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REFERENCE TO PENDING PRIOR PATENT APPLICATION
This is a continuation of prior U.S. patent application Ser. No. 09/896,258, now U.S. Pat. No. 6,692,513 filed Jun. 29, 2001 by Richard B. Streeter et al. for INTRAVASCULAR FILTER WITH DEBRIS ENTRAPMENT MECHANISM, which in turn claims benefit of U.S. Provisional Patent Application Ser. No. 60/215,542, filed Jun. 30, 2000 by Richard B. Streeter et al. for INTRAVASCULAR FILTER WITH DEBRIS ENTRAPMENT MECHANISM, which patent application is hereby incorporated herein by reference, and of U.S. Provisional Patent Application Ser. No. 60/231,101, filed Sep. 8, 2000 by Richard B. Streeter et al. for INTRAVASCULAR FILTER WITH DEBRIS ENTRAPMENT MECHANISM.
FIELD OF THE INVENTION
This invention relates to intravascular filtering apparatus and methods in general, and more particularly to apparatus and methods for filtering and irreversibly entrapping embolic debris from the vascular system during an intravascular or intracardiac procedure.
BACKGROUND OF THE INVENTION
Intracardiac and intravascular procedures, whether performed percutaneously or in an open, surgical, fashion, may liberate particulate debris. Such debris, once free in the vascular system, may cause complications including vascular occlusion, end-organ ischemia, stroke, and heart attack. Ideally, this debris is filtered from the vascular system before it can travel to distal organ beds.
Using known filter mechanisms deployed in the arterial system, debris is captured during systole. There is a danger, however, that such debris may escape the filter mechanism during diastole or during filter removal. Apparatus and methods to reduce debris escape during diastole or during filter removal may be desirable to reduce embolic complications.
SUMMARY OF THE INVENTION
An object of the invention is to provide a filtering mechanism that irreversibly entraps debris therein.
Another object of the invention is to provide a filtering mechanism that permanently captures debris from the intravascular system of a patient.
A further object of the invention is to provide a filtering mechanism with greater ability to collect debris in the intravascular system of a patient to decrease the number of complications attributable to such debris.
Another further object of this invention is to provide a filter holding mechanism suitable to be secured to a retractor used to create access to the heart and surrounding structures during heart surgery procedures.
A still further object is to provide a method for using a filtering mechanism in the intravascular system of a patient to permanently capture debris therefrom.
Another still further object of the present invention is to provide a method for introducing a filtering device in the aorta downstream of the aortic valve to restrict the passage of emboli while allowing blood to flow through the aorta during cardiovascular procedures, and to entrap debris collected in the filter so as to prevent its escape during cardiac diastole or during manipulation, repositioning or removal of the device from the aorta.
With the above and other objects in view, as will hereinafter appear, there is provided apparatus for debris removal from the vascular system of a patient, said apparatus comprising: a filtering device having a proximal side and a distal side said filter being sized to allow blood flow therethrough and to restrict debris therethrough and said filter having a first given perimeter, wherein blood flow in a first direction passes from the proximal side to the distal side of the filtering device; an entrapment mechanism having a proximal side and a distal side, the entrapment mechanism forming a selective opening to allow debris and blood flow passage in the first direction from the proximal side to the distal side therethrough, the selective opening having a restriction mechanism to prevent debris passage in a second direction opposite to said first direction the selective opening having a second given perimeter, the first given perimeter and the second given perimeter being deployed within the vascular system so as to form a chamber between the distal side of the entrapment mechanism and the proximal side of the filtering device, wherein the entrapment mechanism allows blood flow and debris to pass therethrough in the first direction, the filtering device allows blood flow to pass therethrough in the first direction, the restriction mechanism prevents debris from passing back through said selective opening in a second direction opposite to the first direction and the chamber contains the debris received through the entrapment mechanism so as to prevent the escape of the debris therein by said filtering device in the first direction and said restriction mechanism in said second direction.
In accordance with another further feature of the invention there is provided a method for filtering and entrapping debris from the vascular system of a patient, the method comprising: providing apparatus for filtering and entrapping debris from the vascular system of a patient, the apparatus comprising: a filter device being sized to allow blood flow therethrough and to restrict passage of debris therethrough, and the filter device having a first given perimeter, a proximal side and a distal side; and wherein the filtering device captures debris carried in a first direction of blood flow from the proximal side to the distal side thereof on the proximal side of the filter device; an entrapment mechanism having a proximal side and a distal side, the entrapment mechanism including a selective opening to allow passage of blood and debris therethrough, the selective opening being configured to allow passage of blood and debris carried therein therethrough in the first direction of blood flow from the proximal side to the distal side of the entrapment mechanism, the selective opening having a restriction mechanism to prevent debris passage from the distal side to the proximal side of the entrapment mechanism in a second direction opposite to the first direction, the selective opening forming a second given perimeter, and the first given perimeter and the second given perimeter being deployed within the vascular system so as to form a chamber between the distal side of the entrapment mechanism and the proximal side of the filtering device; wherein the entrapment mechanism allows blood and debris carried therein therethrough in the first direction of blood flow, the filtering device allows blood therethrough in the first direction of blood flow, and the restriction mechanism prevents debris back through the selective opening in the second direction of blood flow opposite to the first direction of blood flow such that the chamber entraps the filtered debris received therein for debris removal from the vascular system of the patient; inserting said apparatus into the vascular system of the patient; allowing blood and debris carried therein to flow through the entrapment mechanism, and into the chamber; and removing the apparatus from the vascular system of the patient.
The above and other features of the invention, including various novel details of construction and combinations of parts and method steps will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular devices and method steps embodying the invention are shown by way of illustration only and not as limitations of the invention. The principles and features of this invention may be employed in various and numerous embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the present invention will be more fully disclosed or rendered obvious by the following detailed description of the preferred embodiments of the invention, which are to be considered together with the accompanying drawings wherein like numbers refer to like parts, and further wherein:
FIG. 1A is a perspective view of a deployable entrapment filtering device for debris removal showing the filtering device in its fully deployed shape as released from its cannula into the blood stream of a patient;
FIG. 1B is an exploded perspective view of the deployable entrapment filtering device of FIG. 1A showing the components thereof;
FIG. 1C is a schematic cross-sectional illustration depicting the deployable entrapment filtering device of FIGS. 1A and 1B during cardiac systole;
FIG. 1D is a schematic cross-sectional illustration depicting the deployable entrapment filtering device of FIGS. 1A and 1B during cardiac diastole;
FIG. 2A is an exploded perspective view of a deployable entrapment filtering device for debris removal showing the components thereof including a set of filter mesh entrapment leaflets;
FIG. 2B is a schematic cross-sectional illustration depicting the deployable entrapment filtering device of FIG. 2A during cardiac systole;
FIGS. 3A-3D are a series of schematic illustrations depicting a method of using the deployable entrapment filtering device of FIGS. 2A and 2B ;
FIG. 4A is an exploded perspective view of a deployable entrapment filtering device for debris removal showing the components thereof including a set of non-porous valve leaflets;
FIG. 4B is a schematic cross-sectional illustration depicting the deployable entrapment filtering device of FIG. 4A during cardiac systole;
FIGS. 5A-5D are a series of schematic illustrations depicting a method of using the deployable entrapment filtering device of FIGS. 4A and 4B ; and
FIGS. 6A-6D are schematic illustrations depicting an orthogonally deployable valve/filter apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A filtration and entrapment apparatus 5 is shown in FIGS. 1A-5D for debris removal from the vascular system of a patient. Filtration and entrapment apparatus 5 generally includes a filter device 10 and an entrapment mechanism 15 . Filtration and entrapment apparatus 5 can be used to filter emboli during a variety of intravascular or intracardiac procedures, including, but not limited to, the following procedures: vascular diagnostic procedures, angioplasty, stenting, angioplasty and stenting, endovascular stent-graft and surgical procedures for aneurysm repairs, coronary artery bypass procedures, cardiac valve replacement and repair procedures, and carotid endardarectomy procedures.
Now looking at FIGS. 1A-1D , a preferred embodiment of the present invention is shown with filtration and entrapment apparatus 5 as described herein below.
FIG. 1A depicts the profile of filtration and entrapment apparatus 5 in its fully deployed shape, with filter device 10 and entrapment mechanism 15 released from cannula 20 into the blood stream (not shown). Prior to deployment, filter device 10 and entrapment mechanism 15 are collapsed within cannula 20 , e.g., by moving the proximal end 25 A proximally along center post 50 .
FIG. 1B depicts the primary components of filtration and entrapment apparatus 5 comprising filter device 10 and entrapment mechanism 15 in attachment to deployable frame 25 . In the present embodiment of the invention, filter device 10 comprises a filter mesh bag 30 , and entrapment mechanism 15 comprises a piece of coarse mesh 35 and a set of entrapment flaps 40 .
FIG. 1C depicts filtration and entrapment apparatus 5 deployed within an aorta 45 during cardiac systole. Blood and debris flow through opened deployable frame 25 , across course mesh 35 , between and through entrapment flaps 40 and into the end of the filter mesh bag 30 . Entrapment flaps 40 ensure unidirectional flow of blood and debris into filter mesh bag 30 .
FIG. 1D depicts filtration and entrapment apparatus 5 within the aorta 45 responding to any retrograde flow of blood and/or back pressure within the aorta 45 during cardiac diastole. The back flow of blood and/or back pressure causes filter mesh bag 30 to partially deform and entrapment flaps 40 to close against coarse mesh 35 . Coarse mesh 35 is of a structure adequate to permit the free flow of blood and debris through it and into filter mesh bag 30 , and serves as a supporting structure against which entrapment flaps 40 can close and remain in a closed position to prevent the escape of embolic debris.
Still looking at FIGS. 1A-1D , it should also be appreciated that the entrapment flaps 40 may be attached to structures other than deployable frame 25 , e.g., the entrapment flaps 40 may be attached to a center post 50 , or to coarse mesh 35 , etc. Furthermore, if desired, entrapment flaps 40 may be biased closed or biased open. In addition, entrapment mechanism 15 may consist of one or more flaps 55 , and have a configuration including, but not limited to, a single disk diaphragm (not shown), a semi-lunar configuration (not shown), a gill slit configuration (not shown), a multi-leaflet flap configuration (not shown), etc.
It should also be appreciated that, while in the foregoing description the apparatus shown in FIGS. 1A-1D has been described in the context of functioning as a filter, it may also function as a one-way check valve. To the extent that the apparatus shown in FIGS. 1A-1D is intended to function primarily as a one-way check valve, filter mesh bag 30 (see FIG. 1B ) may be retained or it may be omitted.
Looking next at FIGS. 2A and 2B , there is shown an alternative form of the present invention as a bidirectional flow filtration and entrapment apparatus 105 . Bidirectional flow filtration and entrapment apparatus 105 of FIGS. 2A and 2B generally comprises a filter device 110 and an entrapment mechanism 115 delivered by a cannula 120 to the interior of a vascular structure 122 (see FIGS. 3A-3D ); a deployable filter frame 125 ; a filter bag 130 attached to the perimeter of deployable filter frame 125 ; a compliant, soft outer cuff 135 (preferably formed out of a biologically inert material such as Teflon, Dacron, Silastic, etc.) for sealing filtration and entrapment apparatus 105 against the inner wall of vascular structure 122 when deployable filter frame 125 is expanded; entrapment leaflets 140 , preferably in the form of a fine filter mesh; a center post 150 (preferably formed out of steel or the equivalent) passing across the interior of the deployable filter frame 125 ; a hinge line 155 on entrapment leaflets 140 , connected to center post 150 , for permitting the entrapment leaflets 140 to open and close; co-aptation strands 160 extending across the interior of deployable filter frame 125 and providing a seat against which entrapment leaflets 140 may close during diastole; and a perimeter seal 165 (preferably formed out of expanded Teflon or the like). Perimeter seal 165 acts like a step to help support entrapment leaflets 140 during diastole.
In addition, it should also be appreciated that soft outer cuff 135 may comprise a radially expandable mechanism (e.g., a balloon, a decompressed sponge, a spring loaded leaflet, etc.) for sealing filtration and entrapment apparatus 105 against the inner wall of vascular structure 122 .
As noted above, entrapment leaflets 140 are preferably formed out of a fine filter mesh. This filter mesh is sized so that it will pass blood therethrough but not debris. Furthermore, this filter mesh is sized so that it will provide a modest resistance to blood flow, such that the entrapment leaflets will open during systole and close during diastole. By way of example but not limitation, the filter mesh may have a pore size of between about 40 microns and about 300 microns.
FIGS. 3A-3D illustrate operation of bidirectional flow filtration and entrapment apparatus 105 shown in FIGS. 2A and 2B . More particularly, cannula 120 of deployable filtration and entrapment apparatus 105 is first inserted through a small incision 170 in the wall of the vascular structure 122 (see FIG. 3A ). Then deployable filter frame 125 is deployed (see FIG. 3B ). Thereafter, during systole (see FIG. 3C ), blood flows through deployable filter from 125 , forcing entrapment leaflets 140 open, and proceeds through filter bag 130 . Any debris contained in the blood is captured by filter bag 130 and thereby prevented from moving downstream past bidirectional flow filtration and entrapment apparatus 105 . During diastole (see FIG. 3D ), when the blood flow momentarily reverses direction, entrapment leaflets 140 (shown in FIGS. 2A and 2B ) close, seating against co-aptation strands 160 (shown in FIGS. 2A and 2B ) extending across the interior of deployable filter frame 140 (shown in FIGS. 2A and 2B ). The blood passes through the fine mesh of entrapment leaflets 140 (shown in FIGS. 2A and 2B ), being filtered as it passes, thus permitting coronary profusion to take place during the diastolic phase. The fine mesh of entrapment leaflets 140 (shown in FIGS. 2A and 2B ) prevents debris from passing back through bidirectional flow filtration and entrapment apparatus 105 .
It should also be appreciated that with bidirectional flow filtration and entrapment apparatus 105 of FIGS. 2A , 2 B and 3 A- 3 D, entrapment leaflets 140 may be attached to structures other than center post 150 , e.g., they may be attached to co-aptation strands 160 , or to deployable filter frame 125 , etc. Furthermore, if desired, entrapment leaflets 140 may be biased closed, or biased open. In addition, entrapment mechanism 15 may consist of one or more flaps (not shown), and have a configuration including, but not limited to, a single disk diaphragm (not shown), a semi-lunar configuration (not shown), a gill slit configuration (not shown), a multi-leaflet flap configuration (not shown), etc.
Looking next at FIGS. 4A and 4B , there is shown a deployable valve/filter apparatus 205 . Deployable valve/filter apparatus 205 of FIGS. 4A and 4B generally comprises a filter device 210 and a valve entrapment mechanism 215 delivered by a cannula 220 to the interior of the vascular structure 222 ; a deployable valve/filter frame 225 ; a filter bag 230 attached to the perimeter of deployable valve/filter frame 225 ; a compliant, soft outer cuff 235 (preferably formed out of a biologically inert material such as Teflon, Dacron, Silastic, etc.) for sealing the filter device 210 against the inner wall of vascular structure 222 when deployable valve/filter frame 225 is expanded; valve leaflets 240 , preferably in the form of a blood-impervious material; a center post 250 (preferably formed out of steel or the equivalent) passing across the interior of deployable valve/filter frame 225 ; a hinge line 255 on valve leaflets 240 , connected to center post 250 , for permitting valve leaflets 240 to open and close; co-aptation strands 260 extending across the interior of deployable valve/filter frame 225 and providing a seat against which valve leaflets 240 may close during diastole; and a perimeter seal 265 (preferably formed out of expanded Teflon or the like). Perimeter seal 265 acts like a step to help support valve leaflets 240 during diastole.
In addition, it should also be appreciated that soft outer cuff 235 may comprise a radially expandable mechanism (e.g., a balloon, a decompressed sponge, a spring loaded leaflet, etc.) for sealing deployable valve/filter apparatus 205 against the inner wall of vascular structure 222 .
FIGS. 5A-5D illustrate operation of deployable valve/filter apparatus 205 of FIGS. 4A and 4B . More particularly, valve/filter apparatus 205 is first inserted through a small incision 270 in the wall of the vascular structure 222 (see FIG. 5A ). Then deployable valve/filter frame 225 is deployed (see FIG. 5B ). Thereafter, during systole (see FIG. 5C ), blood flows through deployable valve/filter frame 225 , forcing valve leaflets 240 open, and proceeds through filter bag 230 . Any debris contained in the blood is captured by filter bag 230 and thereby prevented from moving downstream past valve/filter apparatus 205 . During diastole (see FIG. 5D ), when the blood flow momentarily reverses direction, valve leaflets 240 (shown in FIGS. 4A and 4B ) close, seating against co-aptation strands 260 (shown in FIGS. 4A and 4B ) across the interior of deployable valve/filter frame 225 (shown in FIGS. 4A and 4B ). The closed leaflets 240 (shown in FIGS. 4A and 4B ) prevent blood from passing back through the valve/filter frame 225 (shown in FIGS. 4A and 4B ).
It should also be appreciated that with valve/filter apparatus 205 shown in FIGS. 4A , 4 B and 5 A- 5 D, valve leaflets 240 may be attached to structures other than center post 250 , e.g., they may be attached to co-aptation strands 260 , or to deployable valve filter frame 225 , etc. Furthermore, if desired, valve leaflets 240 may be biased closed, or biased open. In addition, valve entrapment mechanism 215 may consist of one or more flaps (not shown), and have a configuration including, but not limited to, a single disk diaphragm (not shown), a semi-lunar configuration (not shown), a gill slit configuration (not shown), a multi-leaflet flap configuration (not shown), etc.
Looking next at FIGS. 6A-6B , there is shown an orthogonally deployable valve/filter apparatus 305 . Orthogonally deployable valve/filter apparatus 305 of FIGS. 6A-6D generally comprises a filter device 310 and a valve entrapment mechanism 315 deployed at an angle substantially orthogonal to an axis 318 of a cannula 320 , such as a catheter introduced to the vascular system at a location which may be remote from the point of operation, in the interior of a vascular structure 322 ; a deployable valve/filter frame 325 ; a filter bag 330 attached to the perimeter of deployable valve/filter frame 325 ; a compliant, soft outer cuff 335 (preferably formed out of a biologically inert material such as Teflon, Dacron, Silastic, etc.) for sealing the filter device 310 against the inner wall of vascular structure 322 when deployable valve/filter frame 325 is expanded; valve leaflets 340 , preferably in the form of a blood-impervious material, having a first portion 350 in attachment to deployable valve/filter frame 325 , and a second portion 355 separable from deployable valve/filter frame 325 , so as to allow valve leaflets 340 to open and close; and a mesh material 360 extending across the interior of deployable valve/filter frame 325 and providing a seat against which valve leaflets 340 may close during diastole. In addition, it should be appreciated that mesh material 360 may comprise coaptation strands such as coaptation strands 160 as first shown in FIG. 2A .
In addition, it should also be appreciated that soft outer cuff 335 may comprise a radially expandable mechanism (e.g., a balloon, a decompressed sponge, a spring loaded leaflet, etc.) for sealing orthogonally deployable valve/filter apparatus 305 against the inner wall of vascular structure 322 .
In addition, it should also be appreciated that valve entrapment mechanism 315 may be mounted for blood flow in either direction within vascular structure 322 .
FIGS. 6A-6D illustrate operation of deployable valve/filter apparatus 305 . More particularly, deployable valve/filter apparatus 305 is first inserted through the interior of vascular structure 322 to a desired location (see FIG. 6C ). Then deployable valve/filter frame 325 is deployed (see FIG. 6D ). Thereafter, during systole (see FIG. 6A ), blood flows through deployable valve/filter frame 325 , forcing valve leaflets 340 open, and proceeds through filter bag 330 . Any debris contained in the blood is captured by filter bag 330 and thereby prevented from moving downstream past deployable valve/filter apparatus 305 . During diastole (see FIG. 6B ), when the blood flow momentarily reverses direction, valve leaflets 340 close, seating against mesh material 360 across the interior of deployable filter frame 340 . The closed leaflets 340 prevent blood from passing back through the valve/filter frame 325 .
It should also be appreciated that with valve/filter apparatus 305 shown in FIGS. 6A-6D , valve leaflets 340 may be attached to structures other than deployable valve/filter frame 325 , e.g., they may be attached to mesh material 260 , or to cannula 320 , etc. Furthermore, if desired, valve leaflets 340 may be biased closed, or biased open. In addition, valve entrapment mechanism 315 may consist of one or more flaps (not shown), and have a configuration including, but not limited to, a single disk diaphragm (not shown), a semi-lunar configuration (not shown), a gill slit configuration (not shown), a multi-leaflet flap configuration (not shown), etc.
The filter design as described herein to prevent the escape of captured debris during diastole or filter removal may also be applied to all intravascular filters. Such a filter design may comprise a one-way valve and a filtering mesh in series. Liberated debris may pass through the one-way valve and come to rest in the filtering mesh. The one-way valve ensures permanent entrapment of debris. Potential applications of such an apparatus extend to all percutaneous and surgical procedures on the heart and vascular system, including open heart surgery, balloon dilatation of cardiac valves and arteries, deployment of stents in arteries, diagnostic catheterizations, and other cardiac and vascular procedures. Advantages of such a system include more complete collection of liberated debris, with a resulting decrease in the complications attributable to such debris.
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Apparatus for filtering and entrapping debris in the vascular system of a patient, the apparatus including a filter to allow blood to flow therethrough and to restrict passage of debris, wherein the filter captures debris carried in a first direction of blood flow. The apparatus further includes an entrapment mechanism which allows passage of debris and blood therethrough, in the first direction of blood flow and prevents debris passage in a second direction. The entrapment mechanism and filter allow blood and debris therethrough in the first direction of blood flow. The entrapment mechanism prevents debris flow in the second direction of blood flow. A method for filtering and entrapping debris in the vascular system includes inserting the apparatus into the vascular system, allowing blood and debris carried therein to flow through the entrapment mechanism, and removing the apparatus and accumulated debris from the vascular system.
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BACKGROUND OF THE INVENTION
This invention relates to breathing exercise devices or pulmonary exercise training devices of the type which impart a controlled stress to a subject's breathing muscles.
A number of spirometers or similar exercise devices have been proposed, both for the treatment of patients having emphysema, chronic bronchitis, or similar respiratory disorders, and also for athletes or other well persons who desire to strengthen their breathing and thus improve oxygen uptake and minimize carbon dioxide retention.
These devices conventionally are one-way training devices only, that is, the device can be used for inhalation therapy only or for exhalation therapy only. Separate breathing exercise devices are required if the subject requires both inhalation and exhalation therapy or training.
In devices for inhalation or inspiration therapy or training, the mouthpiece of the device is placed in the patient's or subject's mouth, and inhalation takes place through a resistance aperture or restricted opening on the device. Exhalation takes place through a one-way valve which imparts a comparatively low resistance to the exhaled air exhausted through it.
Exhalation or expiration therapy takes place in a similar device, in which these functions are reversed. That is, exhalation takes place through the resistance aperture, while inhalation takes place through a low resistance one-way valve.
A conventional device for conducting inhalation or inspirational breathing exercise therapy is described in U.S. Pat. No. 4,533,137, and a device for exhalation or expiration therapy is described in U.S. Pat. No. 3,863,914. Another conventional breathing exercise device is described in U.S. Pat. No. 4,444,202. An inspirational muscle training device is shown in Design Pat. No. Des. 280,765. Each of these devices is for inspiration or expiration use only, and cannot be used both as an inspiration and expiration exercise or therapy device. Furthermore, these devices tend to be cumbersome, with projecting or protruding parts, which limit the patient's or subject's ability to carry the device in a pocket and use it when convenient.
OBJECTS IN SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide a breathing exercise device which is compact and rugged, and avoids the drawbacks of the devices of the prior art.
It is another object of this invention to provide a breathing exercise device which can be used alternately in an inspiration therapy mode and an expiration therapy mode.
It is still another object of this invention to provide such a breathing exercise device whose mode can be changed from inspiration therapy to expiration therapy or vise versa, without requiring interchanging or removal of any of its parts.
It is still another object of this invention to provide a one way flap valve or check valve suitable for use in such breathing exercise devices, and which permits the selection of unidirectional air passage from one direction to the other, simply by rotating a portion of the housing.
According to an aspect of this invention, a breathing exercise device is formed of a tubular body with a mouthpiece at its proximal end, an opening in the tubular body, and a resistance sleeve coaxially disposed thereon with a number of resistance openings that can be aligned with a resistance opening on the tubular body. At the distal end of the tubular body is a selective unidirectional flap valve which can be rotated to select the direction of blocking of air flow through the distal end, and likewise the direction through which it admits air flow, so that the breathing exercise device can be used for either inspirational exercise therapy or expiration exercise therapy by selecting the direction of flow of the flap valve means. Favorably, the unidirectional flap means includes a flexible disc or diaphragm, a rotatable end cap pivotally mounted at the distal end of the tubular body, and mounting the disc or diaphram. The end cap includes first stop means disposed to the distal side of the disc and second stop means disposed to the proximal side of the disc. The first and second stop means are favorably arranged as generally semicircular members that are disposed on an interior wall of the end cap and diametrically opposite one another. The tubular body can include a cooperating substantially semicircular baffle at the distal end, which leaves a generally semicircular opening. The end cap is then rotatable into first and second positions to align the first and second stop means, respectively, with this semicircular opening, and so select inspriation or expiration modes.
The above and many other objects, features, and advantages of this invention will be more fully understood from the ensuing detailed description of the preferred embodiment, which should be read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a prospective assembly view of a breathing exercise device according to a preferred embodiment of this invention.
FIG. 2 is an elevation, partly in section, of the breathing exercise device of FIG. 1, here set in its mode for inspirational breathing stressing.
FIG. 2A is a partial section elevation of the device, similar to that of FIG. 2, but set in its mode for expiration therapy.
FIGS. 3, 4, and 5 are a distal end view, a sectional elevation, and a proximal end view, respectively, of the end cap or sleeve of the breathing exercise device of FIG. 1.
FIGS. 6 & 7 are an end view and a sectional view, respectively, of the resistor sleeve of the breathing exercise device of FIG. 1.
FIGS. 8, 9, and 10 are a top plan view, a side sectional elevation, and an end view, respectively, of the main body tube portion of the breathing exercise device of FIG. 1.
FIG. 11 is an exploded assembly view of the breathing exercise device of FIG. 1.
FIG. 12 is an exploded partial assembly view for illustrating a variation of the device of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the Drawing, and initially to FIG. 1 thereof, a breathing exercise device 10 of this invention comprises, in the direction from its proximal to its distal ends, a mouthpiece 12 formed of a biocompatible flexible resin material, a body tube 14, a resistor sleeve 16, which is rotatable to select the amount of resistance to breathing, and an end cap 18, which contains a rubber disc diaphragm 20, and which is rotatable on the body tube 14 to select the direction of blocking of air flow through the distal end of the body tube 14.
