 -DMSO, internal standard TMS), (ppm): 1.21 (3H, t), 3.10 (2H, t), 3.2-3.9 (2H, m), 4.20 (1H, m), 4.34 (2H, br-s), 6.4-7.2 (6H, m)
The starting material of the above compound has melting point of 117°-119° C., and was prepared by a conventional manner.
The following compounds were also prepared.
4-(3,4-dimethoxyphenyl)-7-ethanesulfonylamido-1,2,3,4-tetrahydroisoquinoline, m.p. 209°-211° C.
2-acetyl-4-(3,4-dimethoxyphenyl)-7-ethanesulfonylamido-1,2,3,4-tetrahdydroisoquinoline (a foamy matter).
EXAMPLE 20 ##STR67##
(1) (i) 16.9 g of (R,S)-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline prepared by the method of example 6(1) was suspended in 50.7 ml of ethanol, and 19.3 g of (-)-dibenzoyl-L-tartaric acid monohydrate in 67.6 ml of ethanol solution was added dropwise under stirring at room temperature, giving colorless crystals. The resulting crystals were recrystallized from aqueous ethanol, affording 12 g of (R)-(+)-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline. (-)-dibenzoyl-L-tartrate as colorless needle crystals. Melting point above 181° C. (decomposition)
______________________________________Elemental analysis (as C.sub.19 H.sub.23 NO.sub.4 C.sub.18 H.sub.14O.sub.8) C(%) H(%) N(%)______________________________________Calcd. 64.62 5.42 2.04Found 64.43 5.48 2.05______________________________________
(ii) The reaction mothor liquor used in the preparation of (R)-(+)-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline . (-)-dibenzoyl-L-tartrate was concentrated. To the residue was added dichloromethane and the mixture was basified by adding 0.5N aqueous sodium hydroxide solution. After separation, the dichloromethane layer was washed with water and dried over anhydrous magnesium sulfate. The solvent was distilled off, and 56 ml of ethanol was added to the resulting residue; 16.3 g of (+)-dibenzoyl-D-tartaric acid monohydrate in 56 ml of ethanol solution was added dropwise thereto, giving colorless crystals which were recrystallized twice from aqueous ethanol, affording 12.4 g of S-(-)-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline, (+)-dibenzoyl-D-tartrate as colorless needle crystals. Melting point >181° C. (decomposition).
(2) Dichloromethane was added separately to (R)-(+)-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline . (-)-dibenzoyl-L-tartrate and to (S)-(-)-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline . (+)-dibenzoyl-D-tartrate obtained at (1) above. Both mixtures were basified by adding 1N aqueous sodium hydroxide. After separation, the dichloromethane layers were washed with water and dried over anhydrous magnesium sulfate. The solvent was distilled off, and the resulting residues were recrystallized from ethylacetate-n-hexane, affording 5.3 g of (R)-(+)-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline and 5.0 g of (S)-(-)-7,8-dimethoxy-4-[3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline respectively.
(i) R-(+)-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline. [α] D 20 =+14° (C=1, CHCl 3 ), melting point 98° C.
______________________________________Elemental analysis (as C.sub.19 H.sub.23 NO.sub.4) C(%) H(%) N(%)______________________________________Calcd. 69.28 7.04 4.25Found 69.04 7.06 4.18______________________________________
(ii) S-(-)-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline [α] D 20 =-14° (C=1, CHCl 3 ), melting point 98° C.
______________________________________Elemental analysis (as C.sub.19 H.sub.23 NO.sub.4) C(%) H(%) N(%)______________________________________Calcd. 69.28 7.04 4.25Found 69.07 7.03 4.12______________________________________
(3) (i) 2.0 g of (R)-(+)-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline was dissolved in 10 ml of dichloromethane; after adding 0.86 ml of anhydrous acetic acid thereto at room temperature, the mixture was allowed to react for 30 minutes. The reaction solution was concentrated and subjected twice to azeotropic distillation with toluene. Then dichloromethane was added and the mixture was basified by adding 1N aqueous sodium hydroxide. After separation, the dichloromethane layer was washed with water and dried over anhydrous magnesium sulfate. The solvent was distilled off, and the resulting residue was recrystallized from ethylacetate-n-hexane, affording 2.12 g of (R)-(-)-N-acetyl-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline. m.p. 128° C.; [α] D 20 =-39° (C=1, CHCl 3 ).
______________________________________Elemental analysis (as C.sub.21 H.sub.25 NO.sub.5) C(%) H(%) N(%)______________________________________Calcd. 67.91 6.78 3.77Found 67.67 6.70 3.77______________________________________
(ii) 3.0 g of (S)-(-)-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydoisoquinoline was treated as in (3) (i), affording 3.19 g of (S)-(+)-N-acetyl-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline. m.p. 128° C.; [α] D 20 =+39° (C=1CHCl 3 )
______________________________________Elemental analysis (as C.sub.21 H.sub.25 NO.sub.5) C(%) H(%) N(%)______________________________________Calcd. 67.91 6.78 3.77Found 67.81 6.82 3.72______________________________________
(4) (i) 1.78 g of (R)-(-)-N-acetyl-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline was dissolved in 9 ml of dichloromethane; after adding 24 ml of 1M boron tribromide-dichloromethane solution at -30° C., the mixture was reacted at room temperature for 90 minutes. Then 4.4 ml of methanol was added at -30° C. The reaction solution was concentrated and subjected twice to azeotropic distillation with methanol. To the residue was added 17.8 ml of 0.1N hydrochloric acid. The crystals which separated out were collected by filtration, affording 1.46 g of (R)-(-)-N-acetyl-7,8-dihydroxy-4-(3,4-dihyroxyphenyl)-1,2,3,4-tetrahydroisoquinoline.1/4 hydrate, m.p. above 230° C. (decomposition); [α] D 20 =-85° (C=1, CH 3 OH)
______________________________________Elemental analysis (as C.sub.17 H.sub.17 NO.sub.5 1/4H.sub.2 O) C(%) H(%) N(%)______________________________________Calcd. 63.84 5.52 4.38Found 63.68 5.46 4.37______________________________________
(ii) 2.0 g of (S)-(+)-N-acetyl-7,8-dimethoxy-4-(3,4-dimethoxyphenyl)-1,2,3,4-tetrahydroisoquinoline was treated as in (4) (i), affording 1.61 g of (S)-(+)-N-acetyl-7,8-dihydroxy-4-(3,4-dihydroxyphenyl)-1,2,3,4-tetrahydroisoquinoline 1/4hydrate. m.p. >225° C. (decomposition); [α] D 20 =+85° (C=1, CH 3 OH)
______________________________________Elemental analysis (as C.sub.17 H.sub.17 NO.sub.5 1/4H.sub.2 O) C(%) H(%) N(%)______________________________________Calcd. 63.84 5.52 4.38Found 63.87 5.52 4.31______________________________________
(5) (i) To 1.15 g of (R)-(-)-N-acetyl-7,8-dihydroxy-4-(3,4-dihydroxyphenyl)-1,2,3,4-tetrahydroisoquinoline 1/4hydrate were added 9 ml of 3N hydrochloric acid and 9 ml of ethanol, and the mixture was heated under an argon gas stream for 24 hours. After the reaction solution was cooled, the crystals which separated out were collected by filtration, affording 1.09 g (R)-(+)-7,8-dihydroxy-4-(3,4-dihydroxyphenyl)-1,2,3,4-tetrahydroisoquinoline hydrochloride monohydrate. [α] D 20 =+15° (C=1, CH 3 OH)
______________________________________Elemental analysis (as C.sub.15 H.sub.15 NO.sub.4 HCl H.sub.2 O) C(%) H(%) N(%) Cl(%)______________________________________Calcd. 54.97 5.54 4.27 10.82Found 54.85 5.49 4.14 11.06______________________________________
(ii) 1.2 g of (S)-(+)-N-acetyl-7,8-dihydroxy-4-(3,4-dihydroxyphenyl)-1,2,3,4-tetrahydroisoquinoline.1/4hydrate was treated as in (5) (i), affording 1.1 g of (S)-(-)-tetrahydroisoquinoline hydrocholride monohydrate. [α] D 20 =-14° (C=1, CH 3 OH)
______________________________________Elemental analysis (as C.sub.15 H.sub.15 NO.sub.4 HCl2.sub.O) C(%) H(%) N(%) Cl(%)______________________________________Calcd. 54.97 5.54 4.27 10.82Found 54.70 5.42 4.34 10.98______________________________________
(6(R)-(-)-acetyl-7,8-dihydroxy-4-(3,4-dihydroxyphenyl)-1,2,3,4-tetrahydroisoquinoline 1/4hydrate and (S)-(+)-N-acetyl-7,8-dihydroxy-4-(3,4-dihydroxyphenyl)-1,2,3,4-tetrahydroisoquinoline 1/4 hydrate obtained above (4) (i) (ii) were treated separately with 3N hydrobromic acid-ethanol, affording (R)-(+)-7,8-dihydroxy-4-(3,4-dihydroxyphenyl)-1,2,3,4-tetrahydroisoquinoline hydrobromide monohydrate and (S)-(-)-7,8-dihydroxy-4-[3,4-dihydroxyphenyl)-1,2,3,4-tetrahydroisoquinoline hydrobromide monohydrate respectively.