The end cap 18, the disc 20 and distal end of the body tube 14 together form a selective unidirectional valve or check valve for admitting fluid flow, in this instance air, in a selected direction (i.e., inhalation or exhalation) and for blocking its flow in the other direction (i.e., exhalation or inhalation).
Details of the end cap 18 are shown in FIGS. 2-5. The end cap 18 is generally cylindrical, and has a first semicircular stop member 22 formed on its inner wall and to the distal side of the diaphragm 20 (left in FIGS. 2 and 4) and a second semicircular stop member formed on the inner wall proximally of the diaphragm 20 (right in FIGS. 2 and 4) and diametrically opposite the first stop member 22. A mounting bar 26 is disposed at the plane of the second stop member 24, and connects its ends, as shown in FIG. 3. A pin 28, formed integrally with the body tube 14 and along its axis, fits through center apertures of the diaphragm 20 and the mounting bar 26 of the end cap 18, and holds the latter pivotally for rotation about the body tube 14. This pin 28 is staked as shown in FIGS. 2 and 2A.
To facilitate gripping with the fingers, ribs or crenellations 30 are formed on the outer surface of the end cap 18. Upper and lower teeth 32 are formed on the inner wall of the end cap 18 and to the proximal side thereof (FIG. 5) and these cooperate with a detente 34 in the body tube 14 (FIG. 8).
The body tube 14, as shown in FIGS. 8, 9, and 10, has a generally semicircular end wall or baffle 36 at its distal end, and this leaves a semicircular opening 38. An annular recess 40 is formed on the circumferencial wall of the body tube 14 proximally of the detentes 34, and this recess 40 includes upper and lower detentes 42. A body tube resistance opening 44 passes through this circumferential wall of the body tube 14, as shown in FIGS. 8, 9, 11.
The resistor sleeve 16, as shown if FIGS. 6 and 7, has a plurality of resistance openings 46 disposed at spaced intervals about its circumference, each being of a different size, and adapted to align with the body tube opening 44. The sleeve 16 has an annular rib 48 formed on its inner wall, and this rib 48 fits into the annular recess 40 of the body tube 14. The sleeve 16 also has a number of longitudinal ribs 50, each of which corresponds to the position of a respective resistance opening 46, which fit into the detentes 42 when the openings 46 are aligned with the body tube opening 44.
As is also shown in FIGS. 1, 6, and 7, ribs or crenellations 52 are formed on the outer surface of the sleeve 16 to facilitate gripping thereof with the fingers so that the same can be easily rotated to select the amount of breathing resistance. The resistance openings 46 occur in the valleys between these ribs 52.
The use of the device for inhalation therapy can be easily described with reference to FIG. 2. With the mouthpiece 12 placed in the subject's mouth, the subject inhales, and this draws the lower half of the disc or diaphram 20 against the stop member 24. Breathing air is thus admitted only through the resistance opening 46 that is aligned with the body tube opening 42, as shown by the solid-line arrows. However, when the subject exhales, the disc or diaphram 20 moves freely outward, as shown in those lines, and the exhalation air follows a low resistance path, as shown with the dash-line arrows.
To use this device for exhalation therapy, the end cap is rotated 180 degrees to the position as illustrated in FIG. 2A. Here, when the subject inhales, the air enters the distal end of the device and deflects the diaphragm inward to the position shown in ghost lines. Inhalation air is subjected to quite low resistance, and flowing as shown by solid-line arrows. When the subject exhales, the disc 20 presses against the stop member 22, and the exhalation air exhausts only through the resistor opening 46 as illustrated by dash-line arrows.
Although the resistor sleeve 16 is here shown to have six resistance openings 46, a different number, such as nine or twelve openings, could be employed instead. The parts of this breathing exercise device 10 can be formed of any suitable material, such as a convenient synthetic resin material, the choice depending on convenience in molding.
A variation of the above device is illustrated in FIG. 12, in which like parts are identified with the same reference numbers to which a prime (') has been added. Here the resistor sleeve 16' is placed over the body tube 14', and the distal end of the latter has a semi-circular baffle 36' which leaves a semicircular opening 38'. The device has a two-part end cap formed of a first portion 18' and a mating second portion 19'. The portion 18' carries the bar 26' and semicircular stop member 24', with the pin 28' being formed on the bar 26'. The disc 20' fits onto the pin 28' and the second portion 19' snaps in place in the first portion 18'. The first portion 18' has a recess 54' and the second portion 19' has mating rib 56' to hold the portions 18', 19' together.
The semicircular stop portion 22' is carried on the second half 19'.
The first half 18' is rotatably held onto the body portion 14' by means of a rib 48' which mates with an annular recess 34' on the wall of the body tube 14'.
While the reversible valve mechanism is employed here in a breathing exercise device, it should be recognized that the valving mechanism, to wit, the end cap 18, body tube 14, and disc or diaphragm 20, could be adapted for controlling fluids other than air, or could be used in devices other than breathing exercising devices.
It should also be mentioned that the exercise device assembly 10 of this embodiment is carried out in a device with slender, streamlined appearance, with all of its parts being generally tubular and disposed coaxially on the body. This provides a compact and convenient design, as well as being inexpensive to manufacture.
While a single preferred embodiment has been described in detail hereinabove, it should be apparent that many modifications and variations would present themselves to those with skill in the art without departing from the scope and spirt of this invention, as defined in the appended claims.
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A breathing exercise device is formed of a tubular body with a mouthpiece at its proximal end, a resistor sleeve coaxial with the body tube and having a number of resistance openings which align with a body tube opening, and a selective one way flap valve assembly disposed at the distal end of the body tube. The flap valve assembly can be rotated 180 degrees to change the mode of the breathing exercise device from inhalation to exhalation thereapy, or vice versa.
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This is a division, of application Ser. No. 577,930, filed May 15, 1976, which, in turn, is a continuation of application Ser. No. 391,204, filed Aug. 24, 1973 (abandoned).
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process for isomerization of lower-polymers of butadiene which comprises treating a lower polymer of butadiene or a lower copolymer of butadiene with a combination catalyst comprising an organic alkali metal compound and a diamine compound to thereby isomerize a non-conjugated double bond in the polymer to a conjugated double bond.
And further, it relates to a process for producing an isomerized butadine lower polymer having conjugated double bonds which comprises performing a lower polymerization and copolymerization of butadiene with an organic alkali metal catalyst or alkali metal, followed by a further reaction with an addition of a diamine compound to the reaction mixture in situ to isomerize their non-conjugated double bond to the conjugated double bond.
2. Description of the Prior Art
It is known that a lower polymer or copolymer of butadiene can be prepared by polymerizing butadiene or copolymerizing it with another monomer in the presence of a catalyst comprising an alkali metal catalyst, an organic alkali metal catalyst or a combination catalyst comprising a compound of a metal belonging to Group VIII of the periodic Table and an alkyl aluminum halogenide.
And there are also many published reports with regard to the production of lower polymers of butadiene and copolymers of butadiene with conjugated diolefines or vinyl-substituted aromatic compounds using organic alkali metals or alkali metal dispersions as a component of the catalyst. Some of the typical catalysts used in the production are, for example, a metallic sodium dispersion-naphthalene complex (Japanese Patent Publication No. 7051/65, 27432/68), a metallic sodium-ether complex and an organolithium compound (Japanese Patent Publication No. 26477/66, U.S. Pat. Nos. 2,913,444, 3,097,108, 3,105,828, 3,119,800 and 3,140,278: a living polymerization in tetrahydrofuran solvent). And a chain transfer polymerization process (Japanese Patent Publication No. 7446/57), which comprises employing aromatic hydrocarbons such as toluene or xylene as a chain transfer agent with the addition of dioxane and isopropyl alcohol, etc. to metallic sodium dispersions.
Since a lower polymer or copolymer of butadiene obtained by such known method has a large amount of 1,2-double bonds and 1,4-double bonds in the molecule and has a relatively high reactivity, the polymer is used in various fields as a paint vehicle, thermosetting resin, adhesive, rubber compounding material, intermediate material for various synthetic reactions and prepolymer. However, since the double bonds of such lower polymer of butadiene are non-conjugated ones, it is still insufficient with respect to the reactivity as compared with compounds containing conjugated double bonds in the molecule such as tung oil and dehydrated castor oil. Accordingly, it is expected that if non-conjugated double bonds of the butadiene units contained in a lower polymer or copolymer of butadiene can be isomerized to conjugated double bonds by an economically advantageous method to thereby improve the reactivity of the lower polymer of butadiene, its application fields will be further expanded.
As an instance of such isomerization method, there is known a method comprising reacting a lower polymer of butadiene at 110° to 250° C, in the presence of a catalyst comprising a compound of a transition metal belonging to Group VIII of the Periodic Table (Japanese Patent Publication No. 5757/68). This method, however, is defective in that the reaction should be conducted at high temperatures and such undesired phenomena as gelation and coloration of the polymer are readily caused to occur. Further, the catalyst comprising a compound of a transition metal belonging to Group VIII of the Periodic Table is expensive, and therefore, this method is disadvantageous from the economical viewpoint.
A method comprising subjecting a lower polymer of butadiene to air oxidation in the presence of a cobalt naphthenate catalyst to thereby improve the reactivity of the lower polymer is also known in the art (Japanese Patent Publications No. 4592/58 and No. 3865/71).
Moreover, in order to commercialize these butadiene lower polymers and copolymers, it will be required that they are isomerized further in their separate ways, and this will result in the increase of production costs. However, according to this method, the amount of the conjugated diene formed by the reaction is very small, and coloration or degradation is readily caused to occur.
SUMMARY OF THE INVENTION
We have made various investigations with a view to developing a method for improving the reactivity of a lower polymer or copolymer of butadiene, and as a result, we have found that when a combination catalyst comprising a specific organic alkali metal compound and a specific diamine compound is employed, non-conjugated double bonds of the butadiene units of such lower polymer can be isomerized to conjugated double bonds at a very high conversion at a low reaction temperature without occurrence of coloration or gelation. Based on this finding, we have now completed this invention.
And further, it has also been found that when the polymerization of butadiene and copolymerization of butadiene with other monomers are carried out by using organic alkali metals or alkali metal dispersions as a catalyst, followed by a further processing under prescribed reaction conditions of the polymerization reaction mixture with the addition of certain diamine compounds, isomerized butadiene polymers can be obtained without disadvantages such as coloring and gelling.
More specifically, in accordance with this invention, there is provided a process for the isomerization of lower polymers of butadiene and lower copolymers of butadiene with at least one monomer selected from the group consisting of conjugated diolefins other than butadiene and vinyl-substituted aromatic compounds, which comprises reacting such low polymer at 0° to 200° C. in the presence of a catalyst comprising an organic alkali metal compound and a diamine compound represented by the following general formula ##STR1## wherein n is an integer of 2 or 3, and R 1 , R 2 , R 3 , R 4 , R 5 and R 6 stand for a hydrogen atom or an organic compound residual group having 1 to 20 carbon atoms and optionally two members of R 1 , R 2 , R 3 and R 4 may be bonded together to form a cyclic structure. Alternatively, according to this invention, there is provided another process for isomerizing lower polymers of butadiene and copolymers of butadiene with other monomers to convert their non-conjugated double bonds into conjugated double bonds, which comprises adding such diamine compounds as shown by the above general formula to the reaction system, normally prior to the inactivation of the catalyst subsequent to the polymerization reaction, regardless of the presence or without the presence of any monomers and performing the isomerization reaction at a temperature of 0° C. to 200° C., or preferably at a temperature of 30° C. to 150° C.
In other words, this invention is characterized in that isomerized butadiene lower polymers can be made economically and at a low production cost by treating the polymer with a combination of organic alkali metal compounds or alkali metal dispersions, which are catalysts for lower polymerization and copolymerization of butadiene, with diamine compounds, and by effectively making use of the polymerization catalyst both for the polymerization reaction and isomerization reaction.
When alkali metal dispersions are employed as a polymerization catalyst and when the polymerization reaction is initiated and propagated, it seems that the alkali metal takes the form of an organic alkali metal. Consequently, even if an alkali metal dispersion is used as the polymerization catalyst, and subsequent isomerization reaction gives the same results as an organic alkali metal is employed as when the same.
DETAILED DESCRIPTION OF THE INVENTION
Conjugated diene-containing lower polymers and copolymers of butadiene prepared according to the process of this invention are light color compounds having a high reactivity, and they are effectively used as quick-dry paint vehicles, molded articles and intermediates for various synthetic reactions.
As a lower polymer or copolymer of butadiene, there can be employed polymers prepared according to conventional methods, such as polymers containing 1,2-double bonds in a large amount, polymers containing 1,4-double bonds in a large amount and polymers containing both 1,2-double bonds and 1,4-double bonds.
Namely, a lower polymer of butadiene or a lower copolymer of butadiene with other monomer obtained by a method comprising polymerizing butadiene alone or butadiene with other monomer in the presence of an alkali metal or organic alkali metal compound as a catalyst is a typical instance of the lower polymer to be used in this invention. In this case, in order to control the molecular weight and obtain a light color lower polymer of a less gel content effectively, there are typically adopted a living polymerization method using a tetrahydrofuran solvent and a chain transfer polymerization method in which an ether such as dioxane or an alcohol such as isopropyl alcohol is added to the polymerization system and an aromatic hydrocarbon such as toluene and xylene is employed as a chain transfer agent or a solvent. Lower polymers obtained by these polymerization methods can be effectively used in this invention. Furthermore, lower polymers rich in 1,4-double bonds in the butadiene units, which are prepared by polymerizing butadiene or copolymerizing it with other monomer in the presence of a catalyst comprising a compound of a metal belonging to Group VIII of the Periodic Table and an alkyl aluminum halogenide, can be similarly employed.
Lower copolymers referred to in the instant specification and claims include copolymers of butadiene with other conjugated diolefin such as isoprene, 2,3-dimethylbutadiene and piperylene, and copolymers of butadiene with a vinyl-substituted aromatic compound such as styrene, α-methylstyrene, vinyl toluene and divinylbenzene. When such lower copolymer of butadiene is employed, it is preferred that the content of the comonomer units does not exceed 50 mole %.
It is desired that the lower polymer or copolymer of butadiene to be used in this invention is liquid or semi-solid at room temperature and it has a molecular weight of 300 to 10,000.
In this invention, either the 1,2-double bond or the 1,4-double bond in the butadiene units can be isomerized to the conjugated diene bond.
The catalyst to be used in this invention comprises (1) an organic alkali metal compound and (2) a diamine compound.
The organic alkali metal compound to be used as component (1) is a compound represented by the following general formula
R--Me
wherein Me is an alkali metal from the group consisting of lithium, sodium and potassium and R stands for an alkyl group such as methyl, ethyl, propyl, butyl and pentyl groups, an alkenyl group such as allyl and methallyl groups, a cycloalkyl group such as cyclopentyl and cyclohexyl groups, or an aryl or aralkyl group such as phenyl and benzyl groups of 1-20 carbon atoms preferablly.
Further, complexes of an aromatic polynuclear compound such as naphthalene and anthracene with sodium or potassium can be used as the component (1). The foregoing compounds can be used singly or in the form of admixtures of two or more of them.
The diamine compound to be used as the component (2) of the catalyst of this invention is a compound represented by the following general formula ##STR2## wherein n is an integer of 2 or 3, and R 1 , R 2 , R 3 , R 4 , R 5 and R 6 stand for a hydrogen atom or an organic compound residual group having 1 to 20 carbon atoms and optionally two members of R 1 , R 2 , R 3 and R 4 may be bonded together to form a cyclic structure.
Preferable examples of members R 1 to R 6 are hydrogen, hydrocarbon residual groups such as alkyl, cycloalkyl and aryl groups, and nitrogen-containing organic residual groups including primary, secondary or tertiary amino groups. When the above diamine compound contains such a functional group as a carboxyl, hydroxyl or thiol group, the effect of the organic alkali metal compound as the component (1) is reduced by the presence of such functional group.
Typical instances of such diamine compounds are ethylene diamines and propylene diamines such as ethylene diamine, tetramethylethylene diamine, tetraethylethylene diamine, propylene diamine, dimethylpropylene diamine and tetramethylpropylene diamine; polyethylene polyamines expressed by the following general formula ##STR3## wherein m is an integer of at least 2, and R' 1 , R' 2 R' 3 and R' 4 stand for a hydrogen atom or a hydrocarbon residue having 1-20 carbon atoms. such as diethylene triamine, pentamethyldiethylene triamine and hexamethyltriethylene tetramine; and cyclic diamines such as piperidine and triethylene diamine.
When an organic alkali metal compound is reacted with such diamine compound, a violent change in the hue is caused to occur, and the organic alkali metal compound insoluble in hydrocarbons is solubilized by this reaction. Thus, it is suggested that a complex in which the --N--C--C--N-- or --N--C--C--C--N-- group acts effectively is formed.
The amount of the diamine compound to be combined with the organic alkali metal compound is not particularly critical, but it is preferred that the diamine compound is added in an amount of 0.1 to 100 mole equivalents to the organic alkali metal compound (0.1 to 100 moles of the --N--C--C--N-- or --N--C--C--C--N-- unit of the diamine per mole of the organic alkali metal compound). Especially high isomerizing effects can be obtained when the diamine compound is used in an amount of 0.5 to 10 mole equivalents to the organic alkali metal compound.
In case the amount of the diamine compound is too small, formation of a complex having an isomerizing activity is inhibited, and in contrast, if the amount of the diamine compound used is too large, any prominent increase of the catalytic activity is not obtained, resulting in economical disadvantages.
In this invention, the amount used of the organic alkali metal compound is not particularly critical, but it is preferred that the organic alkali metal compound is used in an amount of 1 millimole to 1 mole, especially 10 millimoles to 100 millimoles, per 100 g of the polymer.
The isomerization using the catalyst of this invention may be conducted in the absence of a solvent when the viscosity of the polymer is low, but when the viscosity of the polymer is high, it is preferred that a solvent capable of dissolving the starting polymer and giving no bad influence to the isomerization reaction, such as aliphatic hydrocarbons and aromatic hydrocarbons, is employed.
The isomerization using the catalyst of this invention is conducted at 0° to 200° C., preferably 30° to 150° C.
There are no restrictions to the isomerization reaction according to this invention, so far as it is performed substantially in a solvent. It is, however, preferable to employ a solvent which does not affect adversely but dissolves the polymer. For example, aliphatic or aromatic hydrocarbons are preferable.
This invention is now illustrated more detailedly by reference to Examples.
EXAMPLE 1
100 g of a polybutadiene having a molecular weight of 1000, a 1,2-double bond content of 86% and a trans-double bond content of 14% was dissolved in 50 cc of benzene, and 20 millimoles of benzylsodium and 40 millimoles of tetramethylethylene diamine were added to the solution. The mixture was reacted in a nitrogen current at 60° C. for 3 hours. 6 cc of methanol was added to the reaction mixture to deactivate the catalyst, and the reaction mixture was treated with activated clay and filtered to remove the sodium compound. Then, the solvent and remaining diamine were distilled off under reduced pressure to obtain a light color polymer free of the alkali metal.
The diene value of the resulting polymer was 23.0. When a composition comprising 100 parts by weight of the so formed polymer and 1 part by weight of cobalt naphthenate (in the form of 6% solution) was coated in a thickness of 30μ and dried at room temperature, the tack free state was obtained in 4 hours and it took 8 hours to complete the curing.
The starting polybutadiene having a diene value of 0.3 was incorporated with 1 part by weight, per 100 parts by weight of the polymer, of cobalt naphthenate (in the form of 6% solution) and the resulting composition was coated in a thickness of 30μ. When the coating was dried at room temperature, the tack free state was obtained in 25 hours, and it took 50 hours to complete the curing. In view of the foregoing test results, it will readily be understood that the reactivity of the starting polybutadiene was highly improved by the isomerization conducted according to this invention.
EXAMPLES 2 TO 6 AND COMPARATIVE EXAMPLES 1 TO 4
100 g of a polybutadiene having a molecular weight of 1100, a 1,2-double bond content of 89% and a trans-double bond content of 11% was dissolved in 100 cc of toluene, and 20 millimoles of benzyl sodium and a tertiary amine indicated in Table 1 were added to the solution. The resulting mixture was reacted in a nitrogen current at 80° C for 3 hours, and the post treatments were conducted in the same manner as described in Example 1 to obtain results shown in Table 1.
Table 1__________________________________________________________________________ Coating Drying rate at Complexing Agent Properties of Polymer Room Temperature (hr) Amount Trans* Vinyl* Diene Tack Complete Kind (m.mole) Content(%) Content(%) Value Free Curing__________________________________________________________________________ComparativeExample 1 starting polymer -- 9 74 0.8 25 50Example 2 ##STR4## 40 11 54 18 4Example 3 ##STR5## 40 11 56 16 5 10Example 4 ##STR6## 40 10 59 14 6 12Example 5 ##STR7## 40 12 50 21 3 7Example 6 ##STR8## 40 10 58 14 6 12ComparativeExample 2 not added 0 9 71 0.8 25 50ComparativeExample 3 NEt.sub.3 40 9 74 1.0 24 50ComparativeExample 4 ##STR9## 40 9 73 0.9 25 50__________________________________________________________________________ *The double bond content was determined by infrared spectrophotometry wit use of the extinction coefficient of Morero. It is considered that the reason why the sum of the trans and vinyl contents is not 100% is that th terminal double bonds are not calculated and some of double bonds are los by cyclization.
As is apparent from the results shown in Table 1, according to the process of this invention the conjugated diene units are formed at a very high conversion and a useful product can be obtained, whereas a monofunctional tertiary amine such as triethyl amine and pyridine does not cause the isomerization of the polymer. This is considered to be due to the fact that such amine does not form a complex with benzylsodium.
EXAMPLES 7 AND 8 AND COMPARATIVE EXAMPLES 5 TO 7
A polybutadiene having a molecular weight of 1000 was dissolved in 100 cc of benzene, and 20 millimoles of phenylsodium and an amine indicated in Table 2 given below were added to the solution. The reaction was carried out in the same manner as in Example 2 to obtain results shown in Table 2.
Table 2__________________________________________________________________________ Coating Drying Rate at Complexing Agent Properties of Polymer Room Temperature (hr) Amount Trans Vinyl Diene Tack Complete Kind (m.mole) Content(%) Content(%) Value Free Curing__________________________________________________________________________Comparative starting polymer -- 9 74 0.8 25 50Example 1Example 7 H.sub.2 NCH.sub.2CH.sub.2NH.sub.2 40 10 56 15 6 12Example 8 H.sub.2 NCH.sub.2CH.sub.2NHCH.sub.2CH.sub.2NH.sub.2 30 10 57 14 7 13Comparative NEt.sub.2 H 40 9 74 1.5 24 50Example 5Comparative H.sub.2 N(CH.sub.2).sub.6NH.sub.2 40 10 75 1.0 25 50Example 6Comparative Example 7 ##STR10## 40 10 75 0.9 25 50__________________________________________________________________________
As is apparent from the results shown in Table 2, when the diamine compound specified in this invention is employed, the isomerization is allowed to proceed very effectively. Even when a primary or secondary amine is employed, if it is a mono-amine, no isomerizing activity is obtained. Further, in the case of a diamine having no complex-forming property such as hexamethylene diamine or p-phenylene diamine, the isomerization is not allowed to advance.
EXAMPLE 9
800 g of a butadiene copolymer having a molecular weight of 1350, a 1,2-double bond content of 89%, a trans-double bond content of 11% and a styrene content of 10 mole % was dissolved in 2200 parts of benzene, and 200 millimoles of benzylsodium and 900 millimoles of ethylene diamine were added to the solution. The mixture was reacted in a nitrogen current at 70° C. for 8 hours, and the resulting reaction liquor was washed with water until no alkali metal was detected in the washing liquor. Benzene was removed from the reaction product by distillation to obtain an isomerized butadiene copolymer.
The so obtained copolymer had a molecular weight of 1370, a Gardner color number of 5 and a diene value of 19. When a composition of 100 parts by weight of the so obtained copolymer and 1 part by weight of cobalt naphthenate (in the form of 6% solution) was coated in a thickness of 30μ and was dried at room temperature, the tack free state was attained in 4 hours and it took 8 hours to complete the curing.
EXAMPLE 10
100 g of a cis-polybutadiene having a molecular weight of 1750, a cis-double bond content of 75%, a trans-double bond content of 19% and a 1,2-double bond content of 6% was dissolved in 100 cc of toluene, and 20 millimoles of benzylsodium and 40 millimoles of tetramethylethylene diamine were added to the solution. The mixture was reacted at 70° C. for 3 hours in a nitrogen current. Methanol was added to the reaction mixture to deactivate the catalyst and then, the reaction mixture was incorporated with 20 g of activated clay and stirred violently. Then, the mixture was filtered, and the solvent and remaining tetramethylethylene diamine were distilled off.
The resulting polymer had a molecular weight of 1800 and the diene value of the polymer was 32. As a result of the infrared absorption spectrum analysis, it was found that the polymer and a cis-double bond content of 53%, a trans-double bond content of 12% and vinyl double bond content of 7%.
From the results of this Example, it will readily be understood that also the 1,4-double bond is isomerized according to the process of this invention.
EXAMPLE 11 TO 13 AND COMPARATIVE EXAMPLE 8 TO 11
100 g of a polybutadiene having a molecular weight of 750, a 1,2-double bond content of 85% and a trans-double bond content of 15% was dissolved in 200 cc of benzene, and 40 millimoles of tetramethylethylene diamine and 20 millimoles of an organic alkali metal compound indicated in Table 3 given below were added to the solution. The mixture was reacted at 50° C. for 5 hours. Results of the analysis of the resulting polymer are shown in Table 3, and results obtained without addition of tetramethylethylene diamine are also shown in Table 3 as results of Comparative Examples.
Table 3______________________________________ Organic Alkali Tetramethyl- Diene Metal Compound ethylene Diamine Value______________________________________Comparative (starting polymer) -- 0.1Example 8Comparative butyl-lithium not added 1.5Example 9Example 11 butyl-lithium added 15Comparative amylsodium not added 0.8Example 10Example 12 amylsodium added 14Comparative phenylpotassium not added 1.0Example 11Example 13 phenylpotassium added 18______________________________________
The results shown in Table 3, as well as the results obtained in the foregoing Examples, indicate that the process of this invention is very effective for isomerizing non-conjugated double bonds to conjugated double bonds in butadiene polymers.
EXAMPLE 14
In a 2 lit. capacity autoclave of stainless steel, 1,000 cc of benzene as a solvent, 50 cc of toluene as a chain transfer agent and 100 millimoles of benzylsodium were taken, and subsequently 500 cc of butadiene was charged therein. The reaction was carried out at 30° C. for 2.5 hr in the way that almost all of the butadiene substantially entered into the reaction. After the completion of the reaction, a part of the reaction liquid was taken out in an amount of 100 cc. Then, 200 millimoles of tetramethylethylene-diamine was added to the remaining reaction liquid. The reaction liquid thus obtained was subjected to isomerization reaction at 70° C. for 8 hr. After the inactivation of the catalyst by adding 60 cc of methanol to the reaction liquid, it was treated with 100 g of activated clay and was filtered to remove sodium compounds. The filtrate thus obtained was distilled under vacuum to evaporate the solvent and remaining amine thereby to produce a pale color polymer without containing any amount of sodium. And the polymer was obtained in an amount of 300 g.