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This invention provides certain novel substituted tetrahydroisoquinoline opticulisomers of the formula: ##STR1## wherein A represents the formula ##STR2## wherein R is hydrogen or halogen; R 1 is hydrogen, lower alkyl, hydroxyl, halogen, amino, or lower acylamino;
R 2 is hydrogen, lower alkyl, hydroxyl, amino, or lower alkylsulfonylamino;
R 3 is hydrogen, lower alkyl, or hydroxyl;
R 4 is a hydrogen atom or a lower alkylsulfonyl;
with the proviso that when R 1 is hydroxyl, R 2 and R 3 are all not hydrogen, or salts thereof.
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CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority from co-pending U.S. Provisional Patent Application 60/460,653, entitled, “Content Bridge for Associating Host Content and Guest Content Wherein Guest Content is Determined by Search,” filed Apr. 4, 2003, which is incorporated by reference herein for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates to content retrieval in general and more particularly to methods and apparatus for associating content and selecting content to be associated with other content.
BACKGROUND OF THE INVENTION
[0003] In a content retrieval system, a user makes a request for content and receives content matching that request. The user can be a human user interacting with a user interface of a computer that processes the requests and/or forwards the requests to other computer systems. The user could also be another computer process or system that generates the request programmatically. In the latter instance, it is likely that the requesting computer user will also programmatically process the results of the request, but it might instead be the case that a computer user makes a request and a human user is the ultimate recipient of the response, or even the opposite, where a human user makes a request and a computer user is the ultimate recipient of the response.
[0004] Content retrieval systems are in common use. One common system in use today uses the network referred to as the Internet, a global internetwork of networks, wherein nodes of the network send requests to other nodes that might respond with content. One protocol usable for content requesting is the HyperText Transport Protocol (HTTP), wherein an HTTP client, such as a browser) makes a request for content referenced by a Uniform Resource Locator (URL) and an HTTP server responds to the requests by sending content specified by the URL. Of course, while this is a very common example, content retrieval is not so limited.
[0005] For example, networks other than the Internet might be used, such as token ring, WAP, overlay, point-to-point, proprietary networks, etc. Protocols other than HTTP might be used to request and transport content, such as SMTP, FTP, etc. and content might be specified by other than URLs. Portions of present invention are described with reference to the Internet, a global internetwork of networks in common usage today for a variety of applications, but it should be understood that references to the Internet can be substituted with references to variations of the basic concept of the Internet (e.g., intranets, virtual private networks, enclosed TCP/IP networks, etc.) as well as other forms of networks. It should also be understood that the present invention might operate entirely within one computer or one collection of computers, thus obviating the need for a network.
[0006] The content itself could be in many forms. For example, some content might be text, images, video, audio, animation, program code, data structures, formatted text, etc. For example, a user might request content that is a page having a news story (text) and an accompanying image, with links to other content (such as by formatting the content according to the HyperText Markup Language (HTML) in use at the time).
[0007] HTML is a common format used for pages or other content that is supplied from an HTTP server. HTML-formatted content might include links to other HTML content and a collection of content that references other content might be thought of as a document web, hence the name “World Wide Web” or “WWW” given to one example of a collection of HTML-formatted content. As that is a well-known construct, it is used in many examples herein, but it should be understood that unless otherwise specified, the concepts described by these examples are not limited to the WWW, HTML, HTTP, the Internet, etc.
[0008] A supplier of content might determine the interests of its users and provide relevant content, such as current news, sports, weather, search services, calendaring, messaging, information retrieval and the like. Content might be in the form of pages that are static (i.e., existing prior to a request for the page), dynamic (i.e., generated in response to a request) or partially static, partially dynamic. Thus, a news report about an event in a particular city might exist as a static page, but that same content might also be generated dynamically in response to a request, taking into account the context of the content and/or demographics of the user making the request.
[0009] As an example of a dynamically generated page, if the news report was being viewed by a user known to live in city in which the event is to occur, the resulting page might include information about how to drive to the location of the event or to purchase tickets, however if the user is known to live far from that city, the resulting page might include information about the weather in that remote city and how to purchase an airline ticket to that city.
[0010] In the above example, host content (the news report) and guest content (the weather, purchase links, directions, etc.) are associated such that a request for the host content returns a page (for HTTP systems, or other content unit for other types of systems) containing the host content and related guest content.
[0011] It is a continuing problem to correctly determine relevant guest content. If the city for which the news story was relevant was correctly determined, the user demographics correctly determined and the city of the guest content was correctly determined, the presentation works well. However, if the news story is not actually related to a particular city or event, then associated guest content will look out of place and confuse the user.
[0012] One approach to host content and guest content association is to create predefined associations between host content and guest content. In such systems, a page containing host content HI would always be presented with its associated guest content G 1 alongside. This approach might work well with systems having a small amount of host content, but is typically unworkable at larger scales, such as a news feed, where the host content could comprise thousands of new news reports per hour.
[0013] Another approach is the taxonomy-taxonomy approach, wherein all, or most all, of the host content is assigned a node in a content taxonomy. The guest content is also assigned nodes in a corresponding context taxonomy or the same content taxonomy. Then, when host content is to be presented, the server reads the taxonomy node ID of the host content and then retrieves guest content that has a matching taxonomy node ID or IDs. This might work well when host content and guest content are well definable, but this approach does not scale well for large bodies of host content and guest content without much effort.
BRIEF SUMMARY OF THE INVENTION
[0014] A content system according to embodiments of the present invention associates host content and guest content. For host content, host content summaries are generated. To determine the guest content to associate with particular host content, the host content summary for the host content is analyzed and a search query generated. A host content dictionary and a host content taxonomy might be consulted. The search query is then applied against a guest content corpus, such as a guest content database, and the results of the query are used as the guest content to associate with the host content.
[0015] In specific embodiments, the user uses a Web browser to specify to a Web server host content of interest and the Web server processes the request, obtains the requested host content, generates a query for guest content, queries a guest content corpus, gets a query response, builds a page associating the host content with the query results, and returns the resulting generated page to the user. The guest content might be related content (such as news stories related to news stories), advertisements, relevant links, topics of relevance, items for sale, special offers, etc. The generation of the guest content query might involve merely reading a host content summary or it might be more involved.
[0016] In some embodiments, setting up the content might comprise obtaining host content from sources external to an electronic content access system, importing the obtained host content to a host content database, distilling the host content to derive host content summary data for the host content, storing the host content summary data in an indexable structure and storing guest content in an indexable structure, such that a query using host content summary data can be applied as a search against the guest content to retrieve guest content related to the requested host content without requiring preassociated links to guest content.