The polymer had a molecular weight of 1,000, a diene value of 19, 1,2-double bond content of 55% and a trans-1,4-double bond content of 12%. A composition comprising 1 part of the polymer and 100 parts of cobalt naphthenate (in the form of 6% solution) was coated in a thickness of 30μ to examine the drying speed at ambient temperature. The result was as shown below;
Set to touch: 4.5 hr
Full hardness: 9 hr.
As a comparison, the reaction liquid taken before the addition of diamine was operated in the same manner without adding the diamine. The polymer in a pale color thus prepared had a molecular weight of 950, a 1,2-double bond content of 78%, a trans-1,4-double bond content of 12% and diene value of only 0.2. A coating composition was prepared by adding 1 part of cobalt naphthenate (in a 6% solution) to 100 parts of the polymer to examine the drying speed of the coated film at ordinary temperature. The drying speed of the coated film 30μ in thickness was as shown below;
Set to touch: 25 hr
Full hardness: 50 hr.
From the above result, it is clearly seen that a butadiene lower polymer formed from the polymerization of butadiene is converted into an isomerized butadiene lower polymer by a joint function of the polymerization catalyst and amine compounds owing to the addition of amine compounds, and that the reactivity of the isomerized polymer is greatly increased by the isomerization.
EXAMPLES 15 TO 21 AND COMPARATIVE EXAMPLES 12 TO 16
In the same way as in Example 14, the polymerization reaction was conducted by using 100 millimoles of benzylsodium, followed by the various amine compounds, and subsequently an isomerization reaction was conducted at 80° C. for 3 hr. The results were summarized in Table 4.
Table 4__________________________________________________________________________Nos. of Drying Speed ofExample Property of Coated Film atand Amine Compound Polymer Ordinary Temp.Compara- Amount Trans* Vinyl* Set Fulltive + Structural (milli Content Content Diene Touch HardnessExample Formula mole) (%) (%) Value (hr) (hr)__________________________________________________________________________15 ##STR11## 300 11 50 21 3 716 ##STR12## 200 13 53 18 4.5 917 ##STR13## 210 12 58 14 6 1218 ##STR14## 200 12 56 16 5 1019 H.sub.2 NCH.sub.2CH.sub.2NH.sub.2 200 11 52 20 4 820 H.sub.2 NCH.sub.2CH.sub.2NHCH.sub.2CH.sub.2NH.sub.2 200 11 59 12 7 1321 ##STR15## 400 12 60 11 8 412.sup.+ NEt.sub.3 400 12 74 0.5 25 5013.sup.+ NEt.sub.2 H 400 11 74 0.6 25 5014.sup.+ H.sub.2 N(CH.sub.2).sub.6NH.sub.2 400 13 75 1.0 24 4815.sup.+ ##STR16## 400 13 74 0.7 24 4916.sup.+ -- 0 12 75 0.2 25 30__________________________________________________________________________ *Double bond content was determined by infrared spectrophotometry by making use of the extinction coefficient by Morero.
EXAMPLE 22
A bulk of 400 cc of tetrahydrofuran was put in a stainless steel autoclave of 2 lit. capacity, and 2 g of o-terphenyl was dissolved therein. After purging the inside of the system with nitrogen gas, a mixture solution containing o-terphenylsodium complex was prepared by adding thereto a dispersion containing 23 g of metallic sodium with an average particle diameter of 8μ in the form of a metallic sodium concentration of 50% which was made by using kerosene as a dispersion medium. The mixture solution was cooled to -70° C., and 1,000 cc of a liquid butadiene was supplied therein over 4 hr while maintaining at the temperature and while stirring. After a pre-determined amount of the butadiene was added, the polymerization reaction mixture solution was heated to ambient temperature to purge off the unreacted butadiene. A part of the reaction solution was taken out in an amount of 100 cc at the temperature. 116 g of tetramethylethylenediamine was added to the remaining solution, and the solution thus formed was heated to 70° C. and was maintained at the temperature for 5 hr. To the heated solution was added 50 cc of methanol to inactivate the catalyst, and subsequently was treated with 100 g of activated clay to eliminate sodium compounds. After distilling off methanol, tetrahydrofuran and amine compounds under vacuum, there was obtained a polymer in a pale color. The polymer had a molecular weight of 1,800, a diene value of 18, a 1,2-double bond content of 55% and a trans-1,4-double bond content of 10%.
On the other hand, the reaction solution which was sampled before the addition of the amine compound was processed in the same manner as described above. The polymer thus prepared had a molecular weight of 1,900, a diene value of 0.4, a 1,2-double bond content of 90% and a trans-1,4-double bond content of 10%.
EXAMPLE 23
After fully purging the inside of the system with nitrogen gas, 1,500 cc of toluene was put in a stainless autoclave of 2 lit. capacity. Then, a dispersion containing 2.3 g of metallic sodium particles with an average particle diameter of 9.5μ, which was prepared in a sodium concentration of 20% by using toluene as a dispersion medium, and 4.4 g of dioxane were added thereto. After 1 hr of the feed of 180 cc of butadiene at 80° C., an additional 700 cc of butadiene was fed in a constant rate over 90 hr. After the supply of butadiene in a pre-determined amount, the reaction solution was kept standing for 10 min, and the unreacted butadiene was purged out of the system. A part of the reaction solution was sampled in an amount of 100 cc., and 46.4 g of tetramethylethylenediamine was added to the remaining solution to further an isomerization reaction. After the isomerization reaction was carried out at 80° C. for 5 hr, 60 cc of methanol was added thereto to inactivate the catalyst, and sodium compounds were separated with 100 g of activated clay. The filtrate thus formed was subjected to a vacuum distillation to distill off toluene, methanol, dioxane and tetramethylethylenediamine, and a resultant polymer was pale and viscous.
The polymer had a molecular weight of 1,500, a diene value of 21, a 1,2-double bond content of 51% and a trans-1,4-double bond content of 8%.
As a comparison, the reaction solution which was sampled before the addition of the diamine compound was processed in the same manner as operated above. The polymer thus formed had a molecular weight of 1,500, a diene value of 0.3, a 1,2-double bond content of 78% and a trans-1,4-double bond content of 13%.
EXAMPLE 24
The inside of the system with a 2 lit. capacity autoclave of stainless steel was fully purged with nitrogen gas and 985 cc of toluene, 13 cc of tetrahydrofuran, 135 cc of styrene, 900 cc of butadiene and 10 cc of a butyl lithium solution were put in the autoclave. The mixture solution thus formed was reacted at 70° C. for 3 hr. After sampling of a part of the reaction mixture solution in an amount of 100 cc, 25 g of ethylenediamine was added to the remaining solution to perform a further isomerization reaction. The isomerization reaction was carried out for another 6 hr at the temperature. And after the completion of the reaction, 40 cc of methanol was added thereto to inactivate the catalyst, followed by washing with water. The washing was repeated until the solution was not alkaline. By distilling off the solvents, there was obtained a butadiene-styrene copolymer in a pale color.
The lower copolymer had a molecular weight of 1,800, a diene value of 19, a combined styrene content of 10%, a 1,2-double bond content of 54% and a trans-1,4-double bond content of 10%. A coating composition was prepared by adding 1 part of cobalt naphthenate (in a 6% solution) to 100 parts of the copolymer. The coated film 30μ thick had a drying speed at ordinary temperature as below;
Set to touch: 4 hr
Full hardness: 8 hr.
In contrast with this, a copolymer, which was prepared by operating in the same way as above the reaction solution taken out before the addition of the diamine compound, had a molecular weight of 1,780, a diene value of 0.4, a combined styrene content of 10%, a 1,2-double bond content of 78%, a trans-1,4-double bond content of 10%.
Another coating composition was prepared by mixing 100 parts of the copolymer and 1 part of cobalt naphthenate (in a 6% solution) to test a drying speed at ordinary temperature of its coated film in a thickness of 30μ. The test result was as shown below;
Set to touch: 24 hr
Full hardness: 50 hr.
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When a lower polymer of butadiene or a lower copolymer of butadiene with a conjugated diolefin other than butadiene or a vinyl-substituted aromatic comonomer is reacted at 0 to 200° C. in the presence of a combination catalyst including an organic alkali metal compound and a specific diamino compound, the non-conjugated double bonds are effectively isomerized to the conjugated diene double bonds at a very high conversion, and a polymer having a high reactivity, which is useful as a paint vehicle, a thermosetting material, an adhesive, a rubber compounding material and an intermediate for various synthetic reactions, can be obtained.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a continuation application based on pending application Ser. No. 13/775,653, filed Feb. 25, 2013, which in turn is a divisional application based on application Ser. No. 12/801,765, filed Jun. 24, 2010, now U.S. Pat. No. 8,399,128 B2, issued Mar. 19, 2013, the entire contents of both of which are hereby incorporated by reference.
[0002] Korean Patent Application No. 10-2009-0104311, filed on Oct. 30, 2009, in the Korean Intellectual Property Office, and entitled: “Bus Bar Holder,” is incorporated by reference herein in its entirety.
BACKGROUND
[0003] 1. Field
[0004] Embodiments relate to a bus bar holder.
[0005] 2. Description of the Related Art
[0006] Due to the increased use of gasoline vehicles, vehicle exhaust gases, which include various harmful substances e.g., nitrogen oxides, carbon monoxide due to incomplete combustion, hydrocarbon, etc., have created a very serious pollution problem. Furthermore, due to the steady depletion of fossil fuels, much research has been conducted on the development of next-generation energy sources and electric-powered vehicles. In this regard, traveling distances of an electric-powered vehicle depend on the performance of its battery. A battery may not be able to supply enough electric energy to guarantee that an electric-powered vehicle travels a sufficient distance. In the case of a vehicle that uses a fossil fuel, e.g., gasoline, light oil, or gas, the vehicle may be quickly resupplied with fuel at a gas station. However, in the case of an electric-powered vehicle, a significant amount of time may be required to recharge a battery, even if recharge stations are established. The time elapsed for charging a battery is a problem that has to be solved for commercialization of electric-powered vehicles. Therefore, improvement of battery performance is considered as the most important issue in relation to the development of electric-powered vehicles.
SUMMARY
[0007] Embodiments are directed to a bus bar holder, which represents advances over the related art.
[0008] It is a feature of an embodiment to provide a bus bar holder having improved connectivity with respect to electrodes of a battery having predetermined tolerances.
[0009] At least one of the above and other features and advantages may be realized by providing a bus bar holder for connecting electrode terminals of a plurality of batteries arranged in a lengthwise direction, the bus bar holder including a bus bar holder plate having an opening in a lengthwise direction thereof and configured such that at least some electrode terminals of the plurality of batteries are extendable through the opening and slidable along the opening; and a bus bar for electrically connecting at least two electrode terminals of adjacent batteries, wherein the bus bar holder plate includes a settling groove in which the bus bar is settled, and the bus bar attached to the electrode terminals is slidable when the electrode terminal slides along the opening.
[0010] The opening may be a single opening through which the electrode terminals are extendable through and slidable along the opening.
[0011] The opening may be configured to correspond to the electrode terminals, the opening having a predetermined length, for slidability of an electrode terminal, and the length of the opening being proportional to a distance from a reference point to the opening.
[0012] The opening may have a length proportional to a summed value of tolerances of the batteries.
[0013] The settling groove may extend in the lengthwise direction of the bus bar holder plate and may correspond to the opening.
[0014] The bus bar holder plate may include an insulator, and the bus bar may include holes through which the electrode terminals extend.
[0015] At least one of the above and other features and advantages may also be realized by providing a bus bar holder for connecting electrode terminals of a plurality of batteries arranged in a lengthwise direction, the bus bar holder including bus bars for electrically connecting at least two electrode terminals of the plurality of batteries; a plurality of unit bus bar holders, the unit bus bar holders being between the bus bars and the batteries, having holes through which the electrode terminals are extendable to be attached to the bus bars, and having settling grooves in which the bus bars are settled; and a bus bar holder plate including an opening in which the plurality of unit bus bar holders are slidable in a lengthwise direction along sliding grooves, the sliding grooves being disposed in inner surfaces of the bus bar holder plate.
[0016] The opening of the bus bar holder plate may have a length sufficient for the plurality of unit bus bar holders to slide.
[0017] The bus bar holder may further include elastic members interposed between adjacent unit bus bar holders.
[0018] At least one of the above and other features and advantages may also be realized by providing a bus bar holder for connecting electrode terminals of a plurality of batteries arranged in a lengthwise direction, the bus bar holder including bus bars for electrically connecting at least two adjacent electrode terminals of the plurality of batteries; a plurality of unit bus bar holders, the unit bus bar holders being between the bus bars and the batteries, including holes through which the electrode terminals are extendable for attaching to the bus bars, and including settling grooves in which the bus bars are settled; and a length adjuster interposed between adjacent the unit bus bar holders.
[0019] The length adjuster may have an elastic bellows structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The above and other features and advantages will become more apparent to those of ordinary skill in the art by describing in detail exemplary embodiments with reference to the attached drawings, in which:
[0021] FIG. 1 illustrates a perspective view of a bus bar holder attached to a battery module according to an embodiment;
[0022] FIG. 2 illustrates an exploded perspective view of the structure shown in FIG. 1 ;
[0023] FIG. 3 illustrates a sectional view taken along a line of FIG. 2 ;
[0024] FIG. 4 illustrates an exploded perspective view of a bus bar holder attached to a battery module according to another embodiment;
[0025] FIG. 5 illustrates a sectional view taken along a line V-V′ of FIG. 4 ;
[0026] FIG. 6 illustrates an exploded perspective view showing a bus bar holder attached to a battery module according to yet another embodiment;
[0027] FIG. 7 illustrates a sectional view taken along a line VII-VII′ of FIG. 6 ;
[0028] FIG. 8 illustrates a sectional view taken along a line VIII-VIII′ of FIG. 6 ;
[0029] FIG. 9 illustrates a modification of the embodiment shown in FIG. 6 ;
[0030] FIG. 10 illustrates a plan view of FIG. 9 ;
[0031] FIG. 11 illustrates an exploded perspective view of a bus bar holder attached to a battery module according to still another embodiment; and
[0032] FIG. 12 illustrates a plan view of the bus bar holder shown in FIG. 11 .
DETAILED DESCRIPTION
[0033] Korean Patent Application No. 10-2009-0104311, filed on Oct. 30, 2009, in the Korean Intellectual Property Office, and entitled: “Bus bar Holder,” is incorporated by reference herein in its entirety.
[0034] Example embodiments will now be described more fully hereinafter with reference to the accompanying drawings; however, they may be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
[0035] In the drawing figures, the dimensions of layers and regions may be exaggerated for clarity of illustration. It will also be understood that when a layer or element is referred to as being “on” another element, it can be directly on the other element, or intervening elements may also be present. In addition, it will also be understood that when an element is referred to as being “between” two elements, it can be the only element between the two elements, or one or more intervening elements may also be present. Like reference numerals refer to like elements throughout.
[0036] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. In this regard, the present embodiments may have different forms and should not be construed as being limited to the descriptions set forth herein. Accordingly, the embodiments are merely described below, by referring to the figures, to explain aspects of the present description.
[0037] Referring to FIGS. 1 through 3 , a bus bar holder 101 according to an embodiment will be described below. FIG. 1 illustrates a perspective view of the bus bar holder 101 attached to a battery module 1 according to an embodiment. FIG. 2 illustrates an exploded perspective view of the structure shown in FIG. 1 . FIG. 3 illustrates a sectional view taken along a line III-III′ of FIG. 2 . The bus bar holder 101 may be interposed between bus bars 110 and the battery module 1 .
[0038] The battery module 1 may include a plurality of batteries 10 , a top plate 20 , a bottom plate 30 , side plates 40 , and end plates 50 . The batteries 10 may be various types of batteries, e.g., primary batteries or secondary batteries. For convenience of explanation, it is assumed below that the batteries 10 are secondary batteries, e.g., lithium secondary batteries. However, the batteries 10 may be other types of secondary batteries.
[0039] The secondary battery 10 may include an electrode assembly (not shown) and an electrode terminal 12 . The electrode assembly may include a negative electrode (not shown), a separator (not shown), and a positive electrode (not shown), and may have a wound structure or stacked structure. The electrode assembly may be housed in the secondary battery 10 and the electrode terminal 12 may be used for electrical connection to an external device. The secondary batteries 10 may be arranged next to each other in a predetermined direction and may be electrically connected to each other in parallel or in series. When connected in series, the secondary batteries 10 may be arranged so that the negative electrode of one secondary battery 10 contacts the positive electrode of an adjacent secondary battery 10 . The electrode terminals 12 of the secondary batteries 10 may be connected to each other via the bus bars 110 .
[0040] In the secondary battery 10 , the electrode assembly may expand or contract during charging and discharging. The expansion and contraction of the electrode assembly may act as a physical force on the secondary battery 10 . Thus, a sealing assembly accommodating the electrode assembly may physically expand or contract according to the physical deformations of the electrode assembly. Due to repeated expansions and contractions, the secondary battery 10 may be permanently deformed; and an increase in volume of the secondary battery 10 may increase the electrical resistance thereof. Thus, the efficiency of the secondary battery 10 may be deteriorated. Therefore, the end plates 50 may be arranged at both ends of the plurality of second batteries 10 ; and the side plates 40 may be connected to the side ends of the end plates 50 to firmly fix the plurality of secondary batteries 10 , to prevent the plurality of secondary batteries 10 from expanding/contracting in the lengthwise direction.
[0041] The top plate 20 may be disposed on top of the plurality of secondary batteries 10 and may be connected to the top ends of the end plates 50 . The bottom plate 30 may be disposed below the plurality of secondary batteries 10 to support the secondary batteries 10 and may be connected to the bottom end of the end plates 50 .
[0042] The bus bar 110 may electrically connect at least two electrode terminals 12 of neighboring batteries 10 . The bus bar 110 may contain a metal. Holes 110 a through which the electrode terminals 12 are to be inserted may be formed in the bus bar 110 ; and attaching units 120 may correspond to the holes 110 a. In other words, the electrode terminals 12 inserted through the holes 110 a in the bus bar 110 may be attached to the attaching units 120 . Thus, the bus bar 110 and the electrode terminals 12 may be attached to each other. The attaching units 120 may be screws or nuts attached to the electrode terminals 12 .
[0043] The bus bar holder 101 may be interposed between the bus bar 110 and the electrode terminals 12 . The bus bar holder 101 may include an insulation material to prevent a short circuit and may guide attachment of the bus bar 110 so that the bus bar 110 is easily attached to the electrode terminals 12 . When the bus bar holder 101 is attached to the electrode terminals 12 , if holes were to be disposed evenly apart from each other in the bus bar holder 101 , attachment problems may occur due to manufacturing tolerances of the secondary batteries 10 . When the secondary batteries 10 are manufactured, if the manufacturing tolerances are high, the manufacturing costs may increase. Furthermore, since the secondary batteries 10 are lithium secondary batteries and the volumes thereof may change during charging and discharging, if the bus bar holder 101 is attached to the electrode terminals 12 through holes disposed evenly apart from each other, a connection problem may occur between the bus bar holder 101 and the electrode terminals 12 when the secondary batteries 10 are charged or discharged.
[0044] The bus bar holder 101 of an embodiment may include a bus bar holder plate 100 . The bus bar holder plate 100 may include an opening 100 a formed in its lengthwise direction so that the electrode terminals 12 of the plurality of batteries 10 may be inserted through the opening 100 a. The electrode terminals 12 may slide, i.e., is slidable, along the opening 100 a. The opening 100 a may be a single opening through which all of the electrode terminals 12 may be inserted. The bus bar holder plate 100 may have a settling groove 100 b in which the bus bar 110 may be settled. The bus bar 110 attached to the electrode terminals 12 may slide in the settling groove when the bus bar 110 is fixed to the battery module 1 . The electrode terminals 12 may slide along the opening 100 a. A first bus bar 110 may be easily attached to the electrode terminals 12 regardless of the volumes of the secondary batteries 10 or manufacturing tolerance of the electrode terminals 12 . Furthermore, even if the volumes of the secondary batteries 10 change, other bus bars 110 attached to the electrode terminals 12 may slide along the settling groove 100 b . Thus, the bus bar holder 101 may have a structure easily adaptable to volume changes of the secondary batteries 10 .
[0045] Referring to FIGS. 4 and 5 , a bus bar holder 201 according to another embodiment will be described below. FIG. 4 illustrates an exploded perspective view of the bus bar holder 201 attached to the battery module 1 according to another embodiment. FIG. 5 illustrates a sectional view taken along a line V-V′ of FIG. 4 . According to the present embodiment, the bus bar holder 201 may include a bus bar holder plate 200 . Openings 200 a may be formed in the bus bar holder plate 200 in the lengthwise direction. First electrode terminals 12 of the plurality of secondary batteries 10 may be inserted through the openings 200 a, and the electrode terminals 12 may slide along the openings 200 a. The openings 200 a may be formed at locations corresponding to the electrode terminals 12 . Furthermore, the openings 200 a may have predetermined lengths so that the electrode terminals 12 may slide therein. In particular, the predetermined lengths may be proportional to a distance from a reference point S to the openings 200 a. The length of the openings 200 a may extend in correspondence to a sum of manufacturing tolerances t of the bus bar holder 201 as a distance A from the reference point S to the openings 200 a increases. The sum of the manufacturing tolerances t of the bus bar holder 201 indicates a value of a portion of the lengths of the openings 200 a of the bus bar holder plate 200 that extends in correspondence to the sum of manufacturing tolerances of the sizes of the secondary batteries 10 and the locations of the electrode terminals 12 . The sum of the manufacturing tolerances t may include dimensional tolerances or geometric tolerances of the secondary batteries 10 , the electrode terminals 12 , and the bus bar holder plate 200 . The manufacturing tolerances t may accumulate as the distance from the reference point S to the openings 200 a increases. Therefore, the openings 200 a may have lengths extending as much as sums of the diameter d and the accumulated manufacturing tolerances t, which is sufficient for inserting the electrode terminals 12 through the openings 200 a. Furthermore, the lengths of the openings 200 a may be determined in consideration of not only the manufacturing tolerances t, but also movements of the electrode terminals 12 due to contraction and/or expansion of the secondary batteries 10 . Distances between the secondary batteries 10 adjacent to each other may be fixed by the bus bars 110 . Thus, the length of openings 200 a corresponding to adjacent secondary batteries 10 may be equal. In other words, referring to FIG. 5 , the length of the opening 200 a, which is two distance units 2 A apart from a reference point, and the length of the opening 200 a, which is three distance units 3 A apart from the reference point, may be d+3t (d indicates the diameter sufficient for inserting the electrode terminals 12 through the openings 200 a, and 3 t indicates the manufacturing tolerances t summed three times). The lengths of the opening 200 a , which is two distance units 2 A apart from the reference point, and the opening 200 a , which is three distance units 3 A apart from the reference point, may both be d+3t, since intervals among the electrode terminals 12 may be evenly maintained by the bus bar 110 , the bus bar 110 may move with respect to the greater value between d+2t, which is required at the point with respect to two distance units away from the reference point, and d+3t, which is required at the point with respect to three distance units away from the reference point.
[0046] Accordingly, the bus bar holder plate 200 with the openings 200 a, which may be formed in consideration of the manufacturing tolerances t, may be easily attached to the electrode terminals 12 of the battery module 1 . Furthermore, the bus bar holder 201 may be effectively adapted to compensate for contraction and expansion of the secondary batteries 10 .
[0047] Settling grooves 200 b may be formed in the bus bar holder plate 200 to correspond to the length of the openings 200 a. Therefore, when the electrode terminals 12 and the bus bars 110 are attached to each other and slide on the bus bar holder plate 200 , the electrode terminals 12 and the bus bars 110 may slide along the settling grooves 200 b.
[0048] Referring to FIGS. 6 through 8 , a bus bar holder 301 according to yet another embodiment will be described below. FIG. 6 illustrates an exploded perspective view of the bus bar holder 301 attached to the battery module 1 according to yet another embodiment. FIG. 7 illustrates a sectional view taken along a line VII-VII′ of FIG. 6 . FIG. 8 illustrates a sectional view taken along a line VIII-VIII′ of FIG. 6 .
[0049] According to the present embodiment, the bus bar holder 301 may include a bus bar holder plate 300 and a plurality of unit bus bar holders 310 .
[0050] The unit bus bar holder 310 may be interposed between the bus bar 110 and the secondary battery 10 . A holder hole 310 a may be formed in the unit bus bar holder 310 ; and the electrode terminal 12 may be inserted, i.e., may extend, through the holder hole 310 a so that the electrode terminals 12 and the bus bars 110 may be attached to each other. A settling groove 310 b for receiving the bus bar 110 may be formed in a surface of the unit bus bar holder 310 .
[0051] Sliding grooves 300 c may be formed in inner surfaces of the bus bar holder plate 300 so that the plurality of unit bus bar holders 310 may slide along the sliding grooves 300 c. Grooves 310 c corresponding to the sliding groove 300 c may be formed in the side surfaces of the bus bar holders 310 . Although the sliding grooves 300 c may be concave grooves and the corresponding grooves 310 c may be convex grooves, as illustrated in FIG. 8 , the embodiments are not limited thereto, and various modifications may be made. For example, the unit bus bar holders 310 may include casters, so that the unit bus bar holders 310 may slide on the inner surfaces of the bus bar holder plate 300 . Also, openings 300 a of the bus bar holder plate 300 may have sizes sufficient for the plurality of unit bus bar holders 310 to slide therein. Therefore, the bus bar holder 301 may be easily adapted to changes in locations of the electrode terminals 12 due to tolerances or deformation of secondary batteries 12 by sliding of the unit bus bar holders 310 . FIGS. 9 and 10 illustrate another modification of the embodiment shown in FIG. 6 . In particular, FIG. 9 illustrates a modification of the embodiment shown in FIG. 6 and FIG. 10 illustrates a plan view of FIG. 9 . According to the modified embodiment illustrated in FIGS. 9 and 10 , an elastic member 420 may be further disposed among a plurality of unit bus bar holders 410 . Accordingly, the unit bus bar holders 410 may elastically maintain intervals therebetween via the elastic members 420 .
[0052] Referring to FIGS. 11 and 12 , a bus bar holder 501 according to still another embodiment will be described below. FIG. 11 illustrates an exploded perspective view of the bus bar holder 501 attached to the battery module 1 according to still another embodiment. FIG. 12 illustrates a plan view of the bus bar holder 501 shown in FIG. 11 .
[0053] The bus bar holder 501 may include a plurality of unit bus bar holders 510 and length adjusters 520 .