[0017] Other features and advantages of the invention will be apparent in view of the following detailed description and preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a block diagram of a content system according to embodiments of the present invention.
[0019] [0019]FIG. 2 is a block diagram showing elements of the content system of FIG. 1 in more detail, showing interactions between a host server and other elements.
[0020] [0020]FIG. 3 is a block diagram showing other elements of the content system of FIG. 1 in more detail, showing interactions between a guest server and other elements.
[0021] [0021]FIG. 4 illustrates an alternative approach to generating queries, using references to host content summaries in requests to a guest content server.
[0022] [0022]FIG. 5 is an illustration of a page that might be presented to a user, including host content and guest content.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Embodiments of the invention will now be described, by way of example, not limitation. It is to be understood that the invention is of broad utility and may be used in many different contexts.
[0024] The example of a search process as described herein below can be modeled by a searcher presenting to a search system a query and receiving a response (search results) indicating the one or more “hits” found. A query can be in the form of key words (e.g., searching for the latest football scores with a query “football games scores recent”), structured query statements (SQL, Boolean expressions, regular expressions, etc.), by selecting terms from choice lists, following links or a number of other methods currently in use or obvious to one of skill in the art upon review of current literature and/or the present disclosure.
[0025] When a query is received by a search system, it processes the search and returns one or more “hits”, where a “hit” is the atomic unit handled by the search system. For example, where the search system manages a structured database, the hits are records from the structured database. Where the search system manages documents, such as text documents, image and text documents, image documents, HTML documents, PDF documents, or the like, the atomic unit is the document. It should be understood that the present invention is not limited to any particular atomic unit, but by way of example, much of this disclosure describes searching using the document as the atomic unit. Furthermore, a structured database is not required.
[0026] A hit is an atomic unit that the search system identifies as matching criteria defined by the query. It should be understood that the search system need not provide all hits or only hits that match the query. For example, the search system might limit the number of hits returned to some number, might apply other limitations to the query term, such as omitting hits that match the query, ignore duplicate hits, etc. The search system might also expand the search results to include hits that almost match the query, hits that are designated to be included in searches, such as special topic hits, advertising hits, etc. Some expansion or contraction might be dependent on the size or content of the search results prior to such expansion or contraction. For example, the search engine might add hits that are close if no hits would otherwise be returned and might remove hits if too many hits would have been returned, such as by deleting common words from queries prior to completing the search results.
[0027] A searcher can be a human user, such as a person typing in search terms into a browser window to query a search engine via the Web, but can also be an automated process, such as a computer program capable of sending queries to search engines in the form expected by the search engine. For example, a computer program might generate queries and form HTTP messages directed at a Web server coupled to a search engine.
[0028] In many of the examples shown herein, the search engine searches among a set of documents for documents (hits) that match the criteria defined by the query. It should be understood that the term “document” is generally used to refer to units of the corpus being searched. A document can be a document, such as a contract, a file, a story, a writing, or the like, but might also be a snippet of text, data that might be considered part of a document in other contexts, program code, image data, a stored file, or the like. Therefore, the term need not be narrowly construed.
[0029] Referring now to the figures, an exemplary content system will now be described.
[0030] [0030]FIG. 1 is a block diagram of a content system 100 according to embodiments of the present invention. Using system 100 , a content requester, referred to herein simply as a “user” or “client”, requests content from a server, which returns the requested content. As shown there, system 100 includes user systems 102 , a network 104 , host servers 106 and guest servers 108 . The interconnections between user systems 102 , network 104 and host servers 106 will not be described in detail, as such methods of interconnections can be accomplished using well-known techniques.
[0031] For example, user systems 102 might be personal computers running an HTTP client, such as a Web browser, and communicating with an HTTP server running at the host server, where network 104 is a TCP/IP network such as the global Internet. It should be understood that other embodiments also fall within the scope of the invention. For example, user system might be a handheld device, a computer with no human user interface, a dedicated device, a kiosk, etc. The network might be a wireless protocol network, a local area network, a wide area network, a network running other than TCP/IP. Also, the clients and servers need not use HTTP, but might use a different protocol for making requests for pages and objects and for responding to those requests.
[0032] The interconnections shown in FIG. 1 will now be described, with the understanding that other connections might exist and not be shown. User systems 102 interact with host servers 106 . In one example, they interact using HTTP over TCP/IP. There need not be a one-to-one correspondence between user systems 102 and host servers 106 and, in fact, most implementations involve a host server serving thousands or millions of user systems. While it will often be the case that a given user system 102 will connect to one host server 106 at a time, nothing prevents a user system 102 from maintaining connections with multiple host servers 106 . In some implementations, for scaling, security and/or performance, traffic servers are interposed between network 104 and host servers 106 . A traffic server might perform load balancing, routing user requests to one of a plurality of host servers that could handle the request, so that the load is evenly spread over the host servers (or at least so that not too many host servers get overloaded).
[0033] The user systems typically initiate a connection by making a request for particular content, such as a news report. The content that is specifically referenced by the request is referred to herein as the “host content”. “Guest content” refers to content that is presented to the user along with the host content, but is not necessarily referenced by the request. For example, the user might click on a link of headlines and thus initiate a request for the news story for which the clicked link is specifically coded for. The page returned to the user can have the content associated with the clicked link, but might also have “guest content”, which is determined separate from the host content.
[0034] Where the host server is the main point of interaction with the user, the host server determines the host content being requested, obtains suitable guest content for the page(s) of host content, and returns that to the user in response to the request. Where the host server is not the main point of interaction, the machine that is interacting with the user might perform this assembly step instead. Thus, in the first example, the user system sends a request for host content to the host server, the host server in turn makes a request of a guest server 108 , receives guest content in response, and the host server returns the host content with the guest content as a response to the user system.
[0035] Note that there need not be a one-to-one or even a one-to-many relationship among host servers and guest servers. Therefore, a host server might interact with one or more guest server and one or more guest servers might provide guest content to more than one host server. One method for determining host-guest interactions is a configuration file maintained for a host server that specifies which guest server the host server should query for particular host content. For scalability, performance, security or other reasons, one or more guest server might be mirrored such that several guest servers hold mirror images of the same data. The selection among one of several guest servers might be done using well-known selection techniques, such as a round-robin technique.
[0036] Of course, what is returned might include links rather than containing the actual content. For example, the host server might return a page that contains links to specific guest content instead of sending the guest content as part of the page. If that is the case, the role of the guest server might not include sending the guest content, but merely determining, from context, what guest content to send and sending a specific reference (such as a URL) to that content.
[0037] [0037]FIG. 2 illustrates aspects of host content management in greater detail. As illustrated there, a host server makes a fetch request for host content 200 from host content database 202 . Host content might also be construed as including a host content summary database 204 , a host content taxonomy 206 and a host content dictionary 208 . Host content might be stored in relational database structures, hierarchical structures, directory name structures, file systems or the like, such that it is retrievable on request, but no specific structure or database format is required. Thus, the host content might be stored as records in a relational database, but might be stored in a database-file association wherein some of the information about the host content is in a structured, record-oriented database while other portions of the information are stored in files referenced by the database. The host content might also include XML files. However, for brevity, such storage is referred to as a database.
[0038] Host content database 202 is populated by a host content gatherer 210 , as well as possibly other mechanisms not shown. As host content gatherer 210 obtains host content, it provides it to an importer 212 that imports the content and formats it as needed to include in host content database 202 . For example, importer 212 might add tags to text portions of the content. Host content database 202 might be populated from document generators, such as an intranet document generator, another type of document generator, a document set crawler that crawls through a network space to generate a document set or a mapping to documents in the network space, an Internet crawler that crawls the Internet following hyperlinks to identify documents to be part of the host content, a hierarchical document structure such as compendiums of XML structured documents, or other sources of documents or document references.