[0054] The unit bus bar holder 510 may be interposed between the bus bar 110 and the secondary battery 10 . A holder hole 500 a may be formed in the unit bus bar holder 510 ; and the electrode terminal 12 may be inserted through holder hole 500 a so that the electrode terminals 12 and the bus bars 110 may be attached to each other. A settling groove 500 b for accommodating the bus bar 110 may be formed in a surface of the unit bus bar holder 510 .
[0055] The length adjuster 520 may elastically connect the unit bus bar holders 510 to the adjacent unit bus bar holder 510 . For example, as illustrated in FIGS. 11 and 12 , the length adjuster 520 may be an elastic object with a bellows structure. Accordingly, the bus bar holder 501 may be easily adapted to changes in length due to manufacturing tolerances as the length adjuster 520 elastically adjusts its length.
[0056] In comparison to the bus bar holder 501 illustrated in FIG. 11 , the bus bar holder 401 illustrated in FIG. 9 may restrict a sliding range of the electrode terminals 12 along the length of the bus bar holder plate 400 and may also be advantageous due to the bus bar holder plate 400 that guides the unit bus bar holders 410 during sliding.
[0057] The bus bar holders 101 , 201 , 301 , 401 , and 501 illustrated in FIGS. 1 through 12 may be applied to the battery module 1 . In an implementation, the battery module 1 may include twelve secondary batteries 10 ; and eight battery modules 1 may be stacked to form a battery pack. Such a battery module 1 or a battery pack may be applied to electric-powered vehicles, and it is clear that the bus bar holders 101 , 201 , 301 , 401 , and 501 may be applied to the battery module 1 and the battery pack.
[0058] Exemplary embodiments have been disclosed herein, and although specific terms are employed, they are used and are to be interpreted in a generic and descriptive sense only and not for purpose of limitation. Accordingly, it will be understood by those of ordinary skill in the art that various changes in form and details may be made without departing from the spirit and scope of the present invention as set forth in the following claims.
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A bus bar holder for connecting electrode terminals of a plurality of batteries arranged in a lengthwise direction, the bus bar holder including a bus bar holder plate having an opening in a lengthwise direction thereof and configured such that at least some electrode terminals of the plurality of batteries are extendable through the opening and slidable along the opening; and a bus bar for electrically connecting at least two electrode terminals of adjacent batteries, wherein the bus bar holder plate includes a settling groove in which the bus bar is settled, and the bus bar attached to the electrode terminals is slidable when the electrode terminal slides along the opening.
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BACKGROUND OF THE INVENTION
Water taps serve to open and close the hot and cold water supply as required. Mixer units permit mixing of hot and cold water with the object of arriving at a specific temperature. Mixer units with thermostatic regulation maintain the pre-set temperature at a constant, completely independent of water supply pressure fluctuations and temperature variations.
It is common to all mixer units that to open the hot and cold supplies and to adjust the required temperature, several hand grips are necessary to simplify which all possible conceivable means are tried. This leads to elaborate one-hand mixer units by which it is possible with one hand grip, mostly by turning and moving, to adjust the desired quantity and temperature of the water. The same is also true of thermostatic one-hand mixer units.
All have at least one, more or less, complex grip for the setting of these values.
BRIEF SUMMARY OF THE INVENTION
It will now be proposed, in accordance with the invention, that by means of pivoting the water outlet, the water quantity and/or temperature is influenced, without a special grip.
This means a substantial simplification of design and also operating advantages. Often the hand grips are slippery, and above all are difficult to operate with wet or greasy fingers. Pivoting of the water outlet with its long lever is possible in every case.
The requirement to avoid an operation of the hand grip with dirty or also with just washed sterile fingers leads to complicated designs with ultra sonics, radar and the like.
For this reason hospitals often install mixer units with a particularly long lever which can be switched off and on by the back of the hand or the elbow.
The influencing of the water quantity and/or temperature by pivoting of the water outlet thoroughly solves this problem, no matter if the water outlet pivots about an almost vertical axis or about an axis which is almost horizontal, and which lays somewhat oblique to the operator standing in front of it.
A combination of both pivoting movements, in accordance with the invention, about a vertical and horizontal axis permits the adjustment of both the water quantity and the temperature of the water. It is greatly advantageous here that the operating method at the end of the long water outlet makes possible a delicate and exact adjustment which is not the case with the current designs with their comparatively small hand grips.
The pivot area is, according to the invention, selected to be advantageously large whereby one can direct all of the water outlet onto the area of useage, e.g., a wash basin, to be comfortably able to wash hair or clean teeth. This wide pivoting-out should in accordance with the invention, firstly be after the area in which the regulating elements are influenced such as, for example, the regulating elements which reduce the water supply to zero, i.e. shut it off. By pivoting inwards again the water supply is only opened by the regulating elements when the water outlet is above the wash basin. If one dispenses with the combination of two pivoting movements in the interests of simplicity of operation, the known regulating sequence is recommended, in accordance with the invention, that first the cold water supply is gradually opened and, by means of further pivoting of the water outlet, hot water is mixed, in increasing quantities while the flow of cold water either remains constant or decreases.
It is advantageous in such a case when means for pre-adjustment are available which determine the maximum water quantity output and/or the desired temperature, e.g. by a thermostat.
An advantageous design of water mixer unit according to the invention, is to connect a regulating element rigidly directly on to the water outlet. This results in simple construction and economic layout.
In accordance with the invention the feasibility of mounting further regulating elements co-axially on the water outlet will be proposed, which, in this fashion solve complex demands and use rotating parts that can be economically manufactured.
New methods are demonstrated by operation of the regulating elements by a cam arranged on the water outlet, particularly in the case of a combination of two pivot movements.
Particularly preferred is the use of totaly reliable ceramic discs as regulating elements.
Particular prominence is due to the kinematic arrangement; the pivoting of the water outlet about two axes, the planar regulating surfaces of the parts moving towards each other in one rotation and one sliding movement. In accordance with the invention, it will be proposed to connect a transmission part either form-locking or fixed to both pivot movements of the water outlet, but at least, and/or to couple with one of the parts.
As the movements follow, on the one side in a space about two axes and, on the other side co-planar as a sliding or turning, it will be proposed to use a universal joint for the transmission part that is rotatable randomly about two vertically superimposed axes. Therewith a transforming of a spatial pivot movement into a rotational movement in the plane of the regulating surfaces is possible.
It will be additionally proposed to arrange one of the axes of the universal joint parallel to, for example, the pivot axis which determines the water quantity output, however not co-incident with it, but at a determined distance between the axes, which serves as a lever to slide the parts together.
It is advantageous to mount an approximately hemispherical sealing surface in a guide housing which has a slot from which protrudes a connective piece, which supplies the connection to the water outlet. The water outlet is therewith either fixed or form locking connected to the sealing surface by the connecting piece and can be pivoted about the pivot axis by these parts.
To prevent the ingress of dirt and foreign bodies in the slot and also for reasons of design, it is advisable to completely or partially close it with a cover.
In the first part of the present application it will be recommended as a preferable arrangement to vary the water temperature, i.e. the mixing ratio of cold to hot water, by pivoting the water outlet about an approximately vertical axis so that, for example, setting the water outlet to the left corresponds to "cold" and to the right "hot".
The arrangement of a setting angle, determined by a carrier, subsequent to the turning of which the commencement of the regulation is introduced, enables the water outlet to be brought into, for example, the most-preferred "middle position" after selection of the desired temperature, without having to alter the previous setting. A variation of the temperature is still possible, by small pivoting actions "touching", of the water outlet, to left or right.
The introduction of an overidable spring detent in the area of the pivot angle, which determines the water outlet quantity, is also new and of great importance in that an "economy position" can be marked by it, in which only half of the water quantity flows out. This alternative is particularly meaningful in the context of water and energy saving. If a greater quantity of water is required, one simply presses a little harder thus overiding the "economy position".
For the practical construction of a water mixer unit according to the invention two features are prominent which substantially favour the dimensions and thereby the simplicity of assembly.
Firstly, it is possible to arrange at least one part of the universal joint inside the hemispherical sealing surface. This achieves a compact location of the individual parts and also a protected and space-saving, i.e. cost-saving, solution.
The second substantial improvement of the complete assembly is to arrange the main axis of the mixer unit not vertically but supported somewhat tilted, namely about approximately half of the pivot angle of the water outlet. This means, firstly, that the connection piece, in a final position (fully turned on) is approximately vertical and thereby the temperature adjustment can be comfortably carried out by pivoting about this, by now also vertical, axis.
The tilted position of the main axis about half of the pivot angle also functions in that the slot in the guide housing lies symetrically, which is very favourable for the location of all the parts in the interior. Not only that but the tilted position looks advantageously attractive.
It will also be recommended to provide a shoulder or assistance, for example by suitably shaping the water outlet, to simplify operation by the back of the hand or the elbow.
Particular eminence also arises from the ability to identify specific locations or positions of the water outlet. The pivot movement could for example be snapped into the "cold" position then "warm" and finally "hot".
The same would be true for example in a combination of two pivot movements where the water quantity setting is also simply adjustable over detents "low", "medium" and "full". The detents naturally in no way prevent the choice of an intermediate setting. A particularly advantageous arrangement of the regulating elements with planar sealing surfaces from, for example ceramics, is given when the plane of the sealing surfaces is approximately vertical to the pivot axis of the water outlet. Slight variations from the precise vertical position, which under some circumstances for reasons of layout shapes could be useful, are unimportant in that they are easily compensated for by the usually necessary transmission element.
This arrangement also enables the twisting of one of the moveable parts, for example, about the pivot axis of the water outlet and the coupling of these two movements.
The arrangement of a cam, for example, in the shape of an eccentric either directly on the water outlet or on a connection piece connected to it, enables a simple overlapping of a second movement on the part.
Through the combination of both the above-mentioned arrangements it is possible, with one single transmission element, to change both pivot motions of the water outlet, for example, about one approximately horizontal axis and about one second axis lying approximately vertical to it, once in one rotation and once in a parallel sliding action of the moving parts.
The desired function lies in that, for example, by the pivoting of the water outlet about a horizontal axis to adjust the water quantity or to turn it off, and by the pivoting of the water outlet about a second axis which is vertical, the mixing temperature of the hot and cold water is brought about by sectional alteration in the overlapping of the openings in the regulating elements.
A further improvement of the inventive concept is in the embodiment of such a device with a setting angle between the travel of the water outlet and the travel of the moving parts coupled to it.
The reason for such a measure is to be able to swing the stream of water side to side, for example in the wash basin, without immediately causing a change in temperature, while adjustably mixing temperature by sideways pivoting of the water outlet about its axis in the area of the setting angle.
The positioning of the plane of the sealing surfaces, according to the invention, vertical to the pivot axis of the water outlet enables the additional arrangement of a further independent regulating element, that consists likewise of at least two parts with planar sealing surfaces which are moveable towards each other.
This additional regulating element can also be operated by pivoting of the water outlet. An example can be drawn from the shut-off function in the case of kitchen mixer units which have the task of protecting a washing or washing-up machine which are usually connected by a flexible pipe.
For specific functions such as, for example, the "economy position" of the water outlet, it will be proposed in accordance with the invention to provide a spring detent which can only be overcome by an additional exertion of strength.
The subject of the present invention arises not only from the subject of the individual patent claim but from the combination of the individual patent claims one with another.
All the details and features disclosed in the documents, particularly those in the drawings illustrating the layout are claimed as being essential to the invention, in so far as they are new, either individually or in combination, compared with the state of the art.
In the following, the invention will be explained by means of drawings illustrating merely one embodiment example. Hereby arise from the drawings and their descriptions, further features and advantages essential to the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1: Schematic pivot operation of the water mixer unit according to the invention
FIG. 2: The pivot operation of the water mixer unit about a vertical axis, seen in side view.
FIG. 3: Same illustration as in FIG. 2, plan view.
FIG. 4: Section through a water mixer unit according to the invention.
FIG. 5: Section through a modified embodiment example of a water mixer unit compared to FIG. 4.
FIG. 6: Section through a further modification of a water mixer unit with combined pivot action seen in side view.
FIG. 7: Same illustration as FIG. 6, plan view.
FIG. 8: Section through a water mixer unit with ceramic plates as regulating elements.
FIG. 9: Partial section through the water outlet of the water mixer unit in FIG. 8 with inserted connection piece.
FIG. 10: Section through the water mixer unit in FIG. 8 in the closed position
FIGS. 11 to 14: Schematic illutrations of various regulated positions.
FIG. 15: Section through an asymmetric embodiment of a regulator fitting with plate seals and without grips.
FIG. 16: Side view of the arrangement in FIG. 15.
FIG. 17: A further section through the arrangement in FIG. 15.
FIG. 18: Illustration of the self-covering openings in the plate seals.
FIG. 19: A further variant of a grip-less regulator fitting in comparison with FIG. 15.
FIG. 20: A section of the embodiment according to FIG. 19 rotated through approximately 90°.
FIGS. 21 and 22: Details of the plate seals.
FIG. 23: A further section through the arrangement in FIG. 15.
DETAILED DESCRIPTION
FIG. 1 illustrates a schematic illustration of the pivot action about a horizontal axis (16) seen on its end. The valve body (1) carries the water outlet (5) which is pivot-mounted about the axis (16). The influence of the regulating elements (4) (not illustrated) is in the area (7). It can be clearly seen from FIG. 1 that in this case the water can only flow into the container (6).
FIG. 1 also schematically illustrates a shoulder (11) which makes pivoting of the water outlet easier.
FIGS. 2 and 3 schematically illustrate the pivoting of the water outlet (5) about a vertical axis (15) in which the same parts have the same index numbers.
By pivoting of the water outlet (5) into the detented positions (12)(13)(14) one achieves first the "cold" position (12), then the "warm" position (13) and finally the "hot" position (14).
All three positions are contained in area (7) in which the influence of the regulating elements (4)(not illustrated) takes place. A pivoting to the left together with an opposite sequence of positions is naturally perfectly possible. FIGS. 1 and 3 show clearly that by a complete pivoting of the water outlet (5) the water container and the area above it can be used without inconvenience.
FIG. 4 illustrates a section through a complete mixer unit which can be operated without any hand grips, just by pivoting of the water outlet (5) about the axis (16). The regulating element (4) is rotatably mounted in the valve body (1) with the warm water supply (2) and the cold water supply (3). The water outlet (5) is mounted on the regulating element (4) and rigidly fixed to it by a screw (17). The seals (18) for example O-rings ensure a sealing of the regulating element (4) against the housing and/or against the water outlet. The seals (19) which surround the water supplies (2) and (3) ensure that when the regulating elements (4) are in the zero position no water can enter the regulating element. By means of a corresponding angle adjustment of the holes (20), one can program the mixture of hot and cold water. The pin (21) with its associated spring (22) together with the recess (23) in the water outlet (5) limit the pivot range. By means of corresponding detents which are engaged by the pin (21) under the load of the spring (22) one can achieve, in simple fashion, spot-positioning. Naturally this type of location is only to be seen schematically as there are numerous possibilities of achieving this function by other practical solutions.
The embodiment example in FIG. 4 shows how drastically simplified a mixer unit according to the invention can appear.
FIG. 5 shows another variant of the water mixer unit according to the invention, shown schematically, in which the same parts are identified by the same index numbers. Additionally, in this embodiment example, a further regulating element (9) is available which is rigidly attached to the hand grips (8) by the screw (24).
The pre-settable regulating element (9) is mounted in regulating element (4) and has holes (25) which, depending on angular position cover, more or less, the holes (20) in the regulating element (4). In this fashion by means of corresponding angular adjustment of the holes (20) and (25) the average ratio of cold water throughput to that of the hot water throughput can be so pre-set by rotation of the hand grip (8) that the desired mixture temperature is achieved. The pivoting of the water outlet (5) in this case controls only the quantity of water outflow.
Naturally in a reverse function the second regulating element (9) is also possible in that it determines only the quantity of water and the pivoting of the water outlet (5) corresponds to determined temperatures. The arrangement of a thermostatic system as regulating element (9) is practically very simple to achieve.
There is nothing further to be said about the way in which the holes (20) and/or (25) are to be arranged in order to achieve the described function as this belongs to the absolute state of the art. The angle of rotation of the knob (8) can be limited to, for example, a stop pin which is arranged in an annular recess in the grip (8).
FIGS. 6 and 7 show an example embodiment of a mixer unit with combined pivot movement. The pivoting about a horizontal axis influences the quantity of the outflowing water and/or the shutting-off of the water supplies (2)(3). The pivoting about the vertical axis (15) influences the average ratio of hot and cold water throughput and therewith the water temperature. The arrangement of detented positions is also possible in this case, so that for each of the positions "low", "medium" and "full" water quantities it is easy to adjust the temperatures "cold", "warm" and "hot".
FIGS. 6 and 7 show sections through a double-pivot mixer unit which the same parts are identified by the same index numbers as in the other figures.
The water outlet (5) is, in this case, pivotable about the horizontal axis (16) and is rigidly fixed to the rotatable insert (28) by the screw (17). The rotatable insert (28) has teeth (29) which engage in the opposing teeth (32) in the flattened part (34) of the control piston (31). By pivoting the water outlet (5) not of the position "off" (36) indicated by dotted lines in FIG. 6, the control piston (31) is moved upwards and opens, more or less, the holes (37) and (38). In this way the total quantity of water outflow is influenced.
By pivoting the water outlet (5) about the vertical axis (15) into the position (35) indicated by dotted lines, the complete pivot housing (27) turns in relation to the actual valve body (1). The control piston (31) guided against torsion in the pivot housing (27) thereby rotates in the vertical bearing bush (30) which is itself rigidly fixed to the valve body (1) by the screw (33).
The angularly offset holes (37) and (38) thereby alter the section of the hot and cold water passage and thus the temperature of the water outflow.
It must be emphasized, even in this description of an example of a double-pivot mixer unit, that all previously known combinations with other regulating elements, e.g. flow limiters, thermostat systems of all types, back-flow shut offs, filters etc are completely feasible.
The water outlet can, as illustrated, be asymmetric or also of a symetrical designed arrangement. A fork-shaped formation of the water outlet with an extension on both sides of the valve body is likewise mentioned.
FIG. 8 shows, by way of an example, a schematic sketch of a water mixer unit with ceramic plates acting as a regulating element. The sketch is in no way restrictive in relation to the embodiment as both the complete fitting or the parts therefrom can be varied according to the state of the art.
In FIG. 8 the valve body (1) is shown as a cylindrical tube which exits into a ball-shaped guide housing (45). The cold and hot water supplies (2) and (3) overlap in FIG. 8 in that they lay one behind the other. The water outlet (5) is connected in form-locking fashion to the approximately hemispherical sealing surface (47) by a connecting piece (46). The guide housing (45) has a slot (48) in which the connecting piece (46) can perform a pivot motion about the pivot axis (42) which is substantially horizontal. The O-ring (70) seals elastically.
In this hemispherical sealing surface (47) a wall (54) is provided, which embraces the slide axis (60) of the universal joint (43). In the slot (56) of the universal joint (43), the fork (57) of the transmission part (39) is guided. The fork (57) transmits all sliding and turning motions of the universal joint (43) (and therefore of the outlet 5) onto the slideable part (40). The part (41) is securely set into the retainer (58). The retainer (58) is pushed into the valve body (1) and is fixed by, for example, a threaded ring (59). The O-ring (55) ensures a sealing of the retainer (58).
In FIG. 8, the open position of the unit is illustrated. In this case the opening (61) in the fixed part (41) aligns with the opening (62) in the slideable part (40). The water can flow in, for example, from the supply (2) through the openings (61)(62) and (63) in the transmission part (39) in the mixing chamber (64) and thus reach both sides of the well (54) in the drilling (65) of the connection piece (46) and finally the water outlet (5). The O-rings (69) are important for sealing.
In FIG. 10, the unit is shown in the closed condition. The water outlet (5) is pivoted upwards together with the connection piece (46) the sealing surface (47) and the wall (54). The slide axis (60) together with the fork (57) with the transmission part (39) and the slideable part (40) are moved in relation to part (41) and the openings (61) and (62) are no longer aligned. The water through-flow is shut off.
In FIGS. 11 and 14 the different regulating positions of the slideable parts (40) and (41) are schematically shown. For ease of illustration the openings (61) and (62) are shown as narrow rectangles. The openings (61) and (62) are for cold water and the openings (66) and (67) are for hot water.
FIG. 11 shows both passages open and thereby luke-warm water.
FIG. 12 shows both passages closed and thereby no through-flow.
FIG. 13 shows only openings (61) and (62) aligned and thereby cold water.
FIG. 14 shows only the openings (66) and (67) are aligned and thereby hot water.
The intermediate positions then correspond to the differing water quantities and/or temperatures. By means of other shapes and positions of the openings (61)(62) and (66)(67) a detailed optimisation and fitting is possible which is already carried out by numerous uses of ceramic plates.
In FIGS. 8 and 9 the arrangement of a cover (52) for the protection of the slot (48) against dirt and foreign bodies is schematically shown. In this example the cover is an integral part of the water outlet (5) it can however be likewise formed as an intermediate piece that is, for example, slid onto the connection piece (46). The usage of such a cover is made easy by the fact that the outer shape of the unit is a ball-surface and thus the cover can follow all pivoting and turning motions.
In FIGS. 8 and 9 the arrangement of a setting angle (50) between the water outlet (5) and the connection piece is also shown as an embodiment example. The sectioned drawing in FIG. 9 shows the water outlet with inserted connection piece (46) which has a segmented slot (68) in which the screw provided as a dog (49) is freely rotatable in a setting angle before it takes with it the connection piece (46) in a form-locking fashion.
FIG. 10 shows schematically the arrangement of a spring detent (51) which is free in the area of the slot (48) but which runs out on the edge of the slot (48) before reaching the end-position. Depending on the strength of the spring fitted (69a) one can adjust the force required to overide the detent. This "economy" position is new and will be highly regarded. This example is also only to be understood as schematic and many other practical solutions are possible.
In FIGS. 8 and 9 the advantages of a tilting of the main axis (53) about approximately half of the pivot angle (44) can be clearly recognised. Thus, the main axis may be vertical or almost vertical. Firstly in FIG. 8 in the case of a completely open setting the axis of the connection piece (46) is approximately vertical and the water outlet is pivoted in an approximately horizontal plane which substantially contributes to ease of use. FIGS. 11-15 show that the slideable part (40) in this embodiment of the invention has two degrees of freedom of movement, namely a linear degree of freedom, as shown in FIGS. 11-12, and a rotational degree of freedom, as shown in FIGS. 13 and 14. Here all internal parts are symmetrical to the main axis (53) particularly the slot (48) which also determines the position of the cover (52) and the O-rings (70)- A host of other advantages can be taken from the illustrated embodiment example.
FIGS. 15 to 22 show schematic embodiment examples of units in accordance with the invention in which parts having the same function are, where possible, identified with the same index numbers in the main and additional applications.
FIG. 15 shows an extremely simple asymmetric embodiment of a grip-less mixer unit with plate seals as regulating elements for water quantity and temperature.
The water outlet (5) is, in this case, fitted onto a connection piece (46) and connected to it in a form-locking fashion. The water outlet (5) can be pivoted about the horizontal pivot axis (42) by the connection piece (46) that is set into the pivot housing (82).
The connection piece (46) is drilled axially from one side and conducts the mixed water through this central drilling (83) to the real water outlet (5) as shown in FIG. 19.
In a partial area the connection piece (46) is formed as an eccentric cam (71), of which however, only a crescent-shaped segment is recognisable in the sections FIG. 17 and FIG. 20 because of the central drilling (83).
The double fork (57) of the transmission element (43) to which the moveable part (40) is connected, surrounds the eccentric cam (71) and is slid into the rectangular cut-out (84) by turning the connection piece (46). This also slides the moveable part (40) in relation to part (41). This causes, in a known way, by an arrangement of the openings in the parts (40) and (41), as shown for example in FIG. 18, an asymmetric condition and therewith a differing coverage of the openings (61)(62) and/or (66)(67). The subsequent contra-rotating change of section ultimately determines the water temperature.
A pivoting movement of the water outlet (5) about the horizontal axis (42) is likewise transmitted from the rectangular cut-out (84) to the transmission element (43) and thereby to the part (40) which this time, however, leads to a rotation about the pivot axis (42) and through this to a similar section change in the coverage of the openings (61)(62). This means a decrease or increase of the water quantity outflow at an unaltered section ratio, i.e. at an unchanged temperature. Naturally any required regular characteristics can be set by different shaping of the openings (61)(62) and/or (66)(67) and their relative positions, FIG. 21 shows only one example.
The spring detent (51) shown in FIG. 15 as a spring-loaded ball is essential. It has the task of locating the position of the pivot motion of the pivot housing (82) about the axis (42) and thus the water outlet (5) connected to it into, for example, the half open position. In this way it is possible to define a so-called "economy" position. With somewhat stronger pressure one can overide the detent to obtain the required water quantity.
It remains to mention that the pivot body (82) in the valve body (1) is fixed by, for example, a screw (85) which runs in a segment slot (86) whose length limits the pivot angle about the axis (42).
The retainer (87) of the fixed part (41) is rigidly secured against rotation to the valve body (1) by means of, for example, a pin (88). The O-rings (70) serve to seal the individual components relative to each other. It can be seen here that it is possible to place all O-rings (89) on the pressure side, i.e. in front of the ceramic seal to form static seals. The remaining O-rings (70) which are moveable, i.e. used as dynamic seals, are located on the side of the open water outlet and are therefore not highly pressurized.
In FIGS. 19 to 23 another variant of a unit according to the invention is shown, this time with a symmetric arrangement of the component parts. The right regulating system is similarly constructed to that in FIG. 15, however, the water supply to the fixed part (41) from the cold and hot water supplies (2) and (3) is achieved through an adaptor (90) with internal channels (92)(93). The adaptor (90) can be simply produced from, for example, two plastic parts welded together. The complete regulating system is sealed on the outside by means of a screw-in plate (91) together with its O-ring (70). The transmission of the pivot movement of the water outlet (5) to the moveable parts (40) and (41) is achieved in the same way as for FIGS. 15 to 17.
The position, according to the invention, of the plane of the sealing surfaces vertical to pivot axis (42) enables the attachment of two further moveing parts (75) and (76) which select a second, rigid water outlet (79) but which is likewise operated by the pivot action of the water outlet (5). The arrangement can be of symmetrical construction as shown in FIGS. 19 and 20.
As no temperature or quantity regulation is necessary for such a safety shut-off, the operation can be achieved by a simple turning motion in the axis (80) which directly follows the pivot movement of the water outlet (5) about the axis (42). Simple cams (95) are provided in the pivot housing (82) which rotate the part (41) and turn against part (76).
FIG. 22 shows an example arrangement of the openings (96) and (97) in part (76) and the recessed cut-out (74) in part (75). In the illustrated position (fully turned on) the openings (96)(97) are covered by the outlines of the cut-out (74) and the water can flow from the inlet (78) through the opening (96) in the cut-out (74) and again through opening (97) to the outlet (79).
If the water outlet (5) is pivoted to the extreme upper 75° position, the cut-out (74) rotates to the dotted position and the water flow is cut off. For this construction and position of the openings and cut-outs other variants are possible where it is, for example, not necessary to close two openings (96) and (97).
Attention is particularly drawn to the simple supply of cold and hot water from the base of the valve body (1) to both regulating elements. A single adaptor (90) is sufficient to connect these systems. The O-rings (89) used to seal are only statically loaded.
For this arrangement according to the invention a spring detent is also recommended, as that in example FIG. 15, which, for example, marks the shut-off of the water system. The comments concerning the setting angle are also valid here. Numerous combinations and variants of the solutions only schematically shown in both examples are possible in accordance with the invention.
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A mixer-unit is attached to the cold and hot water mains and serves to adjust the quantity and temperature of the water. The mixer unit is not fitted with an operating handle or lever, the adjustment of the water quantity and temperature is achieved by pivoting the water outlet about two independent axes of movement. Disc-shaped regulating elements serve for the independent adjustment of both the water quantity and temperature which are operable by means of a cam connected to the rotatable and pivotable water outlet.
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This is a continuation of application Ser. No. 08/102,929 filed Aug. 6, 1993, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to nozzles for providing fine atomization of liquids expelled therethrough, and more particularly to nozzles used for atomizing fuel before injection into an internal combustion engine.
2. Prior Art
Stringent emission standards for internal combustion engines suggest the use of advanced fuel metering techniques that provide extremely small fuel droplets. The fine atomization of the fuel not only improves emission quality of the exhaust, but also improves the cold start capabilities, fuel consumption and performance.
Smaller fuel droplets generally are dispersed over a larger area and therefore have greater volumes of surrounding air as required to complete the combustion process. Smaller fuel droplets also promote a more homogeneous mixture of fuel and air, which in turn provides a faster, more complete combustion process. This improved combustion process reduces hydrocarbon (HC) and carbon monoxide (CO) emissions which are generally caused by localized high fuel to air ratios resulting from heterogeneous injector sprays.
Also, under cold start conditions, smaller fuel droplets allow the use of smaller quantities of fuel in the cold start procedure, thereby greatly reducing the HC and CO emissions. If the fuel can be made to vaporize more quickly, the air/fuel mixture favorable for ignition will develop more quickly and the engine will start sooner, thereby reducing the uncombusted and incompletely combusted fuel/air mixture.
As an example of micromachined devices that are used for atomizing liquids, U.S. Pat. No. 4,828,184 discloses the use of silicon plates having openings for metering the fuel flow. A first opening in a first silicon plate is offset from a second opening in a second silicon plate juxtaposed with the first silicon plate. The area between the first and second openings has a reduced thickness so as to form a shear gap for accelerating the flow of the fuel through opposing shear gaps in a direction substantially parallel to plane of the first and second plates. Such shear flow causes turbulence and fluid dispersion advantages for atomizing the fuel before it is propelled into the combustion chamber of an internal combustion engine.
SUMMARY OF THE INVENTION
A method for improving the atomization quality from a fluid injector, includes the steps of inducing a first turbulence in the fluid flowing past a first protrusion in a supply orifice having a flow axis therein, guiding the fluid through a turbulence cavity and then out through a first metering orifice having another protrusion positioned downstream from the first protrusion by a distance y measured generally parallel to the flow axis and by a distance x measured generally perpendicular to the flow axis, and minimizing the droplet size of the fluid exiting from the metering orifice by maintaining the x/y ratio greater than 0.5. A second turbulence may be induced in the fluid adjacent the metering orifice for enhancing the atomization of the fluid.
A fuel injector nozzle practicing this process includes a supply plate having an input orifice that includes a first turbulence generator adjacent a downstream section of the supply orifice. A metering plate is provided downstream from the supply plate and includes at least one metering orifice for regulating the flow of the atomized fuel therethrough. The metering plate also includes a second turbulence generator adjacent an upstream section for interacting with the turbulent fuel downstream of the first turbulence generator. The mean diameter of the atomized fuel is minimized when the lateral offset of the turbulence generators in the supply orifice and the metering orifice is at least greater than half the vertical offset between the two turbulence generators.
A nozzle in accordance with the present invention may be fabricated using silicon micromachine, selective metal etching, or conventional metal machining techniques and produces a fluid flow of high velocity, and relatively small diameter fuel droplets.
It is therefore a primary object of the present invention to define a structure and process that will introduce turbulent flow at the optimum location in an atomizing nozzle so as to minimize the size of atomized droplets of liquid.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the present invention will be apparent from studying the written description and the drawings in which:
FIG. 1 illustrates a simplified frontal cross-section view of an automotive fuel injector of the type that may be used in conjunction with the present invention.
FIG. 2 illustrates a frontal sectioned view of a first preferred embodiment of the injector nozzle in accordance with the present invention. FIGS. 2a, 2b and 2c illustrate the top, frontal sectioned, and bottom views of the nozzle of FIG. 2.
FIG. 3 illustrates an alternate embodiment having a different height for the turbulent cavity in the nozzle in accordance with the present invention.
FIG. 4 illustrates an alternate, non-preferred embodiment of the nozzle in accordance with the present invention.
FIG. 5 illustrates a simplified hypothetical representation of possible fluid flow lines showing turbulence and eddies within the fuel injector and nozzle in accordance with the present invention.
FIG. 6 is a graphical representation of the Sauter Mean Diameter (SMD) of the injector spray fuel droplets as a function of the x-y variables. The x value is a variable which is varied from -200 to +300 μm for each of the three different y values.
FIGS. 7 is a graphical representation of the cone angle of the injector spray fuel droplets as a function of the x-y variables. The x value is a variable which is varied from -200 to +300 μm for each of the three different y values.
FIGS. 8 is a graphical representation of the cone angle of the injector spray fuel droplets as a function of the x-y variables. The x value is a variable which is varied from -200 to +300 μm for each of the three different y values.
BACKGROUND TECHNICAL DISCUSSION
It is well known that supplying energy to a fluid may improve the atomization of liquid jets flowing from an exhaust orifice. Energy may be added by several well known means, including ultrasonic, heat, pumped air, laser, etc. In contrast to these prior art teachings, the present invention introduces energy into the liquid through the development of turbulent eddies upstream of the orifice plate in the tip of the fuel injector.
A turbulent flow condition in a fluid flowing through a confined area can be created in three possible ways. First, the rapid fluid flow past a solid wall can lead to unstable, self-amplifying velocity fluctuations. These fluctuations form near the wall and then spread into the remainder of the internal fluid flow or stream. Second, velocity gradients between a fast moving fluid stream and a slow moving fluid stream can produce turbulent eddies. Third, fluid flow past a solid body or sharp angularity in the internal flow causes eddies to set-up in the wake of the body. This is the primary mechanism which will be implemented in the present invention.
In such cases turbulent flow arises from some instability which is present in laminar flows at high Reynolds Numbers. The transition to turbulence is usually initiated by an instability which is two dimensional in simple cases. These two dimensional instabilities produce secondary motions, not parallel to the mean fluid flow, which are three dimensional and also unstable. These three dimensional instabilities are formed locally and when several local three dimensional instabilities interact, a large turbulent field is produced.
Fluids flowing past a solid object that produces turbulence can be described with regard to-several common characteristics. Turbulent flows are very random and irregular. Turbulent flows exhibit diffusivity of turbulence which promotes mixing, and increases momentum, heat and mass transfer rates. A flow is not turbulent unless velocity fluctuations are present throughout the field. Turbulent flows usually originate due to some instability in laminar flow, but turbulent flows are always created at high Reynolds Numbers. Turbulence is both three dimensional and rotational, therefore creating vortices. Vortex stretching is the phenomenon which causes turbulence to be three dimensional. Without vortex stretching, there would be no fluctuation of the eddies and the eddies would therefore be two dimensional and non-turbulent.
Kinetic energy of the turbulent flow dissipates into internal energy contained in the fluid due to the viscous shear stresses on the fluid. For this reason, turbulence cannot sustain itself and needs a continual supply of external energy to maintain structure. Large eddies are located in the center of the flow. These large eddies turn into small eddies as the wall is approached, and kinetic energy of the smaller eddies is dissipated into thermal energy at the wall. Turbulent flow is a continuum, wherein no section of the turbulent flow can be readily distinguished from its neighboring section.
When fluid flows in a pipe under turbulent conditions, smaller eddies form near the wall due to strong velocity gradients tearing the fluid. Vortex shedding at angularities (sharp corners) can induce strong eddie currents at Reynolds Numbers as low as 300-400. The sharpness of these angularities is very important, since eddies are shed much more readily from sharp corners then from smooth ones. Sharp corners having included angles of approximately 90 degrees or less are preferred.
The present invention will utilize these physical phenomenon relating to turbulence generators in order to induce additional energy into fluid flowing past a protruding object. The energy introduced in the fluid will be isolated and then utilized in order to promote the fine atomization of the fluid as it is metered and then ejected from an orifice.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A simplified fuel injector element is illustrated in FIG. 1 and designated by the reference numeral 100. The fuel injector includes a nozzle element that comprises an orifice plate or metering plate 12 attached to a turbulence generator 14, both of which are compressed between the injector body 16 and a flow element tip washer 18. In turn, these elements are compressed between a flow element tip 20 and a injector body 16. A circumferential washer 22 seals the flow element tip washer 18 to the flow tip 20, and the injector body 16 is restrained within the flow element 26. The injector illustrated in FIG. 1 is a test fixture utilized to simulate an actual nozzle and fluid flow therefrom. While the illustrated test fixture was used in the development Of the present invention and the data presented herein, other fuel injector designs may be used in production embodiments. For example, the test fixture form of the fuel injector element 30 is illustrated as having a truncated distended end 31, which may or may not be used in a production embodiment.
As illustrated in FIG. 2, a first preferred embodiment the nozzle element 110 comprises a turbulence generator plate 140 and an exhaust orifice plate or metering plate 120. The compound silicon micromachined orifice plates can be manufactured from silicon wafers using well known semiconductor processing techniques, with one plate being bonded to the top of the other. The top silicon orifice plate mimics the turbulence generator 14 and the bottom silicon orifice plate mimics the metering plate 12. FIG. 2a illustrates a top view and FIG. 2c illustrates a bottom view of the nozzle shown in FIG. 2 and 2b. Even though the supply and metering orifices illustrated in FIGS. 2a, 2b and 2c are shown as being rectangular, they may also have other shapes without departing from the basic teachings of the present invention.
While the preferred embodiment of the present invention has been illustrated as being constructed from silicon wafers, the invention may also be constructed of various metal plates, including stainless steel and various laminate materials having differential etch rates (e.g. copper-nickel, nickel-stainless), without departing from the teachings of the invention. However, the silicon construction is preferred because of the processing capability to maintain 10 micron alignment accuracy and to achieve sharp acute angles at the edges of the operative orifices.
FIG. 3 illustrates another preferred embodiment of the compound orifice plate having different x and y dimensions as compared with the plate illustrated in FIG. 2. In FIG. 3 the position of the corner turbulence generator 142 is moved between positions a, b and c to illustrate the x variable adjustment in accordance with the present invention. The importance of the x and y dimensions for each of the elements in the plate will be discussed subsequently.
With reference to FIG. 2, turbulent eddies may be formed in a turbulence cavity 160 defined between the metering plate 120 and the turbulence generator plate 140 due to the acute edges 141 and 142 on the turbulence generator plate 140. These eddies greatly aid in the breaking up of the liquid into droplets. With additional reference to FIG. 5, the location of the eddies is critical in the atomization process of the liquid. If the eddie E1 can be forced to reside directly above the metering orifice 124 in the metering plate 120, the atomization should be greatly enhanced. As the size of the turbulence generator orifice 144 increases, the edge 141 of the orifice will approach the edge of the metering orifice 124 (or 134) in the metering plate 120.
As illustrated in FIG. 3, as the effective diameter of the turbulence generator orifice 144 increases from positions a to b to c, the edge 142 of the orifice 144 approaches the center of the exhaust orifice 134 in the metering plate 120. In this manner the eddie E2 as illustrated in FIG. 5 is moved outwardly from the supply orifice 144. At some point the eddie E2 is no longer above the metering orifice 134 in the lower metering plate 120. It is this relationship between the two orifices 144 and 134 (or 144 and 124) and the location of the resultant eddies E1 and E2 that determines the SMD of the spray droplets.
The creation of turbulence in the turbulence cavity 160 upstream of the metering plate 120 results in a dramatic improvement, that is a significant reduction, in the SMD of the spray emitted from the exhaust or metering orifices 124 and 134. A high Reynolds Number is not necessary to achieve good atomization. However, the flow must not be overly restricted, thereby creating a very low Reynolds Number, since the restricted flow does not result in a lower SNID.
Of the turbulence generators tested, the. single orifice generators were the most effective because they did not restrict the flow of fluid as much as a multiple orifice generator at the same flow rate capability. This geometry results in a higher fluid velocity and more energy contained in the eddies. The location of the eddies, as previously discussed, is critical in that if the eddies are placed outside of the metering orifices in the lower plate, the SMD of the atomized fluid droplets tends to increase.
With reference to FIGS. 2 and 3, the dimension x is defined as the horizontal distance between the acute angled edge 141 (or 142) of the supply orifice 144 in the upper plate 140 and the acute angle edge 121 (or 122) of the corresponding exhaust or metering orifice 124 (or 134) in the lower metering plate 120. While both edges are illustrated with the preferred acute angle, the principles of the present invention also work well with edges up to and including an included angle of approximately 90 degrees, as long as the edge is designed to create an effective eddy within the downstream section of the flow.
The y dimension is defined as the gap height of the turbulence cavity 160 defined between the upper orifice plate 140 and the lower metering plate 120. When the edge 141 of the upper orifice 144 lines up directly with the edge 121 of the exhaust orifice 124 in the metering plate 120, the x/y ratio will equal zero. As the supply orifice 144 in the upper plate 140 is reduced in size, the edge 141 moves inwardly, and the x/y ratio becomes more positive. As the supply orifice 144 in the upper plate 140 becomes larger, the outer edge 141 moves outwardly (away from a central axis of the injector), and after the x dimension passes below zero the x/y ratio becomes negative. FIG. 4 illustrates the position of the edges 121 and 141 in a non-preferred embodiment of a nozzle having a negative x/y ratio.
Given this definition of the x/y ratio, measurements can be taken along the center line of the supply orifice 144, approximately three inches downstream from the injector tip. With the fuel pressure remaining constant at 40 psi, and with a constant Stoddard fluid temperature of 70° F., the plot of FIG. 6 illustrates the Sauter Mean Diameter (SMD) of the injector spray as a function of the x/y ratio. As can be seen, as the x/y ratio increases from -2 toward 0.5, the resulting SMD of the spray decreases. The SMD decreases dramatically up to an x/y ratio value of 0.5, and then no significant improvement is apparent for x/y ratios beyond 0.5. Therefore, in order to create the optimum or smallest atomization for given aperture sizes, the relative separation distance between the supply orifice 144 in the upper plate 144 and the exhaust orifice 124 (and 134) in the lower metering plate 120 should be at least one-half the gap height.
This result is predicted from the hypothetical discussion of the location of the eddies as previously discussed. At x/y equals 0.5, the eddies E1 and E2 which were created by the sharp corners 141 and 142 in the upper orifice 144 are located in the optimal position above the metering orifices 124 and 134 in the lower metering plate 120 as illustrated more clearly in FIG. 5. This results in the lower SMD of the spray shown in FIG. 6. As the sharp corner 141 of the upper orifice 144 is moved outside of the metering orifice 124 in the lower plate 120, that is in a negative y direction, the eddie E1 becomes less effective and the atomization size of the resulting droplets increases. As a result of experimentation, the optimum orifice plate geometry was produced with an SMD of 53 microns, a flow rate of 6.37 liters per hour, producing a cone angle of 41° with an x/y ratio of 4.0. This SMD of 53 microns is approximately 62% smaller than the SMD produced by a base line SMM injector (approximately 140 microns).
Another visible trend in FIG. 6 is that of the gap height y in relation to the SMD of the spray. As the gap height y decreases, the SMD decreases for a given value of the x/y ratio. If this result is extrapolated, then the smaller the gap height y becomes, the smaller the SMD of spray will become. This may be explained in one of several ways. First, the exhaust droplets may become smaller because they are being forced through a smaller opening, thus creating shear forces on a larger surface area of the fluid. Another explanation may be that the eddies which are formed by the sharp corners of the supply orifice are being moved closer to the exhaust orifices in the metering plate, causing more random motion immediately above the metering orifices. This would put more energy into the fluid immediately above the exhaust orifices, which in turn provides a better atomization of the liquid.
In general terms, it may be concluded that as the x/y ratio increases, the flow rate generally decreases. As the x/y ratio increases, an increased restriction to the flow of the fluid results. When the x/y ratio is highly negative, the supply orifice in the upper plate completely exposes the exhaust orifices in the lower metering plate, thus causing no restriction to the fluid flow. As the x/y ratio increases further, the supply orifice size is reduced for a constant gap height, and the exhaust orifices in the metering plate begin to be covered up so that the fluid must turn a sharp corner as it exits the metering orifices in the lower plate. Therefore, as the x/y ratio increases, the flow rate decreases.
FIG. 7 is a plot of the cone angle, which is defined aS the angle of the spray with respect to the axis of the supply orifice, for the injector spray versus the x/y ratio. The trends are similar for all of the curves for the selected test geometry. As the x/y ratio increases, the cone angle of the spray from the metering orifice also increases. This can be explained by the fluid turning the sharp corner of the supply orifice in the upper plate. When the x/y ratio is highly negative, the exhaust orifices in the metering plate are completely exposed to fluid and the fluid may flow directly through the metering orifices. All of the motion then is in the vertical direction through both orifices. However, as the x/y ratio becomes more positive and the flow is restricted, the fluid must turn the corner in the supply orifice, thus producing fluid momentum in the horizontal direction. It is this horizontal momentum that creates the enlarged cone angle. As with the droplet size curve shown in FIG. 6, the cone angle appears to reach a maximum at an x/y ratio approximating 0.5, and remains relatively constant as the x/y ratio increases beyond this value.
With continuing reference to FIG. 7, it is apparent that the cone angle changes as a function of the height y of the turbulence cavity. However, the cone angle does change as a function of the gap height y. FIG. 8 is a plot of cone angle of the injector spray versus the SMD of the spray. It is apparent that as the cone angle is reduced, the SMD of the spray increases. As the cone angle is reduced by increasing the size of the supply orifice in the upper plate, thereby causing the x/y ratio to become more negative, the SMD of the spray becomes larger. Therefore, as a general rule, as the cone angle increases, the size of the droplets in the spray decreases. This corresponds to the fluid being spread over a larger area.
It is also apparent that as the fuel pressure increases, the droplet size decreases. This is predictable since more energy is being forced into the liquid, creating higher velocities and therefore high viscous shear forces, which provides more energy to break up the liquid and enhance the atomization.
Under dynamic pulsing conditions similar to those actually encountered in the operation of an internal combustion engine, it can be observed that the SMD of the fluid droplets is smaller in all sections of the spray pulse. The distribution of the droplets within the pulse is also much more uniform when utilizing the geometries illustrated in FIGS. 2 and 3.
Therefore, the x/y ratio parameter is a key design parameter for the compound orifice plate nozzle. As long as the x/y ratio equals or exceeds 0.5, the exhaust spray will exhibit the minimum Sauter Mean Diameter, with minimal variation in cone angle and an adequate flow rate. If smaller cone angle is desired, a compound orifice plate having a 200 micron gap can deliver relatively small droplets in the 80 micron range with a 15°-23° cone angle.
While the supply and metering orifices have been illustrated and discussed as having generally square shapes in the preferred embodiments, similar results can be obtained using orifices having other shapes, such as rectangular, parallelogram, circular, elliptical, etc., without departing from the teachings of the present invention. The exact measurement of the x and y dimensions and the optimum x/y ratio may change slightly depending on the exact shapes and sizes of the orifices.
While particular embodiments of the invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the invention, and it is intended to cover in the appended claims all such modifications and equivalents of fall within the true spirit and scope of this invention.
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A method for improving the atomization quality from a fluid injector includes the steps of inducing a first vortex turbulence in the fluid flowing past a first protrusion in a supply orifice having a flow axis therein, guiding the fluid through a turbulence cavity and then out through a first metering orifice having another protrusion positioned downstream from the first protrusion by a distance y measured generally parallel to the flow axis and by a distance x measured generally perpendicular to the flow axis. The droplet size of the fluid exiting from the metering orifice is reduced by sizing the x and y dimensions to position the first vortex turbulence within the turbulence cavity operatively adjacent to and upstream from the first metering orifice. In a preferred embodiment, the ratio of x/y is greater than 0.5 and less than 5. A fuel injector nozzle practicing this process is also provided.
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FIELD OF THE INVENTION
The present application relates to the mechanical field, specifically to an engine brake device, and particularly to a mechanical linkage engine brake device.
BACKGROUND OF THE INVENTION
It is well known in the prior art to use an internal combustion engine as a brake means by converting the engine temporarily to an air compressor. The conversion starts by cutting off the provision of the fuel, opening the exhaust valve(s) at or near the end of the compression stroke of the engine piston, and allowing the compressed gases (air during braking) to be released. The energy absorbed by the compressed gas during the compression stroke of the engine can not be transmitted to the engine piston through the subsequent expansion stroke, but is dissipated by the exhaust and cooling systems of the engine, resulting in an effective engine braking. Thereby the vehicle is slowed down.
An example of the engine brake device is disclosed in U.S. Pat. No. 3,220,392 by Cummins, and an engine brake system based on the patent has achieved a great commercial success. However, this kind of engine brake system is a bolt-on accessory mounted at the top of the engine. In order to mount this kind of brake system, a spacer is additionally provided between the cylinder head and the valve cover, which adds unnecessary height, weight and costs to the engine. The above problems occur due to the fact that the engine brake system is employed as an accessory to, rather than an integrated part of, the engine.
The prior engine brake transmits the mechanical input to the exhaust valve(s) to be opened through a hydraulic circuit. A master piston reciprocating in a master piston bore is located in the hydraulic circuit. The reciprocating motion is provided by the mechanical input of the engine, such as the rocking of the injector rocker arm. The motion of the master piston is transmitted, through hydraulic fluid, to a slave piston located in the hydraulic circuit, causing the slave piston to reciprocate in a slave piston bore. The slave piston acts, directly or indirectly, on the exhaust valve(s), generating the valve event for the engine braking operation.
Therefore, the conventional hydraulic-driven engine brake has another drawback due to the compliance or deformable of the hydraulic system, which is relevant to the flexibility of the fluid. High flexibility of the fluid greatly reduces the brake valve lift. The reduction of the brake valve lift leads to the increase of the braking load, which in turn causes a higher flexibility, thereby forming a vicious circle. In addition, the brake valve lift reduction caused by the hydraulic deformation increases with the increase of the engine speed, which is against the engine braking performance requirement that higher engine speed needs higher brake valve lift. In order to reduce the hydraulic flexibility, a large diameter hydraulic piston is needed, which increases the volume and weight as well as the time of oil refill or discharge for extending or retracting such a large diameter piston. That is to say, a large diameter hydraulic piston will increase the momentum of inertia and response time of the engine brake system.
SUMMARY OF THE INVENTION
The purpose of the present application is to provide a mechanical linkage engine brake device to solve the technical problems of the prior hydraulic-driven engine brake system, for example, the increased height and weight of the engine, the increased system complexity and inertia of the engine brake system, and the slow response of the engine brake system.
The mechanical linkage engine brake device according to the present application includes a brake housing, an actuation mechanism and a brake mechanism. The brake housing is provided therein with an upright blind bore and a horizontal blind bore perpendicularly intersecting the upright blind bore. The actuation mechanism includes a ball or an actuation piston, or a ball-piston combination. The brake mechanism includes a brake plunger. The ball, or the actuation piston, or the ball-piston combination is disposed in the horizontal blind bore. The brake plunger is disposed in the upright blind bore. The brake housing is provided therein with a fluid passage in communication with an entrance of the horizontal blind bore. An outer diameter of the ball or the actuation piston, or an outer diameter of the ball-piston combination matches an inner diameter of the horizontal blind bore. The brake plunger has an upper limit position and a lower limit position in the upright blind bore. In the upper limit position, a top of the brake plunger stands in the horizontal blind bore; and in the lower limit position, the top of the brake plunger stands outside of the horizontal blind bore.
Further, the actuation mechanism includes a return spring, which has one end acting on the brake housing and the other end acting on the actuation piston or on the ball-piston combination.
Further, a liquid seal is formed between the actuation piston and the horizontal blind bore.
Further, the actuation mechanism further includes a ball. One side of the ball is in contact with the actuation piston, while the other side of the ball is in contact with the return spring.
Further, the actuation mechanism includes a return piston. The return piston is disposed in the horizontal blind bore and is pressed against the ball by the return spring. A liquid seal is formed between the return piston and the horizontal blind bore.
Further, the return piston has a decompression and bleeding orifice communicating with the horizontal blind bore and a space outside the brake housing.
Further, the actuation mechanism includes two return springs provided in the horizontal blind bore, and the two return springs are arranged at opposite sides of the ball.
Further, the upright blind bore is provided therein with a brake spring, the brake spring being provided between a lower end of the brake plunger and the brake housing.
Further, a position limiter is provided between the brake plunger and the upright blind bore.
Further, the position limiter includes a groove and a stop pin, wherein the groove is formed in a central portion of an outer surface of the brake plunger and is extended axially, the stop pin is fixedly provided in a middle portion of an inner wall of the upright blind bore. A length of the groove is larger than a diameter of the stop pin, and the stop pin is located in the groove.
Further, an upper end of the brake plunger is provided with a brake transition surface and a brake bearing surface. Each of the brake transition surface and the brake bearing surface is a flat surface including a stepped surface and an inclined surface, or a conical surface, or an arc surface, or a cylindrical surface, or a spherical surface, or a combination of two or more of the above-mentioned surfaces.
Further, one end of the actuation piston is provided with a brake actuation surface. The brake actuation surface is a flat surface including an inclined surface, or a conical surface, or an arc surface, or a cylindrical surface, or a spherical surface, or a combination of two or more of the above-mentioned surfaces.
Further, the brake housing includes at least one of the following:
a dedicated bolt-on brake housing, a dedicated brake rocker arm, an engine exhaust rocker arm, and an engine valve bridge.
The operation principle of the present application is: when it needs to convert the state of the engine from the normal operation to the engine braking operation, the engine brake controller is turned on to supply oil to the fluid passage in the brake housing through a brake fluid passage. The actuation piston or the ball is pushed, overcoming the actions of the returning spring and the braking spring, to the right along the horizontal blind bore under the pressure of the oil, such that the brake plunger is moved downwards in the upright blind bore. Thereby the engine brake is switched from the inoperative position to the operative position, and the engine is converted from the normal operation to the engine braking operation. When it does not need the engine braking operation, the engine brake controller is turned off to drain the oil, such that no oil pressure is applied to the actuation piston or the ball, thereby the actuation piston or the ball is moved to the left under the action of the return spring until the actuation piston is stopped against the left end surface of the horizontal blind bore. The brake plunger is moved upwards in the upright blind bore under the force of the brake spring. The engine brake is switched from the operative position to the inoperative position, and the engine is free of the influence of the engine brake and can operate normally.