[0039] Host content summary (HCS) database 204 is populated as well by host content gatherer 210 , and HCS database 204 might be populated as well by other mechanisms not shown. As host content gatherer 210 obtains host content, it provides it to a distiller 214 and distiller 214 generates a summary for the host content and stores it in HCS database 204 . In the process of summarizing host content, distiller 214 might reference host content taxonomy 206 and host content dictionary 208 .
[0040] One use of host content taxonomy 206 might be to generate host content summaries that are dependent on one or more positions of the host content in the host content taxonomy. The host content taxonomy might be generated automatically, generated manually, supplied from the external source that supplies the host content or supplied from another external source.
[0041] One use of host content dictionary 208 is for identifying phrases that are understood and specific to the area of the host content. For example, where the host content is a stream of sports stories, the professional football team names and popular players would be phrases stored in the host content dictionary. Likewise, where the host content is a stream of financial news stories, active company names and financial news terminology might be included as phrases stored in the host content dictionary.
[0042] Host content gatherer 210 can obtain its host content from a variety of sources. For example, authors might provide works especially for inclusion in host content database 202 . Other host content might come from data feeds, such as feeds of sports scores, news, weather, financial performance, etc. Host content gatherer 210 might also obtain host content from crawlers 220 that “crawl” an unstructured corpus 222 to obtain additional host content. As an example, an unstructured corpus might include the collection of static and/or dynamic documents formatted as hyperlinked pages stored on HTTP servers and available over the Internet, generally referred to as the “World Wide Web”, or simply “the Web”. In that example, the crawler might gather pages, identify other pages from links present on the already gathered pages, gather other pages, determine from already gathered pages what other pages to gather, etc. and provide the gathered pages to host content gatherer 210 for inclusion in host content database 202 .
[0043] Note that the actual content of all of the host content supported by host content database 202 need not be stored there. In some embodiments, it might be sufficient for crawler 220 to note the references to the host content (such as it's URLs) and pass those to host content gatherer 210 . When the content is actually needed, such as for some steps of distillation, the content can be retrieved. Thus, crawler 220 might determine that a particular page is suitable for inclusion in the host content and pass the page's URL to host content gatherer 210 , which would then provide the URL to importer 212 and distiller 214 . If distiller 214 needed to know the content of the page being imported, it could use its facilities to make a request over a network for the content using the provided URL. Also, if the content is only available by reference in host content database 202 , host server 106 might retrieve URLs from time to time from host content database 202 and use its separate facilities to obtain the host content for a response to a user.
[0044] Host content database 202 might be a database strictly speaking, but might also be a non-database structure. For example, it might be a large XML document. As explained herein, “document” is used generally herein to refer to data that is treated as a unit for querying purposes.
[0045] An operation of the elements shown in FIG. 2 will now be described. Preferably before a user system makes a request of host server 106 , host content 200 is available. Host content can be created in a number of ways, one of which is that host content gatherer 210 receives host content (or references thereto, in the form of URLs or other references) and provides the host content or references to importer 212 and distiller 214 . Importer 212 stores the host content, or the references, in host content database 202 . Importer 212 might import the host content unchanged, but might also alter the host content, such as by formatting it as needed or desired and possibly adding tags.
[0046] Distiller 214 generates host content summaries for the host content provided to it. Through this process, the host content and related summaries are generated. Host content taxonomy 206 might be populated from an external source or automatically determined. Host content dictionary 208 might be populated in a semi-automated fashion and might be periodically updated. For example, where the names of professional sports players are included in host content dictionary 208 , those names might be updated at the beginning of each season.
[0047] Once host server 106 receives a request from a user system for host content, it begins the response process. Typically, but not required, the user system request includes a URL referencing the requested host content. In many cases, the user system would obtain the URL in another page that has a hypertext link to the requested host content. When a user at the user system clicks or otherwise selects the hypertext link, the user system generates the request for the referenced host content and directs the request to host server 106 .
[0048] Having the reference, host server 106 makes a fetch request to host content 200 , often in the form of a request for information from host content database 202 . In response, host server 106 receives a content page and host content summary back. If the host content does not include the referenced content, host server 106 might reply with an error message, or send a message to crawler 220 , host content gatherer 210 , a Web client, or some other object, to obtain the referenced content.
[0049] The host can generate a bridge_ID for that host content and supply the bridge_ID to the guest server, which the guest server can use for tracking and other purposes. In some embodiments, the guest server that is used is determined by the bridge_ID and the guest content that works well is determined by the bridge_ID. Multiple bridge_ID values might be used with the same host content.
[0050] If host server 106 has or gets the requested host content, it then sends a request to guest server 108 as needed to obtain guest content. In many cases, the host content pages will have placeholders indicating where guest content is to go. One manner of implementing this is for host content pages to be formatted as HTML pages with hyperlinks to included elements, where the hyperlinks reference the guest server. Such hyperlinks might have embedded therein the bridge_ID and host content summary for the page to be returned to the user. Host content pages might have other links to information that is not considered guest content. For example, host content pages might have a standardized set of icons for common actions. For those areas of a user's display of a page, the host server (or the user system) need not query guest server, but would have a URL for the element referenced by the host server.
[0051] Guest server 108 then replies with the guest content according to the request. As explained below, typically the host server does not request specific guest content known ahead of time, as that might more easily be stored with other host content. Instead, the guest content is typically determined at run-time based on the user's demographics, operating parameters (time of day, number of campaigns in operation, etc.) and the content available to the guest server at the time.
[0052] With the host content and the guest content in hand, host server 106 returns a page to the user system responsive to its request. What is returned can be either the content itself, or content including links to elements of the host content and the guest content. For example, where the requested host content is a news story, what is returned might be the text of the news story, a link to a related photograph, a link to a guest content image and links to related stories, all formatted as an HTML page. In that example, then, it might be the user system's HTTP client that does the actual integration of the host content and the guest content, even though it was the action of the host server and the guest server to determine what host and guest content would appear. The use of bridge_ID values to associate host content with guest content that is served together allows for easy tracking of the associations. For example, if the guest host logged bridge_ID values with indicators or guest content that was served, the combinations of host content and guest content could be tracked for various purposes, such as measuring performance of content and the content delivery system.
[0053] [0053]FIG. 3 illustrates guest server 108 in greater detail, including a distiller 300 that interfaces with a query interface 310 . Query interface 310 is shown coupled to a guest content database 320 , which might be direct database access or access via a database application that handles interaction with guest content 322 . Also shown in an evaluator 306 that receives guest content results, evaluates the results (such as to select a subset of the results), and provides results as the response to the host server request, as well as providing log data.
[0054] In operation, guest server 108 receives a request from a host server. The request includes an indication of the bridge_ID and the host content summary. The host content summary might be structured as a query string and guest server 108 could then obtain query results using the query string and use those results as the guest content to be provided. In a very specific example, the bridge_ID might be a number such as bridge_ID= 58792 and the host content summary might be “gourmet cooking wild mushrooms” for a news article about a wild mushroom recipe from an upscale restaurant.
[0055] Distiller 300 might obtain query results as follows. In a simple case, distiller 300 provides the host content summary as the query. In other variations, the distiller might interface to bridge configuration database 302 to obtain configuration records for the identified bridge_ID values and then formulates a query for guest content.
[0056] The query is preferably in the form of a query and query interface 310 or guest content database system 320 performs a search from that query. Guest server 108 uses the results of the search as what it returns to the host server in response to the host server's request for guest content.
[0057] Guest content 322 can be generated in a number of ways. For example, where advertising campaigns are included in guest content, content might be associated with certain search terms. When distiller 300 arrives at a search query to present to query interface 310 and the set includes the associated certain search terms, the query results would include the associated content. Of course, if more content is returned than guest server 108 can provide to the host server, it should select some of the content to return. This might happen, for example, where multiple advertising campaigns are running simultaneously, or the host content has more than one context. For example, a news story about San Francisco-New York interactions might be summarized as being about San Francisco as well as summarized as being about New York. If the host content included one area for a weather report for whatever city is related, guest server 108 might retrieve the weather for both cities and return only one, based on a random selection, a determination about which weather report might be more extreme, more current, etc., or based on some other criteria. Guest content might be included or based on how prior viewers reacted to it and/or demographics.
[0058] Guest content might include advertisements, alerts from the operator of the access system, leads to related host content, offers, notes or the like. Guest content that is returned as part of a query might be adjusted or reordered based on other factors, such as how a bridge performed. For example, if guest content relates to a sports team, but the request is made during the off season, guest content related to television viewing times and travel to the team's home city would be given a lower priority (perhaps not even shown) relative to guest content related to training reports, team changes, fantasy leagues, etc. This is one example of reordering—this example assumes that during the active season some content is going to be more interesting than outside the active season.
[0059] Other reasons for reordering might relate to paid placements. For example, if the guest content query returns more sales offers for team-related items than can be displayed, the offers might be ordered and included or not based on payments for placement.
[0060] [0060]FIG. 4 illustrates a variation of GCQC300, wherein guest server 108 receives a request that includes a host_ID rather than needing to include a reference to a bridge. And a distiller 402 uses the host_ID to obtain host content summaries. In this case, guest server 108 uses the host_ID to obtain host content summaries from HCS database 204 .
[0061] [0061]FIG. 5 illustrates a sample page 300 as might be displayed on a user system combining host content and guest content. Such a page might include host content, guest content and common page elements. Host content in this example includes a title 302 and a story 312 with a headline 310 . Guest content in this example includes a banner advertisement 304 , a related story sidebar 314 , a photo sidebar 316 , a book offerings banner 320 , an auction items banner 322 and a sales items banner 324 . Common page elements, which might be present on each similarly-formatted page but not required, include a home page icon 306 , a host image map 308 , and icons 330 .
[0062] Using methods and/or apparatus described above, sample page 300 might have been presented to a user system in response to some identified host content (the news story), in response to the request, a host server supplying the news story would combine the news story on the sample page with guest content obtained based on a search of guest content. While banners, such as advertisements, and sidebars can be fixed to specific host content, having guest content determined from a search allows for more relevant guest content and provides other advantages.
[0063] Example Implementation
[0064] An example of a host server is a Yahoo! server, such as Yahoo! Sports, Yahoo! Weather, Yahoo! News or Yahoo! Travel servers. Each page of these properties can be considered a “host page” possibly including placeholders for latter inclusion of guest content.
[0065] Guest content can be derived from another Yahoo! property, the same Yahoo! property or any other Web site or source. For example, a host content story about a particular sporting event might have links to other sporting events (the same property) but might also have links to guest content for making airline reservations to the city in which the sports event is being held. Such guest content might come from the Yahoo! Travel property.
[0066] The guest content can be stored in a guest content database, which is a data structure that allows for queries against a search index. Thus, the guest content need not be retrieved by exact reference to particular guest content. Instead, guest content is retrieved according to a search process based on a search query.
[0067] The search query that goes with particular host content might be the host content summary for that host content or might include elements from a host content summary, which might be done ahead of time. Thus, as each sports-related story is input to a host content database, its content is summarized. If the story is about particular teams or people, the summary might make reference to those particular teams or people. For example, if the story is about a championship game, the summary might include the name of the championship game, the sports league, the names of the teams, their home cities, the date(s) of the game(s), etc. This host content summary can be the result of a distillation process as the host content is received, but the host content summary might be updated as time goes on, based on additional information learned later or for other reasons. The host content summary might also be obtained later, to allow host content to come on line quickly. In that case, the guest content might not be as relevant before the host content summary data is available.
[0068] In one embodiment of the content distillation process, the host content is scanned for keywords and those keywords are determined using a content dictionary (e.g., all the sports team names for major or significant leagues, sports player/coach/manager/owner names for those teams, home cities, etc.). A content taxonomy might also be used to classify the host content. For example a story about a running back on the Pittsburg Steelers football team might be associated with the nodes in a sports hierarchy at various levels: “football”, “NFL”, “AFC”, “Pittsburgh Steelers”, “running backs”, down to a node for that particular player.
[0069] The guest content could also be associated with links in the hierarchy and associated with host content based on a match of hierarchy associations, but that is not very scalable and using search at the time of request allows for dynamic changes to guest content, quicker response and potentially more relevant responses. When guest content is needed for given host content, one or more of the host content summary, host content taxonomy paths, host content dictionary associations, etc., are used to form a search query. The host content summary could itself be a search query argument, in which case the guest server might not need to interact with the host content taxonomy or host content dictionary.
[0070] The search query is then applied to the guest content and the query results provide guest content to be provided with the host content. For example, for host content relating to a running back on the Pittsburg Steelers football team, the guest content might be searched using “NFL Pittsburgh Steelers” with the search query directed against all products from the Yahoo! Shopping property, with offers selected from the results based on some text relevancy criterion.
[0071] Content distillation can be done automatically on the fly, without requiring efforts of a host content publisher or a host server. For example, when a new page is published, the content distiller can scan that page and extract out key content summary. If links to trigger guest content are to be included in the host content, that new page might be embedded with references that are sufficient to trigger guest content retrieval. For example, it might be enough that a guest content management system provides the host server with a snippet of JAVA™ code to call a guest content management system with a reference to the host content. Content distillation can be done dynamically on the client side using mechanisms such as JAVASCRIPT™ code so that the work for a host publishing server is limited to embedding a JAVASCRIPT call.
[0072] In some cases, the guest content could be “subsetted”. For example, where a news story is about two teams, there could be one set of guest content for the first team and another set of guest content for the second team, possibly the result of two independent searches of the guest content.
[0073] In yet another variation, the searches of guest content are informed by user demographics. In other words, the search query for guest content might differ from user to user based on their demographics. For example, a guest content search might find several items of suitable guest content, more than would be presented to the user, and the guest content server might select among those items based on user demographics.
[0074] The invention has now been described with reference to the preferred embodiments. Alternatives and substitutions will now be apparent to persons of skill in the art. Accordingly, it is not intended to limit the invention except as provided by the appended claims.
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A method and apparatus for generating content for an electronic content access system wherein requests for host content are received and responses to such requests include at least references to the host content requested and at least references to guest content related to the host content requested, comprising obtaining host content from sources external to the electronic content access system, importing the obtained host content to a host content database, distilling the host content to derive host content summary data for the host content, storing the host content summary data in an indexable structure and storing guest content in an indexable structure, such that a query using host content summary data can be applied as a search against the guest content to retrieve guest content related to the requested host content without requiring preassociated links to guest content.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the grid tubes used notably as television amplifiers or in industrial heating devices, etc. These grid tubes are notably of a triode or tetrode type.
2. Discussion of the Background
FIG. 1a gives a schematic view of a semi-tetrode. It has cylindrical electrodes mounted coaxially about an axis XX'.
The central electrode is the cathode K emitting electrons when it is heated. Around this cathode K, there is a control grid G1, a screen-grid G2 and then an anode AN. In a triode, there is no screen-grid.
The cathode K and the control grid G1 form an input resonant cavity 1. The input resonant cavity 1 comprises an active zone 10 between the reference points B and D and extend on either side of this active zone 10 towards the base of the tube between the reference points D and E and towards its top between the reference points A and B. The active zone corresponds to the zone where the electrons sent out by the cathode pass before crossing the control grid G1. The reference point C shows the central part of the active zone.
The input cavity 1 has means 4 to introduce a signal to be amplified. The screen-grid G2 and the anode AN form an output resonant cavity 2. It has means 5 to extract the amplified signal.
The input resonant cavity 1 and output resonant cavity 2 are generally closed, at the base of the tube, by a movable plate-type tuner 3 that enables their resonance frequency to be respectively adjusted.
In the input cavity, it is generally the TEM mode that is set up. The magnetic field B and electrical field E have been shown. This type of cavity is generally tuned in quarter-wave mode. This means that between the reference point A at the top of the tube on the axis XX' and the reference point E at the plate-type tuner 3, the electrical length I of the input cavity is:
I=(2n+1)λ/4
n is an integer≧0 and λ is the wavelength of the wave set up in the input cavity.