The present application has many advantageous technical effects over the prior art. The present application does not employ a hydraulic brake control valve, which simplifies the design, reduces the cost and the braking response time. The present application does not employ liquid to carry the braking load, and therefore can avoid problems, such as leakage, deformation or load fluctuation caused by high oil pressure and temperature. The brake valve lift can be designed with a smaller value because it is not affected by oil temperature, oil pressure and air content in oil, which allows a smaller clearance between the engine piston and valve. Also the mechanical linkage engine brake device of the present application can be integrated into the engine to reduce the height, the size and the weight of the engine brake.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a first embodiment of the present application at the “off” position;
FIG. 2 is a schematic diagram of the first embodiment of the present application at the “on” position;
FIG. 3 is a schematic diagram of a second embodiment of the present application at the “off” position;
FIG. 4 is a schematic diagram of the second embodiment of the present application at the “on” position;
FIG. 5 is a schematic diagram of a third embodiment of the present application at the “off” position;
FIG. 6 is a schematic diagram of the third embodiment of the present application at the “on” position;
FIG. 7 is a schematic diagram of a fourth embodiment of the present application at the “off” position;
FIG. 8 is a schematic diagram of the fourth embodiment of the present application at the “on” position;
FIG. 9 is a schematic diagram of an application of the fourth embodiment of the present application;
FIG. 10 is a schematic diagram of a fifth embodiment of the present application at the “off” position;
FIG. 11 is a schematic diagram of the fifth embodiment of the present application at the “on” position;
FIG. 12 is a schematic diagram of a sixth embodiment of the present application at the “off” position; and
FIG. 13 is a schematic diagram of the sixth embodiment of the present application at the “on” position.
DETAILED DESCRIPTION
First Embodiment
As shown in FIG. 1 and FIG. 2 , the mechanical linkage engine brake device 100 according to the present application includes a brake housing 2102 , an actuation mechanism and a brake mechanism. The brake housing 2102 is provided therein with an upright blind bore 190 and a horizontal blind bore 260 that intersect each other. The actuation mechanism includes an actuation piston 164 and a ball 175 . The actuation piston 164 and the horizontal blind bore 260 form a liquid seal. One end of the actuation piston is in contact with the ball to form a linkage. The brake mechanism includes a brake plunger 160 . As shown in FIG. 1 , the actuation piston 164 and the ball 175 are disposed in the horizontal blind bore 260 in the brake housing 2102 , and are pushed to the left by a return spring 156 to thereby abut against the end surface 246 of the piston bore 260 at normal state. One end of the return spring 156 is on the ball 175 of the actuation mechanism while the other end thereof is on the spring seat 158 . The spring seat 158 is positioned by a retaining ring 157 fixedly connected on the brake housing 2102 . The spring seat 158 has a venting hole 168 . The brake plunger 160 is disposed in the upright blind bore 190 in the brake housing 2102 . The upper end of the brake plunger has a brake transition surface 126 and a brake bearing surface 128 . The brake transition surface 126 is a conical surface but may also be a flat surface (including a stepped surface and an inclined surface), or an arc surface, or a cylindrical surface, or a spherical surface, or a combination of two or more of the above-mentioned surfaces. Similarly, the brake bearing surface 128 may be a flat surface (including a stepped plane and an inclined plane), or a conical surface, or an arc surface, or a cylindrical surface, or a spherical surface, or a combination of two or more of the above-mentioned surfaces. One end of a brake spring 177 is provided at the lower end of the brake plunger 160 , while the other end thereof is fixedly connected on the brake housing 2102 by a screw 179 . As shown in FIG. 1 , under the action of the spring 177 , the brake transition surface 126 of the brake plunger 160 is stopped against the lower right side of the ball 175 .
The brake mechanism further includes a position limiter for the brake plunger 160 , including a stop pin 142 fixedly provided in the brake housing and a groove 137 in the brake plunger 160 . The position limiter may also be formed in other ways, such as by using stepped surfaces.
The work process of the present embodiment is as follows: when it needs to convert the state of the engine from the normal operation ( FIG. 1 ) to the engine braking operation ( FIG. 2 ), an engine brake controller (not shown) is turned on to supply oil to the actuation mechanism of the mechanical linkage engine brake device 100 through a braking fluid passage including a fluid passage 214 in the brake housing 2102 . The actuation piston 164 and the ball 175 are pushed, overcoming the force of the return spring 156 , to the right under the pressure of the oil. The ball 175 is pushed to press the brake transition surface 126 on the upper end of the brake plunger 160 to overcome the action of the brake spring 177 , such that the brake plunger 160 is pushed downwards along the upright blind bore 190 from an inoperative position to an operative position. At the same time, the ball 175 is moved from the brake transition surface 126 to the brake bearing surface 128 at the upper end of the brake plunger 160 ( FIG. 2 ).
When it does not need the engine braking operation, the engine brake controller is turned off to drain the oil, such that no oil pressure is applied to the actuation piston 164 and the ball 175 , thereby the actuation piston 164 and the ball 175 are moved to the left under the force of the return spring 156 and are stopped against the left end surface 246 of the horizontal blind bore 260 . The brake plunger 160 is pushed, under the force of the brake spring 177 , upwards in the upright blind bore 190 , such that the brake transition surface 126 at the upper end is stopped against the lower right side of the ball 175 . Thereby the brake plunger is back to the inoperative position ( FIG. 1 ), and the engine is free from the influence of the brake plunger and can operate normally.
Second Embodiment
As shown in FIG. 3 and FIG. 4 , the second embodiment is a variation of the first embodiment. The actuation piston 164 and the ball 175 in the first embodiment are combined into one body. The left part of the body is part of the actuation piston 164 that provides guide and seal, while the right part of the body is the actuation surface 163 of a spherical shape (which may also be a cone surface or other surfaces).
Third Embodiment
As shown in FIG. 5 and FIG. 6 , the third embodiment is also a variation of the first embodiment. Compared with the first embodiment, the actuation piston in the first embodiment is eliminated, and a return piston 162 that forms a liquid seal with the horizontal blind bore 260 is further provided. The return piston 162 is provided with a decompression hole 122 and a bleeding orifice 168 (which may also be a combined cone-shaped decompression and bleeding orifice). The return piston 162 functions together with the return spring 156 . The return spring 156 forces the return piston 162 against the ball 175 such that the decompression hole 122 is closed and to ensure that the ball 175 is always in close contact with the return piston 162 .
The present embodiment operates as follows: when it need to convert the state of the engine from the normal operation (see FIG. 5 ) to the engine braking operation ( FIG. 6 ), the engine brake controller (not shown) is turned on to supply oil to the actuation mechanism of the engine brake device 100 through the brake fluid passage including the fluid passage 214 in the brake housing 2102 . The ball 175 is firstly pushed, overcoming the force of the return spring 156 , under the action of the oil. At the same time, the oil flow passes the ball (through the gap between the ball and the bore or an axial groove not shown in the Figure), and pushes, overcoming the force of the brake spring 177 , the brake plunger 160 downwards along the upright blind bore 190 . The maximum downward stroke of the brake plunger 160 is determined by the position limiter (the stop pin 142 and the groove 137 ). The ball 175 is pressed against the return piston 162 , and the two move together to the right until the return piston 162 is stopped by the spring seat 158 . At this point, the ball 175 is moved onto the brake bearing surface 128 on the top of the brake plunger 160 , and the brake plunger 160 is moved downwards to the operative position as shown in FIG. 6 .
When it does not need the engine braking operation, the engine brake controller is turned off to drain the oil such that no oil pressure is applied to the return piston 162 and the ball 175 , thereby the return piston 162 and the ball 175 are moved to the left by the return spring 156 and are stopped against the left end surface 246 of the horizontal blind bore 260 . The brake plunger 160 is moved upwards in the upright blind bore 190 by the brake spring 177 , such that the brake transition surface 126 at the upper end is stopped against the lower right side of the ball 175 . Thereby the brake plunger is back to the inoperative position ( FIG. 5 ) and is separated from the normal engine operation.
Fourth Embodiment
As shown in FIG. 7 , FIG. 8 and FIG. 9 , the present embodiment, compared with the third embodiment, only is further provided with a brake valve lash adjusting screw 1102 that is fixedly connected on the brake housing 2102 by a lock nut 1052 . The operation principle of the fourth embodiment is similar to that of the third embodiment.
FIG. 9 is a schematic diagram illustrating an application of the present embodiment. The brake housing 2102 of the engine brake device 100 is a dedicated brake rocker arm of a dedicated exhaust valve actuator 2002 for engine braking. The dedicated exhaust valve actuator 2002 further includes a brake cam 2302 , a cam follower 2352 and a rocker brake spring 1982 . The brake cam 2302 is merely provided, on the inner base circle 2252 thereof, with the small cam lobes 232 and 233 for engine braking.
The normal operation of the engine exhaust valves 300 is driven by an engine exhaust valve system or an engine exhaust valve actuator 200 . The exhaust valve actuator 200 includes many components, including a cam 230 , a cam follower 235 , a rocker arm 210 , a valve bridge 400 , and exhaust valves 300 . The exhaust valves 300 are biased, by engine valve springs 3101 and 3102 , against the valve seats 320 in the engine cylinder block 500 , to prevent gas flow between the engine cylinder and the exhaust manifold 600 . The rocker arm 210 is rotationally installed on the rocker shaft 205 , passing the motion of the cam 230 to the exhaust valves 300 for their cyclic opening and closing. The exhaust valve system may also include other components, such as a valve lash adjusting screw and an e-foot, etc., which are omitted herein for brevity. The cam 230 has a large cam lobe 220 on the inner base circle 225 thereof to produce the main valve lift profile for the normal engine operation.
When it needs to convert the state of the engine from the normal operation to the engine braking operation, the engine brake controller (not shown) is turned on to supply oil to the engine brake device 100 through the brake fluid passage that includes a fluid passage 211 and a radial hole 212 in the rocker arm shaft, a groove 213 and a fluid passage 214 in the rocker arm. The ball 175 together with the return piston 162 is pushed, overcoming the forces of the brake spring 177 on the brake plunger 160 and the return spring 156 successively, to the right under the action of the oil, such that the brake plunger 160 is moved from the retracted position (shown in FIG. 7 ) to the extended position (shown in FIG. 8 ). The stroke of the brake plunger eliminates the gap 132 between the brake plunger 160 and the brake rod 116 (shown in FIG. 9 ). The motion of the small cam lobes 232 and 233 of the brake cam 2302 is transmitted to the exhaust valve 3001 through the rocker arm 2102 , the brake valve lash adjusting screw 1102 , the ball 175 , the brake plunger 160 and the brake rod 116 , for engine braking.
When it does not need the engine braking operation, the engine brake controller is turned off to drain the oil, such that no oil is applied to the ball 175 and the return piston 162 , thereby the ball 175 and the return piston 162 are moved to the left under the action of the return spring 156 until the ball 175 is stopped against the end surface 246 of the horizontal blind bore 260 ( FIG. 7 ). The brake plunger 160 is moved upwards in the upright blind bore 190 to the inoperative position, forming the gap 132 with the brake rod 116 (shown in FIG. 9 ). Thereby the engine is free from the influence of the engine brake device 100 and can operate normally.
In addition to the dedicated brake rocker arm, the brake housing 2102 of the engine brake device 100 may be a dedicated bolt-on brake housing (box), the exhaust rocker arm of the engine, or the valve bridge of the engine.
Fifth Embodiment
As shown in FIG. 10 and FIG. 11 , the fifth embodiment is a variation of the third embodiment. The ball and the return piston are combined into one actuation piston. The right part of the actuation piston 164 functions as a guide and forms a liquid seal with the horizontal blind bore, while the left part is the actuation surface of a spherical shape (it may be of other shapes including a stepped surface, or an inclined surface, or a conical surface, or an arc surface, or a cylindrical surface, or a combination of two or more of the above-mentioned surfaces). The central part is a spherical surface 163 which may also be a conical surface. The operation principle of the present embodiment is similar to that of the third embodiment and detailed description thereof is omitted.
Sixth Embodiment
As shown in FIG. 12 and FIG. 13 , compared with the third embodiment, the sixth embodiment is additionally provided with a return spring 166 . One end of the return spring 166 is on the brake housing 2102 , while the other end thereof is on the ball 175 of the actuation mechanism. The force of the return spring 166 is smaller than that of the return spring 156 such that when no oil pressure is applied, the ball 175 can be stopped against the shoulder 246 at the left end of the horizontal blind bore 260 . At the same time, there is no decompression orifice or bleeding orifice (or a combined decompression and bleeding orifice) in the return piston 162 . The operation principle of the present embodiment is similar to that of the third embodiment and detailed description thereof is omitted.
While the above description describes some embodiments, these embodiments should not be regarded as limitations to the scope of the present application, but are exemplifications of the preferred embodiments thereof. Many other variations are likely to be derived. For instance, the return spring and the brake spring herein may be of a cylindrical type, a leaf type, and a wave form, etc., and may also be installed or positioned at different places or orientations. In addition, the position limiter of the brake plunger may also be other forms. Accordingly, the scope of the present application should not be determined by the embodiments illustrated, but is determined by the claims and their legal equivalents.
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A fixed chain engine braking device includes a brake box, a driving mechanism and a braking mechanism. One upright blind hole and one horizontal blind hole are placed in the brake box, and the upright blind hole intersects the horizontal blind hole orthogonally. The driving mechanism includes a rolling ball and/or a driving piston placed in the horizontal blind hole, the braking mechanism includes a braking plunger placed in the upright blind hole. A fluid passage is placed in the brake box, and the fluid passage is communicated with the entry of the horizontal blind hole.
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BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for retaining a trim to a lighting fixture.
Lighting fixtures, such as recessed fixtures are often installed in ceilings and in walls within buildings. Typically, the recessed lighting fixture includes a frame or can structure which lies within the ceiling or wall and serves to support a reflector and lamp, as well as the necessary electrical elements. Normally, a trim is placed over the recessed lighting fixture for the purpose of diffusion of light and/or for decoration. U.S. Pat. No. 5,410,462 depicts a modular recessed lighting fixture utilizing a frame and typical electrical and mechanical components, which is incorporated by reference hereto in its entirety.
In the past, it has proven quite difficult to install such trims, which can be quite bulky and heavy in certain instances. Moreover, removal of the trim is required to relamp the fixture at various intervals. Further, installation or removal of a trim from a recessed lighting fixture can pose a safety hazard if such trim is dropped during these operations. Finally, damage to the trim results if the same is dropped, requiring replacement of the same at a notable expense.
A system for retaining a trim on a recessed light fixture would be a significant advance in the lighting field.
SUMMARY OF THE INVENTION
In accordance with the present invention a novel and useful trim retention mechanism for a recessed light is herein provided.
The apparatus of the present invention is usable with a trim for a lighting fixture mounted to a wall or ceiling. The lighting fixture generally includes a lamp and a reflector which is recessed relative to the mounting surface. The light fixture is also generally provided with a plaster frame or plate, and includes a distending rim having an inner surface defining the opening, through which light travels from the lamp of the lighting fixture.
The apparatus of the present invention includes as one of its elements a first bracket connected to the frame. The first bracket possesses a first portion placed along the rim surface and a second portion which extends outwardly from the rim. The first bracket second portion could be in the form of a movable element, such as one that is hingedly attached to the first portion of the first bracket. First fastening means permits connection of the bracket to the plaster frame or plate. Such connection may be an adjustable connection to accommodate walls or ceilings of varying thickness. The first bracket may be fastened directly to an anchor or clip which may be placed in a series of preformed openings in the plate or into openings which are created de novo to fasten the anchor. The first bracket also possesses second fastening means for connecting the movable element to the trim. Thus, the trim connected to the second portion of the first bracket would naturally hang vertically, leaving the opening through the plaster frame and rim accessible for maintenance or installation of items such as lamps and the like.
The apparatus of the present invention also possesses a second bracket connected to the plaster frame. The second bracket includes a first portion similar to the construction of the first bracket first portion. That is to say, third fastening means, of similar construction to the first fastening means, permits the connecting of the second bracket to the plaster frame such that the bracket is adjustable along the surface of the rim to accommodate ceilings, walls, and the like of varying thicknesses. Fourth fastening means allows the connecting of the trim to the second portion of the second bracket such that the trim has been fixed in its intended position relative to the lighting fixture recessed in the wall or ceiling. The fourth fastening means may take the form of a slot which engages a flange or protuberance on the trim to hold the same in place. It should be noted that the trim may be rotated into the slot of the fourth fastening means to accomplish such interconnection between the trim and the second portion of the second bracket.
It may be apparent that a novel and useful apparatus for retaining a trim to a lighting fixture has been described.
It is therefor an object of the present invention to provide an apparatus for retaining a trim to a lighting fixture which greatly eases the installation of a trim on the exterior mounting surface of a wall or ceiling holding the lighting fixture.
It is another object of the present invention to provide an apparatus for retaining a trim to a lighting fixture recessed in a wall or ceiling that facilitates the relamping of such lighting fixture and eliminates interim support of the lighting fixture trim and the unfastening of decorative nuts.
A further object of the present invention is to provide an apparatus for retaining a trim to a recessed lighting fixture in a wall or ceiling which is unobtrusive and does not detract from the esthetics of the trim itself.
A further object of the present invention is to provide an apparatus for retaining a trim to a lighting fixture which is retrofitable to a standard lighting structure.
Another object of the present invention is to provide an apparatus for retaining a trim to a lighting fixture recessed in a wall or ceiling which is easily adjustable to varying thicknesses of the wall or ceiling.
A further object of the present invention is to provide an apparatus for retaining a trim to a lighting fixture which greatly reduces hazards associated with the installation and maintenance of the lighting fixture through the falling of objects downwardly.
The invention possesses other objects and advantages especially as concerns particular characteristics and features thereof which will become apparent as the specification continues.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a bottom right perspective view of a trim in place on a recessed lighting fixture utilizing the apparatus of the present invention.
FIG. 2 is a bottom right perspective view of a trim hinged away from the opening of the recessed lighting fixture and held in that position by the apparatus of the present invention.
FIG. 3 is a sectional view of the apparatus of the present invention in place, with the trim depicted in exploded configuration relative to the trim retaining apparatus of the present invention.
FIG. 4 is a bottom left perspective view of the first bracket and fastening means of the apparatus of the present invention.
For a better understanding of the invention reference is made to the following detailed description of the preferred embodiments thereof which should be taken in conjunction with the prior described drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Various aspects of the present invention will evolve from the following detailed description of the preferred embodiments thereof which should be referenced to the heretofore described drawings.
The invention as a whole is shown in the drawings by reference character 10. Apparatus 10 is employed in conjunction with recessed lighting fixture 12, which is schematically depicted in the drawings. Recessed lighting fixture 12 is placed at a mounting surface 14 such as a ceiling or wall. In the drawings, mounting surface 14 is shown as a ceiling. Lighting fixture 12 includes a frame 16 which is formed with a circular rim 18 having a curved surface 20 which defines opening 22. Opening 22 permits light from lamp 24, shown schematically in FIG. 3, to emanate therethrough. Recessed lighting fixture 12 also includes the necessary electrical components above ceiling 14 (not shown).
Apparatus 10 is intended to hold trim 26 to lighting fixture 12. Needless to say, trim 26 is represented as a typical structure. Trim 26 may include ornamental elements and fragile portions. In addition, trim 26 may be relatively heavy and difficult to handle when being installed against a ceiling such as ceiling 14.
The invention 10 includes as one of its elements a first bracket 28, which is depicted in detail on FIG. 4, and is illustrated as being connected to trim 26 in the remaining figures. Bracket 28 includes a first portion 30 and a second portion 32. Second portion 32 also includes a movable element 34 which is hingedly attached to horizontal portion 36 by the use of a pivot pin 38. First portion 30 of bracket 28 connects to frame or plate 16 by the use of an anchor 40. Anchor 40 includes plurality of prongs 42 which fit into openings within frame 16. Thus, anchor 40 is capable of snapping into place at opening 22 of frame 16 as depicted in FIG. 3. It should be understood that anchor 40 may be fixed by other means to frame 16. Returning to FIG. 4, it should be understood that first bracket 28 has been rotated for the sake of viewing clarity. First portion 30 includes a slot and a set screw 46 which serves as means 48 for adjustably fastening or connecting first bracket 28 to frame 16. It should be noted that first portion 30 of first bracket 28 lies against curved rim surface 20, in this regard.
Means 50 is also depicted in the drawings for connecting movable part or element 34 of second portion of bracket 28 to trim 26. Means 50 includes the provision of a keyhole slot 52 which accepts flanged nut 54 fastened to trim 26. That is to say, the flange portion of flange nut 54 slips into the narrowed portion of slot 52 to hold trim 26 in place, as depicted in FIG. 2. Directional arrow 56 indicates that trim 26 may be rotated along the axis of pivot pin 38.
Second bracket 58, best shown in FIGS. 2 and 3, includes a first portion 60 and a second portion 62. First and second portions 60 and 62 of second bracket 58 are angularly disposed relative to one another, but are not articulated. Second portion 62 includes an open slot 64 for accepting flanged nut 66 on trim 26. Referring to FIG. 1, it may be observed that directional arrow 68 indicates that flanged nut 66 is rotated into position about a axis of flanged nut 54 on the other end of trim 26. Plate 70 possesses a slight spring action to hold flange nut 66 in place, following insertion within open slot 64. Thus, trim 26 may be rotated upwardly along directional arrow 56, FIG. 2 and into place, as shown in FIG. 1.
First portion 60 of second bracket 58 connects to an anchor 72 which may be snapped, or otherwise fixed, into place, in a similar manner to anchor 40. In fact, anchor 72 is identical in shape to anchor 40 in this regard. Again, first portion 60 includes a slot similar to slot 44 (not shown) which permits the use of set screw 74 to adjustably attach first portion 60 of second bracket 58 to frame 16 via anchor 72.
In operation, apparatus 10 is utilized by the installing of first bracket 28 and second bracket 58 to frame 16 via anchors 40 and 72, respectively. Anchors 40 and 72 are snapped into place by utilizing openings found in frame 62 for this purpose. Set screws 46 and 74 permit the upward or downward movement of first portions 46 and 60 of first and second brackets 28 and 58, respectively, according to directional arrows 76 and 78 of FIG. 3. Means 50 is employed to connect trim 26 to movable portion 34 of bracket 28. Specifically, flange nut 54 is placed within keyhole slot 52. At this point, trim 26 may hang downwardly as depicted in FIG. 2, although flange nut 54 permits rotation of trim 26 about the axis of flange nut 54. Trim 26 is then rotated into place along directional arrow 56 such that flange nut 66 fits within open slot 64 of second bracket 58. Spring plate 70 holds flange nut 66 in this position. It should be noted that reflector 80 and lamp 24, shown in phantom in FIG. 3, is placed against surface 20 and brackets 28 and 58 prior to the installation of trim 26 in certain cases.
While in the foregoing, embodiments of the present invention have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such detail without departing from the spirit and principles of the invention.
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An apparatus for retaining a trim to a lighting fixture utilizing a frame which is fixed relative to a surface at which the lighting fixture is mounted. The frame includes an opening and a surface surrounding the opening. One or more brackets are placed along the frame surface. A movable element of one bracket connects to the trim for support. Retaining of the trim is a accomplished by further fastening of the trim to another bracket placed along the surface surrounding the opening of the frame.
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BACKGROUND OF THE INVENTION
The present invention relates to a hand held tactile toy or amusement device having exterior surfaces of differing texture and resiliency. The sensation associated with holding and manipulating an object comprising different textures and/or resiliency provides both physical and psychological pleasure, particularly a sense of calmness and sereneness. The device can therefore aid in reducing anxiety as well as induce a comfortable, relaxed state of mind.
BACKGROUND ART
The following patents typify hald-held objects which have components which are pliable to some degree.
U.S. Pat. No. 1,549,710 describes an oblong object having a compressible outer shell and an inner core of air.
U.S. Pat. No. 3,265,389 describes an object of uniformly resilient material having open areas.
U.S. Pat. No. 2,994,530 describes an object for exercising particular parts of the hand. Two connected rigid gripping bodies are provided with a wrap of a spongy resilient pad to provide a secure grip when the two grip members are compressed toward each other.
U.S. Pat. No. 4,040,619 describes an exercise device comprising a flexible hour-glass shaped object, having two interior compartments containing a liquid which can be squeezed from one compartment to the other.
U.S. Pat. No. 4,754,963 describes a hand held exercise device having a generally puck-shaped body of resilient material within which are openings containing relatively rigid ball members held by friction in the openings of the resilient material. The inserted balls provide increased resistance to compression of the puck-shaped body.
In common, none of these patents disclose a hand-held tactile object wherein a hard smooth body has a portion of its surface interrupted by cavities containing soft pliable bodies which protrude from the surface of the hard body. In contrast to the prior art devices, the present invention provides a generally rigid support body and requires little or no applied pressure to achieve the benefits of contrasting sensations of a hard smooth surface interrupted by one or more smooth pliable soft surfaces.
SUMMARY OF THE INVENTION
In accordance with the invention, a generally oblong smooth, hard body which resides comfortably in the palm of the hand is provided with at least one cavity within which resides a pliable, smooth, generally round or ellipsoid soft body. A portion of the soft body protrudes from the first body and provides an independent and localized area of contact and pressure with the hand. The tactile contrast of the smooth relatively unyielding surface of the hard body with pliable forgiving nature of the soft body provides a pleasing sensation to the holder. The object can be manipulated so that different portions of the hand come in contact with the pliable second body, thus moving the contrasting of hard/soft bodies to differing sensing areas of the hand.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a plan view of one embodiment of the device of the invention.
FIG. 2 is a view along line 2--2 of FIG. 1
FIG. 3 is a section view of one embodiment of the soft body of the invention.
FIG. 4 is a plan view of another embodiment of the device of the invention.
FIG. 5 is a view along line 5--5 of FIG. 3.
FIG. 6 is an isometric view of an embodiment of the invention.
FIG. 7 is the plan view of another embodiment of the device of the invention.
FIG. 8 is a partial section taken along lines 8--8 of FIG. 7.
FIG. 9 depicts an embodiment of the invention held in a hand.
FIG. 10 depicts an embodiment of the invention wherein the object has a plurality of soft bodies.
FIG. 11 depicts a side view of an embodiment wherein an image is included between the soft body and the cavity.
FIG. 12 depicts a front view of an embodiment wherein an image is located between the soft body and the cavity.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2 of the drawings the device of the invention show is a hand held tactile object 10 which comprises a smooth hard body 11 whose surface has a cavity 12 which is adapted to receive a generally round, smooth soft body 13 made from a pliable material. The soft body 12 fills only a portion of the cavity, there being at least a substantial portion of the soft body which protrudes from the cavity and extends beyond the surrounding surface areas of the hard body 11. The size of the hard body 11 is that which would comfortably fit within the human hand. Different sizes could be provided for persons of different hand-size or growth. A generally oblong shape is shown for the rigid body as this is a comfortable shape for the hand and maximizes the area of tactile contact and hence sensation. The soft body, on the other hand, provides a separate area of contact. Because it protrudes, the soft pliable nature of the body will necessarily be sensed when the object is held and squeezed. However, the different sensation does not require much pressure, and ordinarily the weight of the object itself will suffice the "squeeze" the smooth resilient body when the latter is positioned against the palm of the hand.
The important feature is that both bodies be relatively smooth, i.e., not rough, and that both be of substantially different resiliency. Although overall smoothness is preferred, the hard body 11 can have some texture, such as the strippled effect of leather. The hard body can be made of any relatively hard material, such as rigid plastics, glass, hard rubber, reconstituted marble, reconstituted stone, metal or wood. Glass, stone, metal and plastic tend to give a "cool" feel, not unlike that of crystal hand-coolers. Wood and hard rubber give a warmer silky feel.
Suitable plastics are, for example, acrylic or Lucite®. Plastics and glass can be clear, but they may also be pigmented or not, to make the hard body a colored transparent, translucent or opaque material. The soft body 13 can be formed from any of the generally known elastomeric polymers, synthetic or natural. For example, elastomers of polybutadiene/styrene, cis-polybutadiene, butyl rubber, ethylene-propylene rubber, and polyisoprene are useful. It is generally preferred that such elastomers be from formulations of relatively low hardness and high softness, in order to maximize the contrast with the hard body 10 and to allow depression of the resilient body 12 with relatively little pressure. Although a resilient elastomer is preferred, it is also contemplated that the soft body be made from malleable materials that maintain their shape to some degree when distorted, such as shape-memory polymers of transpolyisoprene.
A preferred embodiment of the soft body 12 is depicted in FIG. 3. That figure shows a soft body 14 having an outer skin or shell 14 of a soft elastomer and an inner core 15 of a viscous liquid or gel-like substance. Very low molecular weight elastomeric polymers make an appropriate gel or liquid core. The combination of FIG. 3 gives a particularly soft, pliable feel and can be depressed with little energy. A preferred example of such a composite elastomeric structure is a silicone elastomer filled with a silicone gel. Silicone elastomers are well known (e.g., Sylgard® 184 or Silastic® Q7-2213 or Q7-2630 from Dow Corning Corp., Midland, Mich.). The base silicone polymer can be formed by known means into a tough, pliable, virtually transparent film. The film preferably has a thickness of between about 0.007 inch and 0.020 inch, with 0.010 inch being preferred. Thicknesses outside this range may be used but are less preferred because thinner thicknesses increase the risk of puncture and thicker ones have less tactile appeal. Typically the film is built up on a mandrel through repeated dippings in a bath of siloxane polymer. When the desired thickness is reached, the film is vulcanized and then sealed into a generally round shape with a silicone adhesive, like, for example, Silastic® adhesive from Dow Corning. The shell 16 thus formed can then be filled with a clear siloxane gel, for example, polydimethylsiloxane (PDMS). A PDMS gel system is available commercially as Q7-2218, Q7-2167/Q7-2108, or Q7-2150/Q7-2146 Silicone Gel Systems from Dow Corning. The gel itself is made in known manner by curing the gel base resin with a suitable polysiloxane hardener. The filling step can be done with a hypodermic needle, the hole being sealed with silicone adhesive. Previously prepared encapsulated gels of the type described exist in commerce and have been used in medical applications such as in female breast repair and testicular implants.
The weight of the object 10 is normally dictated by the composition of the hard body 11. For lighter weights an acrylic plastic can be used. If a heavier weight is desired, one can select from the heavier materials such as stone, metal and glass. The selection of materials may also be dictated by the desire to achieve a certain visual appearance, e.g., clear vs. opaque, or dark vs. light, or metallic vs. glass-like.
The gel-filled soft body 13 of FIG. 3 is generally clear and can provide a pleasant visual contrast with the various choices of materials available for the hard body 11. It is also contemplated by this invention to achieve visual effects in addition to those dictated by the choice of materials for the rigid body and the soft body. The gel 17 may itself be pigmented to provide additional visual effects. It is also contemplated by this invention that the core of the soft body 13 contain, in addition to the gel or viscous liquid, admixed thermochromic liquid crystals which are capable of changing color in reaction to temperature changes created by the warmth of the hand, as by the pressure of the hand. Such crystals, also known as cholesteric or chiral nematic crystals, change color at low temperatures, generally going from clear to red as the temperature is changed or pressure is increased and then on to other colors as the temperature or pressure continues to change. When using such crystals in a clear soft body 13 of the invention, the back of the cavity 12 is suitably colored flat black to provide better contrast and visualization. It is preferred that such crystals be of the micro-encapsulated variety. Thermochromic liquid crystals are available from Hallcrest, Inc. of Glenview, Ill. The amount of such crystals needed to provide a desired visual effect, depending on the clarity of the soft body 13 and the reflectivity of the selected cavity, can be readily established through trial.
As noted, the capsules or soft bodies are of generally round shape, but they may also be oblong, egg-shaped, pear shaped, etc. Thus, by "generally round" I do not limit myself to spheroids, but include ellipsoid bodies having substantially continuous surfaces wherein at least some of the plane sections are circles or ellipses. A round clear body will behave naturally like a magnifying a lens. Therefore it is further contemplated by this invention that the cavity of the hard body can contain a colored symbol, insignia, message or other image which will be magnified by the clear soft body Referring to FIGS. 11 and 12, such an embodiment is depicted wherein an image 25 located between the cavity and the soft body is magnified when viewed from the front. It could be used, for example, to provide indicia of an event, organization or award. The whole object 10 could therefore be suitable for presentations, advertising, and promotional gifts. The image to be observed through the soft clear body could be attached in any suitable manner such as a coating applied to the cavity wall or on the adjacent surface of the soft body or on a separate film or sheet placed in the back of the cavity before the soft body is put in the cavity.
Depending on the rigidness and relative resilience of the hard body and the soft body, the latter may either be held in the cavity by friction, or by an adhesive appropriate to the selection of materials. In most cases, an adhesive will be required. In the event no adhesive is used, the soft body may be removed and exchanged for other soft bodies of contrasting properties (e.g, colored rather than clear, or containing thermochromic liquid crystals, or containing a different symbol on the interior surface).
The hard body may be provided with a multiplicity of cavities containing soft bodies. FIGS. 4 and 5 depict such an embodiment. There, the hand held tactile object 16 comprises a hard smooth body 17 having several cavities which receive smooth soft, pliable protruding bodies 18. This embodiment spreads out the areas of soft contact when the object is held in the hand and thereby changes the over-all tactile information the holder senses. The number of such soft contact areas and hence the relative sensations between softness and hardness is obviously a matter of choice. Conceivably the entire surface could be covered by the soft bodies in which case the sensation is almost totally one of smooth softness supported by the heft and weight of the hard body 17. FIG. 10 depicts such an embodiment. Here too, any of the soft bodies, when made of a clear material such as silicone elastomer/gel, could be modified to contain thermochromic crystals, pigmentation or magnified indicia as indicated above for the single soft body. However, with the multiple soft bodies, one could provide each or any of the bodies with different such treatments thereby creating, if desired, image/patterns from the composite effect of the differing treatments of individual soft bodies.
Users of tactile toys take particular pleasure in observing and handling an object in the shape of an animal. Hence, it is advantageous to make the body in the shape of an animal, such as a bird, rabbit, cat, etc. FIG. 6 depicts such an embodiment in the shape of an owl 19. The cavity for receiving the soft body 21 is located in the breast area of the hard body 20. The contours of the body are kept smooth and with a minimum of sharp features or detail so that the object as a whole will still feel comfortable in the hand. The user could derive tactile pleasure by gently touching or poking the animal in the soft area of the central body with the finger from one hand while holding the animal in the other, or the user could hold the object in the palm of the hand, squeezing the soft component against the fat of the palm or by the thumb.
FIGS. 7 and 8 depict another embodiment in which the hard body 22 resembles a hollowed out semi-ellipsoid, the cavity being substantially co-extensive with a plane through the central axis of the ellipse (as shown in FIG. 7). A single relatively large soft body 24 resides within that cavity. In this embodiment the single soft body has almost the same contact area with the hand as the hard body.
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A shaped object that fits into the palm of the hand to give a pleasurable tactile sensation is disclosed. The tactile sensation is created by a unique combination of resistant and pliable sections in the object.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention refers to a device for adjusting the locking point of an electrode through an electrode-holding vice of an electric arc smelting furnace.
2. Description of the Related Art
Smelting furnaces, generally used in the steel sector, make use of the heat released by electric arcs created through graphite electrodes in order to work.
These electrodes, which are of substantial size, possibly even having a diameter of 800 mm and a length of over 10 m, are supported by vices that are the end part of long steel and copper arms, through which the current necessary for creating the aforementioned electric arcs passes. Such arms stay outside the furnace. Only the part of electrode situated below the vice enters into the furnace.
During operation the electrodes wear down in the bottom part where the arc sparks, and therefore they become gradually shorter. The arc must however always stay in the bottom area of the furnace, in other words where the steel to be poured is located, for which reason the arms go down as low as the cover of the furnace will allow, after which it is necessary to intervene to adjust the relative position between arm and electrode. This normally occurs, after stopping the furnace from operating, through the bridge crane that, in different ways, hooks and holds the electrode while the vice is opened, moved vertically and closed again higher up.
This system, which is currently used in almost all steelworks, has some substantial drawbacks.
In order to carry out the operation it is necessary to stop the furnace for the entire duration of the operation itself, in other words for 2-5 minutes, which, for a modern steelworks, represents a very long time and therefore a very high cost.
The overwhelming majority of steelworks uses the hook of the crane directly to take hold of the electrode. Such a hook, in order to be able to hook onto and unhook from the ring of the nipple located on the top part of the electrode, must be without the obligatory safety device.
The crane in a steelworks is an extremely valuable piece of machinery, which should always be available for emergencies.
BRIEF SUMMARY OF THE INVENTION
The purpose of the present invention is to provide a device that can carry out the adjustment of the positioning of the electrode, with respect to the vice of the furnace, automatically, without the use of the crane and preferably exploiting the idle times that exist when the furnace is open to be able to tap the molten steel.
Another purpose is to provide a device, which can also operate at the high temperatures connected with melting of steel.
In accordance with the present invention, such purposes and others are accomplished by a device for adjusting the locking point of the electrode of a smelting furnace comprising: a vice for supporting and supplying said electrode with power, characterised in that it comprises a structure coupled with said vice comprising support means for said electrode and means for moving said electrode vertically.
Such purposes are also accomplished by a method for adjusting the locking point of an electrode of a smelting furnace through an electrode-holding vice, comprising the steps of coupling support means of said electrode with said vice and means for moving said electrode vertically.
Further characteristics of the invention are described in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristics and advantages of the present invention shall become clear from the following detailed description of some practical embodiments thereof, illustrated as non-limiting examples in the attached drawings, in which:
FIGS. 1 , 2 , 3 and 4 show a device for adjusting the locking point of the electrode in accordance with a first embodiment, the first two figures with the device open and with the gripping members in their highest point, and the other two with the device closed and with the gripping members in their lowest point;
FIGS. 5 , 6 , 7 and 8 show a device for adjusting the locking point of the electrode in accordance with a second embodiment, the first two figures with the device open and with the gripping members in their highest point, and the other two with the device closed and with the gripping members in their lowest point;
FIGS. 9 , 10 , 11 , 12 , 13 and 14 show a device for adjusting the locking point of the electrode in accordance with a third embodiment, the first three figures with the device open and with the gripping members in their highest point, and the other three with the device closed and with the gripping members in their lowest point;
FIGS. 15 , 16 , 17 and 18 show a device for adjusting the locking point of the electrode in accordance with a fourth embodiment, the first two figures with the device closed, and the other two with the device open;
FIGS. 19 , 20 , 21 and 22 show a device for adjusting the locking point of the electrode in a fifth embodiment, the first two figures with the device closed and the gripping members in their highest point and the other two with the device open and the gripping members in their lowest point.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the attached figures, a device 10 for adjusting the locking point of the electrode 11 through an arm 12 with relative electrode-holding tongs 120 , or electrode-holding vice, comprises a metallic structure 13 intended to be fixed through screws 14 , suitably electrically insulated, to the electrode-holding arm 12 , in the bottom part or even in the top part. Such a structure 13 is intended to be adjusted along the length of the arm, to define the correct position with respect to the electrode 11 .
The structure 13 comprises support means and means for moving the electrode 11 vertically.
As indicated above, the structure 13 can be fixed to the arm 12 in the bottom part or in the top part thereof.
In the first four embodiments of the device 10 illustrated in FIGS. 1-18 , the structure 13 is fixed to the bottom part of the arm 12 . In this case, in operating configuration, the support means and the means for moving the electrode 11 vertically are at a lower height than that of the electrode-holding tongs 120 , in other words they are below them.
In the fifth embodiment of the device 10 , illustrated in FIGS. 19-22 , the structure 13 is fixed to the top part of the arm 12 . In this case, in operating configuration, the support means and the means for moving the electrode 11 vertically are at a greater height than that of the electrode-holding tongs 120 , in other words they are above them. This arrangement, as shall become clearer hereafter, offers advantages both in terms of structure and in terms of operation.
In accordance with a first embodiment of the present invention, a horizontal plate 20 is connected to the structure 13 . The plate 20 is hinged, on one side, to a suspension pin 21 , having its axis arranged along an axis alongside the electrode 11 , and perpendicular to it.
On the other side of the plate 20 two tongs 22 and 23 are coupled, through the respective pivots 24 and 25 .
A first hydraulic cylinder 26 is connected between the structure 13 and the plate 20 , on the opposite side to where the plate 20 is hinged. The cylinder 26 provides a vertical movement of an extremity of the plate 20 and thus a vertical movement of the tongs 22 and 23 .
A second hydraulic cylinder 27 is connected between the two tongs 22 and 23 on the opposite side to that of the gripping members 28 and 29 . The cylinder 27 provides an opening and closing movement of the tongs 22 and 23 and thus of the gripping members 28 and 29 .
The adjustment of the position of the electrode 11 with respect to the arm 12 is carried out automatically or manually with the following sequence.
The cylinder 26 closes and positions the gripping members 28 and 29 in their highest point.
The cylinder 27 extends and closes the gripping members 28 and 29 of the two tongs 22 and 23 on the electrode 11 .
The electrode-holding tongs 120 of the arm 12 open.
The cylinder 26 extends and moves the electrode 11 downwards.
The electrode-holding tongs 120 of the arm 12 close.
The cylinder 27 closes and opens the gripping members 28 and 29 .
What has been described above relates to the downward movement of the electrode 11 , for a possible raising of the electrode 11 the sequence is reversed but is analogous.
Since the vertical movement is relatively small (for example 100 mm), it is foreseen for it to be possible to programme many successive cycles also automatically.
As an alternative to the suspension pin 21 and the hydraulic cylinder 26 it is possible to use four hydraulic cylinders 30 , 31 , 32 , 33 , as better described in the following embodiments. The two structures should be considered equivalent for the vertical movement of the electrode.
In accordance with a second embodiment of the present invention, the structure 13 has four hydraulic cylinders 30 , 31 , 32 , 33 connected to it, which are in turn connected to a bar 34 ending with a ring 35 that encircles the electrode 11 .
The four hydraulic cylinders 30 , 31 , 32 , 33 allow the vertical movement of the bar 34 .
Three jaws 36 , 37 , 38 are mounted on the ring 35 that moves only radially, by means of special guides, controlled by a circular crown 39 provided with three oblique grooves 40 , 41 and 42 .
On the bar 34 there is a first gear 43 that engages on the circular crown 39 and on a second gear 44 . The second gear 44 has a lever 45 positioned on it that is controlled by a hydraulic piston 46 .
The hydraulic piston 46 actuates the gears 43 and 44 , making the circular crown 39 rotate. When the circular crown 39 rotates, the grooves 40 , 41 and 42 , engaged on three rollers mounted on the jaws 36 , 37 , 38 , force them towards the electrode locking it.
The adjustment of the position of the electrode 11 with respect to the arm 12 is carried out substantially like for the previous case.
The cylinders 30 , 31 , 32 , 33 close and position the ring 35 in its highest point.
The cylinder 46 extends and closes the jaws 36 , 37 , 38 on the electrode 11 .
The electrode-holding tongs 120 of the arm 12 open.
The cylinders 30 , 31 , 32 , 33 extend and the electrode 11 moves downwards.
The electrode-holding tongs 120 of the arm 12 close.
The cylinder 46 contracts and the jaws 36 , 37 , 38 open.
In accordance with a third embodiment of the present invention, the structure 13 has four hydraulic cylinders 30 , 31 , 32 , 33 connected to it, which are in turn connected to a bar 34 ending with a ring 35 that encircles the electrode 11 .
The four hydraulic cylinders 30 , 31 , 32 , 33 allow the vertical movement of the bar 34 .
The ring 35 has six jaws 50 , 51 , 52 , 53 , 54 and 55 mounted on it that move only radially, by means of special guides, controlled by a metallic cable 56 in a closed loop that closes on the jaws themselves through the effect of the movement of a hydraulic cylinder 57 . The hydraulic cylinder 57 actuates a pulley 58 , which can move along the longitudinal axis of the bar 34 , on which the metallic cable 56 is made to run.
In order to lock the electrode 11 , the hydraulic cylinder 57 is closed, which, bringing the pulley 58 closer to it, places the cable 56 under tension, which makes the six jaws 50 , 51 , 52 , 53 , 54 and 55 run in the special guides that come into contact with the electrode 11 .
In order to release the electrode 11 and move the ring 35 , the hydraulic cylinder 57 is opened, and some springs (not shown) take the pulley 58 back into its rest position.
In accordance with a fourth embodiment of the present invention, the structure 13 has a structure 60 connected to it on which two tongs 61 and 62 are coupled, through the respective pivots 63 and 64 . A hydraulic cylinder 65 is connected between the two tongs 61 and 62 on the opposite side to that of the gripping members 66 and 67 .
The gripping members 66 and 67 consist of two gears, controlled by two hydraulic motors 68 and 69 , which, rotating in synchrony with each other, move the electrode 11 with continuity downwards or upwards.
The hydraulic cylinder 65 opens and closes the two tongs 61 and 62 and the two hydraulic motors 68 and 69 raise and lower the electrode 11 .
In accordance with a fifth embodiment of the device 10 object of the present invention, the structure 13 is fixed to the arm 12 in the top part thereof so that, in operating configuration, the support means and the means for moving the electrode 11 vertically are at a greater height than that of the electrode-holding tongs 120 , in other words they are above them.
The support means and the means for moving the electrode 11 vertically comprise a pair of tongs 70 and 71 each of which is pivoted around a respective pin 72 and 73 and has an end for gripping the electrode 11 provided with respective gripping members 74 and 75 . The ends of the tongs 70 and 71 opposite the gripping end are connected together by a first cylinder 76 that controls its closing and opening, respectively, to hold and release the electrode 11 .
The two tongs 70 and 71 are also hinged to the structure 13 around respective pins with horizontal axis 77 so as to be able to oscillate on the vertical plane.
The oscillation of the two tongs 70 and 71 around the horizontal axis 77 is controlled by a second cylinder 78 , which has one end 78 a articulated to the structure 13 and the opposite end 78 b articulated to a bracket 79 fixedly connected to the two tongs 70 and 71 . The extension and the retraction of the second cylinder 78 control the oscillation of the tongs 70 and 71 around the horizontal axis 77 in the two opposite directions, so as to move the gripping ends of the tongs 70 and 71 vertically downwards or upwards.
The adjustment of the position of the electrode 11 with respect to the arm 12 takes place in the following way:
When the electrode-holding tongs 120 are still clamped around the electrode 11 , the second cylinder 78 is actuated so as to make the tongs 70 and 71 rotate around the horizontal axis 77 so as to lift their gripping ends, kept in open configuration, vertically upwards.
When the gripping ends of the tongs 70 and 71 have been raised to the desired height, the first cylinder 76 is extended so that the two tongs 70 and 71 , oscillating around the respective pins 72 and 73 , are closed to clamp their gripping ends around the electrode 11 .
The electrode-holding tongs 120 are released and the electrode 11 is supported by the tongs 70 and 71 .
The second cylinder 78 is then actuated so as to make the tongs 70 and 71 rotate around the horizontal axis 77 so as to lower their gripping ends, kept in closed configuration around the electrode 11 , vertically downwards; in this way the electrode 11 is moved vertically downwards by a programmed height.
At this point, the electrode-holding tongs 120 are clamped around the electrode 11 and the first cylinder 76 is retracted so that the two tongs 70 and 71 , oscillating around the respective pins 72 and 73 , are opened moving their gripping ends away from the electrode 11 .
The electrode-holding tongs 120 support the electrode 11 and feed it with power and the device 10 is ready to repeat the sequence of operations described above.
Should it be necessary to raise the electrode 11 , for example to add a portion of graphite, the operations indicated above are carried out in reverse.
The arrangement of the tongs 70 and 71 and, more generally, of the support means and of the means for moving vertically to a greater height, in operating conditions, than that of the electrode-holding tongs 120 , has some advantages compared to the opposite arrangement.
Indeed, with such an arrangement the tongs 70 and 71 and, more generally, the support means and the means for moving the electrode 11 vertically, are connected to a portion of the electrode itself that, with the furnace in working configuration, does not have current passing through it. Such a portion, therefore, constitutes an open electric circuit and is at the same electrical potential with the power supply provided by the electrode-holding tongs 120 .
In this case, therefore, it is not strictly necessary to electrically insulate the device 10 from the arm 12 , since it is not possible for so-called “electric loop” effects to be created that, on the other hand, are created with the opposite arrangement, in other words with the arrangement of the means for supporting the electrode 11 and for moving it vertically beneath the electrode-holding tongs 120 .
The arrangement of the tongs 70 and 71 and, more generally, of the means for supporting the electrode 11 and for moving it vertically, at a greater height than that of the electrode-holding tongs 120 , thus results in the bulk and weight of the entire device being kept low.
In any case, the device object of the invention allows the electrode to be moved vertically in shorter periods of time compared to what is required by the prior art with consequent gains in terms of productivity. Moreover, the device object of the present invention allows the height of the electrode to be modified without the need to open the furnace, with a consequent energy saving.
In practice, the materials used, as well as the sizes, can be whatever according to the requirements and the state of the art.
The device thus conceived can undergo numerous modifications and variants, all of which are covered by the scope of protection of the inventive concept; moreover, all of the details can be replaced with technically equivalent elements.
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A device ( 10 ) for adjusting the locking point of the electrode of a smelting furnace includes a vice ( 120 ) for supporting said electrode and supplying it with power. A structure ( 13 ) is coupled with the vice ( 120 ), supports the electrode and moves the electrode vertically.
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BACKGROUND OF THE INVENTION
The present invention relates generally to grain drying equipment and more particularly to an improved low profile continuous crossflow column grain dryer with optimum exhaust drying air recirculation through the burner to reduce fuel consumption, automatic preheat of fresh incoming grain, improved drying and cooling airflow volume and cfm/bushel vs blower horsepower by a variable grain column thickness design through both the drying zone and cooling zone, and precise external adjustment for control of grain flow to the metering rolls for optimum drying uniformity along the dryer length.
It is generally believed that continuous crossflow dryers, that is, those dryers which have wet grain continually or semicontinually entering the dryer and dried grain continually or semicontinually exiting (i.e. continuous "periodic unloading" of specific amounts of grain) the dryer, with drying air passing generally perpendicular through the flowing column of grain, were not suitable for drying grains having a high moisture content. The reason for the difficulties experienced in the use of conventional continuous crossflow dryers was that they only operated at their optimum design performance level over a fairly narrow range of moisture removal due to noncontrollable design conditions such as a fixed cooling airflow, and a fixed heated airflow, flowing through a constant width column or a constant depth of grain.
At a grain moisture removal of 6 to 8 percentage points, most conventional dryers work satisfactorily. The cooling rate is matched fairly well with the drying rate. The grain column is usually split 25-35 percent cooling and 65-75 percent heating. The total blower horsepower is normally split at between 30-40 percent cooling and 60-70 percent drying. Dryers with 25 percent cooling PG,3 column usually use the upper extreme in cooling horsepower, thus operating the cooling plenum at a higher static pressure than the heating plenum and delivering 50-100 percent more cool air per bushel than drying air.
Under conditions wherein grain coming from the field is very high in moisture, and the drying rate is slowed significantly, the grain in such prior art systems was over cooled, which is not a particular problem from the standpoint of the quality of the grain dried, but it does waste considerable energy. Under very dry grain inlet conditions wherein the moisture removal is in the 3-5 percentage range, the grain flow rate is high and cooling is inadequate. If grain conditioned by such a process is to be stored in a non-aerated storage and therefore has to be cooled considerably after being dried in the dryer, the only reasonable solution was to significantly reduce the drying temperature thereby drastically slowing the drying rate to the point where the grain retention time in the cooling zone was adequate to cool the grain. It is well known that the efficiency of the drying process is reduced and the fuel cost per bushel increased considerably when the plenum operating temperature of a crossflow dryer is significantly reduced. It is also well known that the grain to be stored in non-aerated storage cannot be too warm or it will deteriorate rapidly.
Another weakness of most conventional continuous crossflow column grain drying devices is that when drying grains under conditions where cooling the grain in the dryer is not desired, the cooling airflow must be blocked off and the cooling grain column is of little or no value in drying. There is, therefore, a need for improved equipment of this type which will adequately compensate for this situation by having a design that can be easily adjusted to provide drying of grain in the grain column area normally used for cooling to maximize the performance and capital investment of the dryer, and to further increase the efficiency of the dryer by providing suitable means for controlling and recycling the very dry high quality air from the lower zone of the grain column (the cooling zone when dryer is used for cooling) while yet being able to differentiate between and return the exhaust air that is suitable and reject the exhaust air that is unsuitable whether this differentiation should occur (1) within the lower zone, (2) between the lower zone and the lower portion of the upper zone, or (3) within the lower portion of the upper zone.