In this TEM mode, the scalar potential V varies between the reference point A and the reference point E as follows: ##EQU1##
The surface reactive currents I on the walls of the cavity are not constant either. The representation made in FIG. 1b of the voltage V and the reactive current I (in terms of absolute value) corresponds to a cavity length I between the reference point A and the reference point E equal to λ/4. An integer n equal to zero has been chosen to simplify the description. The voltage V is shown in a solid line and the reactive current I in dashes.
Between the reference point A and the reference point E, the voltage V follows substantially a quarter sinusoid, this voltage V being the maximum (voltage antinode) for I=0 at the reference point A and the minimum (voltage node) for I=λ/4 at the reference point E. At the top of the tube, at the reference point A, on the axis XX', there is an open circuit and at the base of the tube, at the reference point E, there is a short circuit. Between the reference points B and D, at the two ends of the active end zone 10, the voltage V and the current I vary. This means that the cathode K is not affected homogeneously in its active part 10. It is also noted in FIG. 1b that the reactive current I is greater at the reference point D than at the reference point B. This means that there is a heating of the tube in the part (reference point D) of the active zone 10 closest to its base while it is part of the active zone 10 that is the least affected. Indeed the peak current given is greater at B than it is at D.
In this type of tube, the height of the active zone (interval BD) is limited by the frequency and the power of the tube. The greater the frequency, the greater the voltage variation V in the active zone 10. The power of the tube is limited because a compromise has to be made between the height of the active zone 10 and the diameter of the cathode K. For example, the most powerful tubes working in the UHF range have a cathode K whose diameter is about 40 mm and whose height of the active zone is equal to about 2 cm.
About forty years ago, to obtain a tube having greater efficiency and greater power and higher frequency, it was proposed to place a voltage antinode V in the central part of the active zone 10.
FIG. 2a gives a schematic illustration of such a tube. This figure can be compared to FIG. 1a and the elements that correspond to one another bear the same references, which may not be all described in detail.
Now, the input cavity 1' has been made between the reference points A' and E'. The reference point C' corresponding to the central part of the active zone 10 is located on the voltage V antinode and hence a node of reactive current I. The input cavity 1' is tuned in a half-wave mode. This means that between the reference point A' (the top of the cavity) and the reference point E' (the base of the tube), the electrical length I' is equal to:
I'=nλ/2
n integer>0.
In the example of FIGS. 2a, 2b, n is chosen as being equal to 1 for purposes of simplification. Now, the voltage V develops substantially as a half-sinusoid.
It is the top of the tube that has been modified with respect to the tube of FIG. 1a. At A' and E', there are tuning pistons 3 and the input cavity ends in short circuits.
With reference to FIG. 1a, the part of the tube located between the reference points A and C has been eliminated and replaced by a part identical to the one located between the reference points C and E. The new input cavity 1' shown in FIG. 2a has an active zone 10' between the reference points B' and D' and therefore extends on either side of the active zone 10' towards the base between the reference points D' and E' and towards the top between the reference points A' and B'. This input cavity 1' is now symmetrical with respect to a plane normal to the axis XX' passing through the reference C'. The input cavity 1' shown in FIG. 2a is equivalent to two input cavities 1 of FIG. 1a mounted upside down with respect to each other. The output cavity 2' is also equivalent to two output cavities of the tube of FIG. 1a mounted upside down with respect to each other.
This configuration gives good results from the electrical point of view. In the active zone 10', the voltage V varies very little and the current I is not very great. By contrast, it is very difficult to make this structure from the mechanical viewpoint because it is very difficult to keep a proper degree of coaxiality between the cathode K and the control grid G1 since they are now fixedly joined by their two ends to the base and top of the tube. The distance between the control grid G1 and the cathode K is some tenths of a millimeter in the active zone while the height of the active zone is equal to some tens of millimeters.
The present invention seeks to overcome these drawbacks. It proposes a grid tube that has electrical performance characteristics comparable to those of the tube of FIG. 2a but is far easier to manufacture, easier to install and therefore costs less.
SUMMARY OF THE INVENTION
The electron tube according to the invention has electrodes that are on the whole cylindrical mounted coaxially about an axis including a cathode surrounded by a grid. The cathode and the grid contribute to the demarcation of an input resonant cavity having an active zone, this cavity extending on either side of the active zone. The resonant input cavity is folded on itself towards the axis on one side of the active zone. The central part of the active zone is subjected to a voltage antinode
Preferably, the input cavity ends in two extremities that contribute to forming the base of the tube.
At least one of the extremities of the input cavity may be closed by a plate-type tuner so as to match the frequency of the tube. To work in the lower frequencies of the frequency range of the tube, the two extremities of the cavity may be closed by a plate-type tuner.
To work in the higher frequencies of the frequency range of the tube, at least one extremity of the tube may form an open circuit. To work in an intermediate part of the frequency range of the tube, at least extremity of the tube ends in a capacitor connected between the grid and the cathode.
The capacitor could comprise a dielectric element placed flat against one of the electrodes by means of a conductive clamping or gripping device and in contact with the other electrode.
Preferably, the clamping device is detachable and the value of the capacitor may be adjusted as a function of need.
The clamping device may comprise a conductive plug screwed into a collar fixedly joined to the other electrode. A spring may be used to improve the contact between the collar and the plug.
The dielectric element will advantageously be ring-shaped. It may be made of mica.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the invention shall emerge from the following description given by way of a non-restrictive example, illustrated by the appended figures of which:
FIGS. 1a and 1b, which have already been described, respectively show a schematic view of a known type of tetrode and a graph of the voltage and current present in the input cavity;
FIGS. 2a and 2b, which have already been described, respectively show a schematic view of a known tube formed by two tetrodes mounted upside down with respect to each other and a graph of the voltage and current present in the input cavity;
FIG. 3 shows a partial sectional view of a tube according to the invention;
FIGS. 4a and 4b respectively show a schematic view of the tube of FIG. 3 and a graph of the voltage and current present in the input cavity;
FIG. 5 shows a partial sectional view of a variant of a tube according to the invention;
FIGS. 6a and 6b respectively show a schematic view of the tube of FIG. 5 and a graph of the voltage and current present in the input cavity;
FIG. 7 shows a partial section of another variant of a tube according to the invention;
FIGS. 8a and 8b respectively show a schematic view of the tube of FIG. 7 and a graph of the voltage and current present in the input cavity.
For the sake of clarity, these figures have not been drawn to scale. In the below described figures, elements that correspond to each other in different figures bear the same reference labels, and may not be described in detail for each figure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 3 gives a schematic and partial view of a tube according to the invention.
This tube, in a standard way, has generally cylindrical electrodes mounted coaxially about an axis XX'. There is therefore a cathode K that emits electrons when it is heated. This cathode K is surrounded by a control grid G1 which is itself surrounded by a screen-grid G2 which is itself surrounded by an anode AN. The electrons emitted are accelerated towards the anode AN and go through the grids G1, G2. The cathode K and the control grid G1 contribute to the demarcation of an input resonant cavity 34 into which a signal may be injected. The input cavity 34 has an active zone 30 between the reference points B' and D'. It extends on either side of the active zone 30 between the reference points A' and B' and between the reference points D' and E'. In a standard way, at the base of the tube 31, the electrodes are spaced out from one another by means of insulating spacers 33. These spacers 33 are used to insulate the electrodes electrically from one another and keep them mechanically in position and ensure vacuum tightness in the active part 30 of the electrodes.
The screen-grid G2 and the anode AN define an output resonant cavity 35 whereby it is possible to extract the amplified signal. The output resonant cavity 35 has been shown only partially to avoid overburdening the figure. It is the part of this output cavity 35 located at the top 32 of the tube that has been omitted. In this example, the output cavity 35 ends in a tuning piston 37.
The input cavity 34 is tuned so that the central part (reference C') of the active zone 30 corresponds to a voltage antinode as shown in FIGS. 4a and 4b.
Instead of having a symmetry with respect to a plane perpendicular to the axis XX' passing through the reference C', the input resonant cavity 34 is folded on itself towards the axis XX' on one side of the active zone 30. The folded part goes from the reference point B' to the reference point A'. The input cavity 34 then has two ends, one being the radially external end (reference E') and the other being the radially internal end (reference A') and these two ends help form the base 31 of the tube. The problems of coaxiality no longer arise. The two ends of the cathode K and of the control grid G1 end conventionally in collars respectively 38, 39. A single connector will be used to receive the tube. A tube according to the invention may then be manufactured and positioned easily at lower cost. With respect to the tube of FIG. 2a, the tube according to the invention will be more compact, which is a non-negligible advantage.
The space inside the cathode is not used in conventional tubes. Here, the folded part of the input resonant cavity 34 will be housed.
The frequency tuning of the input cavity 34 may be done by at least one plate-type tuner 36. In FIG. 3, the two ends of the input cavity 34 are closed by such a piston. The input cavity 34 is then tuned in the half-wave mode. FIG. 4a gives a schematic view of the input cavity 34 and FIG. 4b illustrates the variation of the voltage V and of the reactive current I (in terms of absolute value) as a function of the electrical length I of the cavity. The two plate-type tuners are located at the reference points A' and E' as shown in FIG. 4a.
The same changes of current and voltage as shown in FIG. 2B are also obtained. Between the reference point A' and the reference point C', the electrical length is λ/4. As compared with the tube of FIG. 1a, the height of the active zone 30 is greater, thus enabling greater frequencies and power values to be attained.
The configuration with the two plate-type tuners 36 generally makes it possible to obtain low frequencies in the UHF range, for example between 450 and 550 MHz.
To enable working in the higher frequencies of the UHF range, for example between 750 and 860 MHz, it is possible to envisage that at least one of the ends of the input cavity 34 will form an open circuit. This is shown in FIG. 5. It shows an input cavity 34 between the reference points A' and E'. One of its extremities ends in an open circuit at the reference point A'. This is the internal end. A plate-type tuner 36 closes the external end of the input cavity 34 at the reference point E'.
As further seen in FIG. 5, a conductive bottom 50 closes the internal end of the control grid G1 and the internal end of the cathode K conventionally ends in a collar 38. The reference point A' is located close to the axis XX'. At this place, the voltage V is the maximum. The input cavity 34 is then tuned in three quarter-wave mode as can be seen in FIG. 6b with reference to FIG. 6a. Between the reference point A' and the reference point C', the electrical length is λ/2.
To make it possible to work at intermediate frequencies, for example between 550 and 750 MHz, it is possible to equip at least one end of the input cavity 34 with a capacitor connected with between the cathode K and the control grid G1. This is what is shown in FIG. 7 which shows only the base of the tube. A capacitor 70 is mounted at the internal end of the cavity. It has a dielectric element 71, made of mica for example, that is placed flat against the collar 38 of the cathode K by means of a conductive clamping device 75. The clamping device is preferably detachable. The dielectric element 71 is ring-shaped. Its thickness measured along the axis XX' and its surface area in contact with the collar 38 determine the value of the capacitor. The clamping device 75 is electrically and mechanically connected to the control grid G1. The clamping device 75 has a conductive plug 72 that comes into contact with the dielectric ring 71 and clamping means 73 such as a screw. The screw gets screwed into a bore 74 borne by the collar 79 of the control grid G1. The bore 74 is centered on the axis XX'. The collar 38 of the cathode K and the plug 72 form the electrodes of the capacitor.
A ring-shaped spring 76 may be designed to provide efficient contact between the plug 72 and the periphery of the collar 79 of the control grid G1. The plug 72 gets fitted about the periphery of the collar 79 of the control grid G1.
The development of the voltage and reactive current (in terms of absolute value) is shown in FIG. 8b, FIG. 8a giving a schematic view of the input cavity with its reference points.
The capacitor 70 is at the reference point A'. At this level, there is a voltage antinode and a current node. The electrical length between the reference point A' and the reference point C' ranges from λ/4 to λ/2.
The making of the capacitor of FIG. 7 is simple and does not raise any problem because the electrical ring 71 and the clamping device 75 are not subjected to a vacuum. An dielectric spacer 33 has been designed between the collar 38 of the cathode K and the collar 79 of the control grid G1 to ensure vacuum tightness.
The value of the capacitor 70 is a function of the thickness and surface area of the dielectric ring. The greater the thickness, the smaller the capacitance. The clamping device 75 may be detachable and a changing of capacitor is easy. The description that has just been given of the capacitor is but an example and other variants of the clamping device notably may be envisaged without departing from the framework of the invention.
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An electron tube includes cylindrical electrodes which are mounted coaxially. The electrodes include a cathode surrounded by a grid, with the cathode and the grid defining an input resonant cavity having an active zone. The cavity extends on both sides of the active zone. The central part of the active zone is located at a point where the voltage reaches a maximum. The resonant input cavity is folded back on itself so that both ends of the cavity are at the base of the tube.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISK
Not Applicable
REFERENCE TO A MICROFICHE APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a modular floating construction, comprising a plurality of floating bodies including platforms having removable latching or locking means.
Said removable locking means are coupled to one another by metal constructions, thereby providing floating boats, wharfs, working stages to be used on sea, rivers and water surfaces in general.
The floating constructions according to the invention, as suitably coupled to one another, may also be used for supporting barring dams, for controlling diffusions through water of polluting liquids.
Those same floating constructions may moreover be used for testing cables and pipes, and have the main characteristic that they can adjust, depending on contingent requirements, their bouyancy properties.
If the floating construction according to the invention is used for installing pipes and cables on deep waters, then it is necessary to provide a plurality of floating bodies, having corrosion resistant properties, and including supporting and releasing means for supporting and releasing the above mentioned cables and pipes, and further having high stability properties, even in a rough see condition.
The subject floating constructions can be coupled to one another, thereby providing wharfs for unloading goods from vessels and for supporting cables and pipes for connecting vessels and other boats to the ground, if harbours and mooring means are lacking in shallow waters.
SUMMARY OF THE INVENTION
Thus, the aim of the present invention is to provide such a modular floating construction which allows to adjust its buoyancy properties, thereby fitting the contingent requirements.
Within the scope of the above mentioned aim, a main object of the invention is to provide such a modular floating construction which can be quickly and easily assembled and disassembled, thereby providing composite floating constructions of the above mentioned type.
In particular, the engagement of the subject floating constructions is facilitated also in relationship to cables and pipes to be supported and optionally to be lowered into the water, thereby simplifying all the related operating steps.
Moreover, the subject floating construction, owing to its specifically designed structural features, is very reliable and safe in operation.
Yet another object of the present invention is to provide such a floating construction for supporting and testing or launching cables and pipes which can be easily made and which, moreover, is very competitive from a mere economic standpoint.
According to one aspect of the present invention, the above mentioned aim and objects, as well as yet other objects, which will become more apparent hereinafter, are achieved by a floating construction, characterized in that said floating construction comprises at least a hollow floating body, made of a plastics material, and connectable to a metal construction, for connecting a plurality of plastics material floating elements, thereby providing modular floating constructions adapted to operate as decks, loading wharfs, working platforms, and also adapted to support cables and pipes.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the present invention will become more apparent hereinafter from the following detailed disclosure of some preferred, though not exclusive, embodiment of a modular floating construction according to the invention, which is illustrated, by way of an indicative, but not limitative example, in the accompanying drawings, where:
FIG. 1 is a schematic perspective view schematically showing the floating body of the modular floating construction according to the present invention;
FIG. 2 is an elevation view showing that same floating body;
FIG. 3 is a top plan view of the floating body;
FIG. 4 shows a floating construction, supporting a pipe;
FIG. 5 shows the subject floating construction, as it is disengaged from the pipe;
FIG. 6 shows, on an enlarged scale, the coupling means for removably coupling a pipe, and related locking or latching removable means;
FIG. 7 shows, on an enlarged scale, the pipe disengaging operation;
FIG. 8 shows a side perspective view of the top portion of a structural element of the modular floating construction according to the invention;
FIG. 9 shows an exploded view of the constructional elements comprising a plastics material floating member and related metal members which can be coupled to the metal modular constructions associated with other adjoining floating components;
FIGS. 10 and 11 show two different views, respectively a perspective view and a top plan view, of a floating body constituting an integrating part of the modular floating construction according to the invention;
FIG. 12 is a cross-sectioned side perspective view, showing the plastics material floating body construction, constituting an integrating part of the present invention;
FIG. 13 is a perspective view of that same plastics material modular element shown in FIGS. 10 and 11 ;
FIG. 14 shows a further side perspective view of four floating plastics material elements associated with connecting metal constructions, which are mutually coupled to one another;
FIG. 15 shows a further perspective view of six plastics material floating elements, having coupling constructions and seen from the bottom;
FIG. 16 shows a further upper side perspective view of a plastics material floating element, and clearly shows the elliptical structure of the crossed tubular compartments, forming said plastics material floating body;
FIG. 17 shows an enlarged-scale partial perspective view, illustrating a section of an approximately elliptical compartment forming an integrating part of the plastics material floating element; and more specifically in FIG. 17 are clearly shown housing recesses for pivot pins allowing to connect a plastics material element to the fitting upper metal construction for coupling a plurality of modular floating constructions according to the invention;
FIG. 18 schematically shows the above mentioned pivot pins to be engaged in cavities formed in the plastics material floating body, a detail of which is shown in FIG. 17 ;
FIG. 19 is an upper side perspective view showing a detail of coupling elements for connecting the plastics material floating body to the top or upper constructional elements forming a fitting element for fitting and coupling structural elements, to be associated with one another thereby simultaneously providing an upper platform; and
FIG. 20 shows a floating construction including auxiliary ring elements for anchoring said floating construction.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the number references of FIGS. 1-7 , the modular floating construction according to the invention, in an embodiment thereof designed for testing or launching pipes, which has been generally indicated by the reference number 1 , comprises a plurality of floating bodies 2 which have advantageously a substantially flat configuration and are made of a polyethylene material, by spin-molding operations.
The thickness of the used materials is so designed as to resist against the hydrostatic force.
The hollow floating body 2 is provided, at the bottom thereof, with resting or bearing projections 3 and, at the top thereof, with recesses 4 for engaging with a supporting framework 5 which will be disclosed in a more detailed manner hereinafter.
More specifically, the floating body 2 , as stated, is hollow and comprises a lead-in element 10 for introducing water thereinto, said lead-in element 10 having a check valve and a quick attachment or fitting.
Moreover, a counter-pressure valve 11 which is adjusted to a preset pressure level is moreover provided.
On the top surface of the floating body an air inlet 12 is arranged, which also comprises a quick type of coupling.
The framework 5 is advantageously provided with top cross members 6 , which are housed in their respective recesses 4 and comprise a plurality of vertical restraining elements 7 laterally engaging with the floating bodies 2 , thereby allowing to practically sling said floating bodies, to easily support them.
Said framework 5 comprises moreover coupling means for removably coupling a pipe, said coupling means being indicated generally by the reference number 20 , and comprising a plurality of recessed portions 21 , made of a metal sheet material, connected to a cross member 6 thereby defining a coupling seat for a pipe generally indicated by the reference letter T.
Removable latching means for removably coupling said pipe are moreover provided, said removable latching or locking means being adapted to be operated from outside and being advantageously arranged at said removable coupling means 20 .
The removable locking or latching means, in particular, comprise a hydraulic cylinder 30 , driving a locking pin 31 , engaging in a respective seat 32 defined on a gusset element 33 , directly welded on the pipe.
An outer central unit drives said hydraulic cylinder 30 which, by driving in turn said pin, allows to perform an unlocking operation, with the consequent launching of the pipe or cable to be lowered into the sea.
In this connection it should be apparent that it is further possible to provide other removable latching or locking means, without directly welding the gusset 33 on the pipe, and by using, for example, very simple systems, such as calandered metal sheet material ties, coupled by bolt elements.
Thus, the provision of the above mentioned water lead-in element 10 , allows to modulate or finely adjust its buoyancy, by introducing a desired amount of water.
The subject system, accordingly, provides the possibility of properly adjusting said buoyancy, by loading, through a pump system, the chamber defined inside the floating body.
Water is introduced through a water loading manifold, also including the above mentioned counter-pressure or check valve.
To empty the chamber, air is pumped from the air inlet duct 12 thereby providing a pressure in the inside of said floating body, allowing the check valve 11 to be opened, while allowing water to exit.
The air inlet 12 also operates as a bleeding element.
In other words, that same valve allows air to exit the chamber, as the vessel is filled-in by water.
In this connection it should be apparent that, if desired, it is possible to use the above disclosed inlets, to supply a polyurethane foam, thereby providing a stable floating characteristic.
It is moreover desired to point out that a main feature of the present invention is the provision of a plastics material body 2 including bulged ridges providing, the thickness being the same, said plastics material floating element, with a very high mechanical strength against impacts and a larger resistance against air or other gas pressures supplied into the duct arrangements coupled to each plastics material floating element.
With reference to FIGS. 8-18 , it should be apparent that the subject modular floating construction 75 comprises a floating body 50 , made of a plastics material, including a plurality of longitudinal recesses 54 for housing therein corresponding longitudinal bars 52 having anchoring brackets for coupling to the floating body 50 a plurality of longitudinal section members 51 , cooperating to form the metal material top platform 62 .
Said floating construction 75 comprises moreover a plurality of longitudinal elements 51 cooperating to form, jointly with said longitudinal bars 52 including corresponding anchoring brackets 74 , the top metal platform 62 applied to the plastics material floating body 50 .
Said top platform 62 comprises moreover a plurality of cross bars 53 , clearly shown in FIG. 9 .
The plastics material floating body 50 comprises a plurality of throughgoing holes 55 .
The top metal platform 62 of the modular floating construction according to the invention comprises a plurality of longitudinal bars 51 , having corresponding brackets 74 matching with plate-like elements 73 rigid with the pins 72 , said pins 72 being received in corresponding cavities 71 formed in the plastics material floating bodies 50 .
More specifically, the longitudinal bars 51 are coupled to cross section members 81 cooperating to form the top platform 62 of the subject modular floating construction.
As shown, the plastics material floating body 50 has a complex construction including longitudinal floating compartments 59 and cross floating compartments 48 , of elliptical cross-sections, providing a complex construction having a great mechanical strength against the air pressure, the air being supplied inside the floating body 50 thereby suitably changing its buoyancy properties.
As a further feature, the modular floating construction 75 according to the invention can also comprise suitable side latching or locking elements 80 , comprising, for example, ring members, for anchoring the individual modular floating constructions 75 .
As shown, the plastics material floating body 50 shown in FIGS. 9 to 20 comprises, in its inside, a plurality of structural elements or ribs 57 , providing said floating body 50 with a great mechanical strength.
If desired, it is possible to use the above mentioned inlets to supply a polyurethane foam, thereby providing floating properties which will be stable in the time.
From the above disclosure it should be apparent that the invention fully achieves the intended aim and objects.
In particular, the invention provides a hollow floating body including a plurality of water and air inlets and outlets, which allows to change in a very broad range, its buoyancy properties.
The invention, as disclosed, is susceptible to several modifications and variations, all coming within the scope of the invention.
Moreover, all the constructional details can be replaced by other technically equivalent elements.
In practicing the invention, the used materials, as well as the contingent size and shapes can be any, depending on requirements.
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A modular floating construction comprises one or more floating bodies having platforms including removable latching means, thereby providing floating stages, wharfs, working platforms to be used on water surfaces in general.
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