It is also known that conventional crossflow dryers are normally: (1) of a full pressure design, using positive pressure in a heating as well as a cooling plenum, or (2) designed with suction cooling and pressure heating. But, they do not in one common structure embody the capability to perform in either method with quick and easy adjustment between methods, a management capability thought to be highly desirable, especially in farming regions where grain sorghum (milo) or sunflowers (both of which are crops with abnormally high combustible seed coat particles which accumulate in the heat plenums of dryers that recirculate the suction cooling air through the burner, causing fires in the dryer plenum or grain column) plus other cereal grain crops are grown in one farming operation. Having a dryer capable of being easily converted in a matter of a few minutes would allow full pressure heating and cooling of milo, sunflowers, or other crops with flammable residue, to be dried with the pressure heating and cooling mode of operation using ambient air with no recycled exhaust air. Then, when it is desirable to dry corn, wheat, soybeans or other "safer" crops with residue that is considerably less flammable, the dryer mode can be adjusted for suction cooling plus recycling of the less humid portion (approximately half) of the exhaust heated air without time consuming dryer modifications, thus, reducing fuel consumption by 35 to 50 percent of the fully pressurized heat and cool process fuel costs, while not significantly affecting drying capacity. In some farming and elevator operations, switching drying modes may take place several times per week during the periods when several types of grain are brought in to be dried.
In addition to easy adjustment and control of the direction, volume, and quality of the airflow when changing grains being dried, it is also desirable to adjust the flow profile of the grain as it enters the metering rolls due to the extreme differences in grain density, shape, size, and frictional surface characteristics, relative drying rates, plus trash and foreign material in the grain. For example, soybeans generally have a density of approximately 60 lbs. per bushel, and are relatively difficult to dry. Corn weighs about 56 lbs. per bushel and varies widely in shape from flats to rounds causing considerable variations in airflow and static pressure, and is relatively difficult to dry. On the other extreme, sunflowers, quite often grown on the same farm with corn, soybeans, or wheat, weigh from 24-32 lbs. per bushel but in some years, may be immature and weigh as low as 16-18 lbs. per bushel; sunflowers dry very rapidly at much lower air temperatures and are very light and bulky, thus require a much thicker grain flow to the metering rolls for proper handling rates to avoid extensive modification of the metering drive train which would cause considerable time loss and inconvenience to the operator.
In conventional drawings a uniform common heat level is used throughout the plenum chamber which is lower than desired in the upper portion of the drying column where the grain is wettest, and higher than desirable where the grain exits the drying zone.
There is, therefore, a need for a continuous flow drying apparatus which will overcome the aforementioned problems found with prior art devices.
SUMMARY OF THE INVENTION
The present invention relates to a grain drying and conditioning apparatus having a housing with an outer pervious skin with impervious end walls, air inlet, grain inlet, grain outlet and air exhaust duct structures connected thereto. Air pervious walls are variably spaced within the structure for optimumly confining a column of grain to be dried for desired airflow rates through the grain for optimum hydraulic and thermodynamic efficiency. A blower and heater mechanism is also connected to the housing for causing heated air to be forced through a first zone of the column of grain in one direction to heat and extract moisture therefrom and simultaneously causing air for cooling the grain to be pulled through a second zone of the grain column in an opposite direction, or, by simple adjustments, to be pushed in the same direction as the flow of the heated air. A plenum chamber is formed between the innermost of the pervious walls, the air duct structure, and an impervious wall opposite the air duct structure; an adjustable plenum divider mechanism is provided between the innermost of the pervious walls and the air duct structure in the plenum chamber for selectively dividing the plenum chamber into a first and second section for the purpose of optimizing the heating and cooling of the grain in the first and second zones, or for combining both zones of the plenum chamber for optimum heated air drying in the entire structure.
It is commonly known that most heaters in grain dryers do not uniformly heat the air. The returning exhaust air of this invention mixes with the cooling air to form a blend of relatively dry warm air which is then forced back to the heater at a temperature significantly higher than outside ambient air temperature. This causes the heater to provide much less additional heat to this elevated uniform blend of air to further elevate the drying air to the desired heat plenum temperature level for drying the grain, thus the lower heat rise from the burner provides a safer, more uniform drying temperature than would be obtained by heating outside ambient air all the way to the heat plenum operating temperature level, resulting in a very significant savings in energy needed to dry the grain, as well as providing a safer dryer.
An air recycling structure containing an air impervious skin which encloses the outer pervious skin of the lower section of the drying zone can direct all or a selected portion of the very warm exhausting air back to the inlet of the blower for recycling through the burner, thus re-using the appropriate portion of available waste sensible heat energy to do further drying.
This air duct and specific air control device (exhaust duct volume separator valve), which can first be used for regulating the volume of exhaust air versus recycled air in the exhaust area of the dryer, is provided for blending the unsaturated exhaust heated air, which is forced through the lower portion of the first zone (drying zone) of the grain column area into the exhaust duct structure by pressure, then is sub-blended with incoming cooling air drawn through the second zone (cooling zone) of the grain column area by suction, or secondly, for recycling only the air from a portion of the exhaust duct at the lower portion of the first zone, while rejecting the less desirable air from the duct to atmosphere, thus saving only the energy in such heated air that is desired, or thirdly for exhausting all drying and cooling air when using pressure heat and pressure cooling drying.
Preheating of the cold grain, in cold weather drying, or increased drying zone for improved drying capacity when grain is warm during warm weather drying is provided by extending pervious metal up the lower sidewall of the wet grain supply column (or garner bin) adjacent the top of the outer pervious wall of the drying zone.
Improved control of the dried grain is obtained by providing a precise method of externally adjusting the grain thickness flowing to the metering rolls, while the dryer is or is not drying, such that either a uniform thickness of grain flows to the metering rolls or a non-uniform flow of grain along the metering roll length can be provided, based on and adjusted to grain and air conditions along the length of the dryer. For example, near the fill point of the dryer. For example, near the fill point of the dryer, most of the broken kernel fragments and foreign material settle out and create a more dense grain mass with less air void space, thus reducing airflow and drying. By reducing the grain flow to the meters at that part of the grain columns, slower relative grain flow can provide equally dry grain, eliminating the discharge of wet partially dried grain that can cause serious grain storage problems.
A novel feature of the invention, is an exhaust duct variable control valve means, whereby select portions of the return air below the valve can be returned to the blower for reuse while the remainder of the air above the valve which may be determined to be unsuitable for reuse is rejected to the atmosphere. This valving apparatus (a butterfly type valve is used in this invention although other valve types can be devised) provides a means whereby the exhaust drying air contained by the exhaust duct can be suitably controlled by increments that are adequate for proper dryer management to maintain a high level of drying efficiency for any normal condition of drying encountered. Under certain conditions when drying very high moisture grain, only the air exhausting below the lowest valve position is suitable for reuse. In this condition, the top exhaust doors would all be open and the lowest valve position would be set. When very low moisture grain is being dried to remove three (3) to five (5) percentage points of moisture, it may be desirable to return all of the air that exhausts into the duct. In this case, the valve would be placed in a neutral or vertical position, and the top exhaust duct doors would all be closed.
To maximize the airflow through the lower portion of the drying zone, adjacent the exhaust duct, during all drying conditions, the valve assembly is designed to allow the valve panel farthest from the blower to be maintained in a vertical or neutral position to allow exhausting of air under the valve near the rear of the dryer if blower suction is inadequate, or to pull fresh air into the space through the open section when blower suction is excessive. The top exhaust doors are always open when the valve is placed in either closed position. The end top exhaust door farthest from the blower can also be left open when the butterfly valve is in the neutral or open position to allow the air in the duct to seek a path of least resistance. Thus, in long dryers, some air may be exhausted; in a short dryer, supplemental air may be drawn in by a negative pressure throughout the air duct.
In conjunction with the use of the valves to provide suitable control selectivity of the exhaust air, the width profile of the grain flow path is reshaped to provide an improved structure for the specific purpose of maintaining improved air to grain contact times for each phase of the drying and cooling functions.
It is commonly known in the grain dryer industry that a conventional constant width grain column is simpler and easier to manufacture and that it can provide marginally adequate drying and cooling of grain under a limited range of grain moistures. However, cooling grain with high grain flow rates during low moisture removal drying (3-5 percentage points of moisture removed) is almost always inadequate in conventional dryers. By careful analysis of a wide range of airflow rates through grain columns of several reduced thicknesses, tests confirmed that a thinner grain column than the conventional column thickness (commonly 12 inches) provide significantly higher airflow volume per unit volume of grain; thus, even though the grain retention time is significantly reduced by the thinner grain column, grain cooling increases due to the higher percentage of air volume, which increases at a geometric or non-linear ratio compared to the grain flow velocity which increases at an arithmetic or linear ratio. Thus, the cooling effort is substantially increased. Also a column tapered from the lower drying zone width to a significantly narrower width at the grain outlet of the cooling zone would provide a gradual increase in cooling airflow rate, thus providing "tempered" cooling to the grain in the early part of cooling with the cooling effort accelerated throughout the cooling zone for greatly increased use of all cooling airflow. A narrower column than the conventional column with either parallel or tapered walls significantly improves the grain dryer when combined with the additional control of cooling air volume as provided in this drying method and apparatus design.
In a similar design approach, the grain column thickness in the top portion of the drying zone was analyzed from the standpoint of exhausting the drying air as close as possible to the point where it had physically reached moisture saturation.
It is commonly known in the grain drying industry that air passing through high moisture grain picks up grain surface moisture very easily during what is known as the "Constant Rate" period of drying, where free surface moisture saturates the air by the time it travels only part of the way through the conventional grain column thickness, as compared to drying in the lower portion of the drying zone in what is called the "Falling Rate" period, where the air that exhausts is not saturated. Thus, in continuous flow dryers, it became obvious from analysis of testing that air exhausts at or near saturation over most or all of the upper portion of the drying zone during high temperature drying (180-240° F. Plenum Temperatures), and also that these saturation or wet bulb exhaust temperatures gradually increased to a point at approximately the middle of the drying zone where the exhaust air began to exhaust at less than saturation. This indicates that as the grain temperature rises, there is a saturated air "frontal line" that starts at an intermediate point in the conventional grain column width (near the beginning of the drying zone) and moves gradually outward as the grain moves through the drying zone during the "Constant Rate" period until the front reaches the outer pervious wall at the point where the air starts exhausting at less than saturation, the beginning of the "Falling Rate" period.
Once drying air reaches saturation, ideally it should be exhausted. If it must pass through additional layers of grain which is colder than the air, the cold grain cools the air, lowering the saturation or wet bulb and dry bulb temperatures of the air and because the saturated air cannot hold as much moisture when it cools, part of the vapor in the air condenses on the cold grain. This moisture must be absorbed by more airflow further down the drying column. This "leap frog" effect of absorbing and condensing takes place continually throughout much of the upper drying zone in a conventional width grain column with normal airflow rates.
However, if the grain column is tapered or narrower at the top of the drying zone and widens as it goes down, the air can be exhausted at or shortly after it reaches saturation such that the "saturated air front" approximately parallels the outer pervious grain wall. Thus, little or no rewetting of the grain takes place, the air exhausts saturated at a higher temperature and thus, according to psychrometric data, carries more moisture while being forced through the grain with less pressure or less blower horsepower. Drying fuel efficiency is significantly improved with less power required, improving drying mechanical efficiency. If the original blower horsepower is maintained, the narrower column with a constant plenum pressure results in an overall increase of air velocity and total air volume, thus the drying rate increases and with a lower "dwell time" of air passing through the grain, the saturation front moves farther out in the grain column. Thus, the dryer design must account for the balance point between revised air velocity versus reduced grain column width to establish the grain column design taper or column thickness. To facilitate production, the upper drying zone portion of the grain column may be a compromise of a narrower parallel width that approximates the tapered column while gaining most of the advantage in increased efficiency and performance.
An additional improvement of the dryer is the extension of the pervious outer wall of the dryer onto the lower portion of the wet grain holding column or garner bin. This expanded area of pervious outer wall extends above the adjacent inner pervious wall such that air passes through a diverging grain volume thus causing the first airflow that passes through the grain column to travel slowly to create a tempering or wet grain preheat zone. As the grain thickness reduces air velocity increases until it reaches the minimum thickness of the main drying zone. The air that travels through this preheat zone has a combination path of counterflow and crossflow drying, an excellent tempering preheat airflow design.
It is commonly understood among grain drying authorities that unless grain is very wet, it must be warm before significant moisture removal or drying begins to occur. Thus, preheating to gradually warm the grain is a very desirable function in a high temperature grain dryer to reduce "thermal shock" and stress on the outer kernel structure, reducing stress cracking or "checking" of the grain surface, while gradually expanding the outer layers to induce drying. This helps to maintain a grain kernel that is less susceptible to shipping and storage damage.
Another improvement of the dryer is the capability of applying hotter air to the wettest grain in the top portion of the drying zone and a lower air temperature to grain drying in the "Falling Rate" period of drying in the lower drying zone. This is accomplished by the modification of the burner design from a uniform fuel output throughout the burner manifold to a design incorporating increased levels of output in the upper portion of the burner.
An inclined adjustable deflector duct, used in conjunction with the modified burner, forces an excess volume of the hotter air through an opening in a partial heat plenum floor that extends to a point near the rear of the heat plenum. Fines and foreign material that drops from the upper sloped grain column is blown to the rear and dropped through a gap across the rear of the partial plenum divider into the lower heat plenum adjacent the automatic cleanout device where it is purged from the heat plenum. Removable center panels provide maintenance access to the stationary floor panels along the length of the heat plenum as well as visual access to the upper heat plenum for housekeeping maintenance.
An object of the present invention is to provide an improved grain drying apparatus.
Another object of the invention is to provide an improved apparatus for separatingly controlling the amount of exhaust air released to atmosphere based on the humidity of the portion of the exhaust air coming from the lower exhaust zone compared to the amount of air allowed to recycle for reuse in drying so that the dryer efficiency is further improved.
Another object of the invention is to more directly and precisely control the volume of the dryer exhaust heated air containing economically usable drying energy and return it to the blower for blending with cooling air and free ambient air to reduce the fuel consumption of the device while drying grain, thus providing a dryer of significantly higher efficiency and operating economy then prior art drying systems.
Still another object of the invention is to provide a dryer in which the grain flow to the metering means can be adjusted from external the dryer while the dryer is operating so the dryness of the grain can be controlled along the full length of the drying column by varying the relative velocity of the grain at any point along the dryer length thus significantly increasing the uniformity of grain moisture level, while also being able to easily make precise major adjustments in the grain flow thickness to the metering roll, a very desirable condition when changing from heavy slow drying grains to light density grains that dry very fast.
A further object of this invention is to provide a dryer with properly adjustable temperatures to provide higher temperatures in the upper heat plenum for drying the wettest grain and thus improved drying performance, and a reduced temperature level in the lower heat plenum for final drying of the grain to minimize heat stress and maintain a higher grain quality, while not adding significant complexity to the operation or maintenance of the dryer.
A further object of the invention is to provide a dryer that provides adequate cooling throughout the normally expected range of dryer capacity (4-5 percentage points of moisture removal or more) while having the capability of being adjusted so it will not have to significantly "over cool" at any time.
An additional object of the invention is to provide an improved grain column design that will provide optimum exhaust air efficiency at all points in the "constant rate" drying zone by exhausting the air soon after it reaches saturation so that little or no condensing of moisture takes place on grain before the air is exhausted.
Another object of the invention is to utilize to the maximum the inner pervious drying zone wall area by providing an extended pervious external wall adjacent or above the inner pervious wall, even in the grain holding column or garner bin wall, thus providing tempered preheating of cold grain to reduce thermal stresses which cause stress cracks, to increase the drying zone, or to warm ambient grain.
A still further object is to provide a grain drying and cooling column profile that is substantially improved throughout the course of grain travel by maximizing the use of inner drying area with extended outer drying area beyond the inner level to provide a tempered counter-crossflow preheat airflow pattern, by providing a tapered upper drying zone grain column that parallels and approximates the "exhaust air saturation front", or a narrower column with parallel inner and outer pervious walls that approximate the tapered column, by providing a thicker drying column in the "Falling Rate" or lower drying zone, by developing a tapered or narrower parallel walled cooling zone to provide improved cooling capacity, and externally controlled metering flow gates at the outlet of the grain column that can provide precisely controlled variable grain velocities along the length of the metering rolls so that variations in airflow and or air temperature within the plenum can be compensated for.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a preferred embodiment of the present invention;
FIG. 2 is a front view of the invention taken along line 2--2 of FIG. 1;
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2;
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 1 but operated with the top exhaust doors open;
FIG. 5 is a cross-sectional view taken along line 5--5 of FIG. 1;
FIG. 6 is a side elevational view of the preferred embodiment of the present invention showing solid panels connected to the exhaust duct and enclosing the base of the dryer;
FIG. 7 is a front view of the preferred embodiment taken along line 7--7 of FIG. 6;
FIG. 8 is a detailed partial close-up end view of one externally adjusted grain flow control gate of the metering system at section 4--4 of FIG. 1;
FIG. 9 is a partial inclined side view of the end and intermediate adjustment apparatus for controlling meter gate grain flow gaps taken along line 9--9 of FIG. 8;
FIG. 10 is a partial cross-sectional view like section 5--5 of FIG. 1 of a conventional grain column, such as shown in U.S. Pat. No. 4,268,971, showing typical temperatures and relative humidities;
FIG. 11 is a partial cross-sectional view at section 5--5 of FIG. 1 of an improved tapered drying and cooling column showing typical temperatures and relative humidities;
FIG. 12 is a partial cross-sectional view at section 5--5 of FIG. 1 of the improved narrowed parallel drying and cooling column, shown also in FIGS. 4 and 5, showing typical temperatures and relative humidities;
FIG. 13 is a partial cutaway segmented isometric view of the preferred embodiment showing features and airflow patterns for Mode I drying; i.e., pressure heating and suction cooling with recycled air from the cooling zone and lower part of the drying zone, with an exposed end view of the grain column profile;
FIG. 14 is a cross-sectional view taken along line 14--14 of FIG. 13 showing butterfly valves in a first open position A;
FIG. 15 is a view like FIG. 14, but showing the butterfly valve in a second position B;
FIG. 16 is a view like FIG. 14, but showing the butterfly valve in a third position C;
FIG. 17 is a partial cutaway segmented isometric view of the preferred embodiment showing the airflow patterns during Mode II drying; i.e., pressure heating and cooling with full exhaust, with an exposed end view of the grain column profile;
FIG. 18 is a partial cutaway segmented isometric view of the preferred embodiment showing the airflow patterns during Mode III and V drying; i.e., pressure heat in both upper and lower zones with no cooling and full exhaust;
FIG. 19 is a partial cutaway segmented isometric view of the preferred embodiment showing the airflow patterns during Mode IV during; i.e., pressure heating in both upper and lower zones and no cooling, but with recycling of exhaust air from the lower zone and from the lower part of the upper zone;
FIG. 20 is a schematic similar to FIGS. 4, 14, 15 and 16, showing three operating positions of the butterfly valve during Mode I drying;
FIG. 21 is a cross-sectional view like FIG. 14, but showing a further embodiment of the present invention;
FIG. 22 is a cross-sectional view taken along line 22--22 of FIG. 21;
FIG. 23 is a partial cross-sectional view taken along line 23--23 of FIG. 21; and
FIG. 24 is a schematic view like FIG. 20, showing three operating positions of the butterfly valve during Mode IV drying.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, FIG. 1 shows a framework of the grain dryer 10 constructed in accordance with the present invention which has an outer pervious skin 21 attached to intermediate structural members 22, and structural outer end members 23 which is attached to the outer grain column retaining wall and extends slopingly from the base of the pervious garner bin wall 39a down the vertical sidewall behind an impervious air return duct wall 25, then along the lower slope structure attached along the center of the dryer to base frame 11. A basic grain dryer 10 of this type is shown in U.S. Pat. No. 4,268,971 to Noyes, et al., which is incorporated herein reference.
The return air duct 25, along the sidewall, has top exhaust vent doors 27 and 127 and bottom exhaust vent doors 28 to allow control of exhaust air for returning through return air control doors 46 to the inlet opening 41 of air circulation blower 40, as can best be seen in FIG. 4, which is housed inside an air return duct housing 29 which completely encloses the centrifugal blower 40.
Ambient air inlet louvers or vents 30 are shown in FIGS. 1, 2, 3, 7 and 11. Electrical control equipment is generally housed in control box 31 which is mounted adjacent the fuel plumbing train 32, FIGS. 1 and 2.
Grain is conveyed to the dryer fill hopper 36, FIGS. 1 and 2, where it flows by gravity into the grain column 12 (FIG. 5) contained by outer pervious wall 21, FIG. 5, and inner pervious wall 75, FIG. 5. The grain fills the grain column 12, between the inner walls 75 and the outer wall 21, FIG. 5, and is contained at the lower end by metering roll 51, FIG. 5. When the grain reaches a sufficient volume, the grain is leveled by leveling conveyor 34, FIG. 5, until the dryer grain column and the garner bin 39 (FIG. 5) is filled. Henceforth, grain level sensing controls cause the leveling auger to operate periodically, keeping the dryer filled as the dry grain is discharged by meters 51 into unload conveyor 52 where it exits from the dryer through grain unloading duct 53, FIGS. 1 and 6.
Once the dryer has been filled with wet grain, the blower 40 (FIG. 3) is energized through use of control devices in control panel 31 (FIGS. 1 and 2). The air from the blower passes across the burner 33 best shown in FIGS. 3 and 4, where it is heated to the desired level by fuel controlling devices in the fuel plumbing train 32 (FIG. 1) that monitor the fuel flow to the burner 33.
Referring to FIGS. 1, 4 and 5, it is noted that the dryer body is formed by an assembly of the outer grain column structural end 23 and intermediate structural members 22 attached to pervious outer skin sheets 21 with structural spacing members 56 (FIG. 5) separating the outer pervious skin assembly 21 from a similar inner pervious skin assembly 75 consisting of inner grain column end structural members, FIG. 1, and intermediate structural member 54 (FIG. 5) attached to pervious inner skin panels 75 (FIG. 4), such that a grain column of variable thickness is formed. Note that in FIGS. 4 and 14-16, the width x of the intermediate portion of the grain column is wider than the distance y of the upper portion and lower portion of the grain column. These pervious inner and outer skin assemblies are further enclosed across each end of the grain bed by front bulkhead sealing panels 47 (FIGS. 1 and 2) mounted adjacent to the blower and rear bulkhead panel 48 (FIG. 1); thus, the grain metering assembly 51 restrains the grain at the bottom of the grain column and controls the grain velocity through the column by the variably controlled speed of the metering rool 51 (FIGS. 4 and 5) combined with the variable setting of the externally adjustable metering gate assembly 100, best seen in FIGS. 8 and 9.
The exterior grain column perforation 20 in panels 21 (FIGS. 10-12) are extended part way up the side of the wet grain holding column 39 (FIGS. 4 and 5) with 39a indicating the perforated part of panel 39 and 39b indicating a non-perforated portion, providing tempered preheating of the wet grain with a reduced air velocity that gradually increases as the grain approaches the top of the narrow drying column formed between perforated walls 21 and 75 (FIG. 12). The narrow grain column in the upper portion of the drying zone is found to be most suitable when the average thickness of the upper tapered column 212, FIG. 11, or the width of the narrow parallel column 12 of FIG. 12, is approximately 70 to 75% of the width of the lower portion 13 of the drying zone. The tapered section varies from approximately 60% (at the top) to 85% at the bottom of the width of the wide lower portion of the drying zone, or a taper of from 7 to 10 inches compared to a 12 inch lower drying column width. This thickness provides a very efficient drying process for a variety of grains and a wide range of moisture contents during the "Constant Rate" or surface moisture portion of drying where moisture removal occurs very rapidly. The thicker parallel section 13 in the lower portion of the grain column 12, FIGS. 4, 5 and 12, causes a significant reduction in air velocity, thus greatly increasing the dwell time of the air in contact with the grain for efficient drying during the "Falling Rate" period of drying.
The narrower upper drying column 39a combined with the added preheat zone on the wet grain holding column wall, provides significantly improved drying conditions as illustrated in the illustrations in FIGS. 11 and 12, the narrow tapered and narrow parallel columns, respectively, as compared to the wide conventional upper zone column 112 of FIG. 10. The exhaust temperatures and relative humidities reach higher saturation temperatures much farther up the slope and exhaust air velocities are considerably higher with the narrow column. This improved dryer performance results from the air being able to exhaust very soon after reaching initial moisture saturation.
Air in the conventional column may reach the same saturation temperature, yet have to travel through the remaining 15 to 40% of the grain column passing through grain with lower temperatures than the grain at the moisture saturation frontal line; thus, the air is chilled as it gives up its sensible heat to the cooler grain. As the air cools, it can no longer retain the amount of moisture it could hold at higher temperatures, so moisture condenses on the grain the remainder of the distance until it exhausts. Thus, moisture is continually absorbed and condensed as the grain travels downwardly until the air reaches moisture saturation, just as the air passes through the outer grain column wall. The narrow column's profile approximates the moisture saturation frontal line for design conditions that account for the increased airflow with the reduced grain thickness, providing an improved drying zone as more drying can be done with the same or reduced blower horsepower.
The width of the upper portion 12 of the cooling zone continues at the same width of the lower portion of the drying zone (FIGS. 4, 5 and 12) for (1) ease of construction, and (2) to provide a reduced air velocity tempered cooling condition initially. The lower portion of the cooling zone is a reverse mirror image of the upper portion of the drying zone (FIG. 11 or FIG. 12).
For cooling, the ideal average narrow grain column thickness is slightly less than in the narrow drying column, in order to develop higher cooling airflow rates without requiring excessive suction pressures. Sixth-five (65) to seventy-five (75) percent average width, as compared to the middle portion 13 of the grain column, provides an adequate cooling column for the narrow tapered or parallel column.
The narrow cooling column provides greatly improved cooling as shown in the exhaust temperature conditions in FIGS. 11 and 12 compared to the conventional cooling shown in FIG. 10. Computer analysis, verified by dryer prototype testing, demonstrates that as grain column thickness is reduced, airflow velocities increase as a geometric or non-linear function of the thickness for a given static pressure, compared to the linear or arithmetic change in grain volume that the airflow is exposed to. So, even though the grain velocity increases through the narrow column to maintain the same total throughput rate, the net volume of air per bushel of grain, and thus the net cooling capacity, is greatly improved.
This may not be critical when grain moisture removal is high and dwell time in the cooling zone is long, but when grain moisture removal is low and grain velocity through the cooling zone is high, and when grain must be cooled to within 10° F. or less from the ambient cooling air temperature, it becomes very important. Many commercial drying installations dry the major portion of their grain during the season while removing five (5) percentage points of moisture or less. With conventional dryers, there is only one safe way to be assured of adequately cooled grain, and that is to reduce the drying rate by reducing drying temperature to provide for an adequate dwell time for the grain in the cooling zone.
Referring again to FIG. 5, the cavity formed between the end bulkhead panels 47 and 48, and the pervious inner wall 75, is the air plenum 57. This volume is further defined by plenum divider panels 50 into a first zone volume 58, used for conveying and distributing heated air into the grain column 12, and a second zone volume 59, used primarily for suction flow cooling or pressure flow cooling of the grain, but which can be secondarily used for heated air from the burner 33 (FIG. 4) to be uniformly distributed through the full plenum chamber 57.
The exhaust air return duct structure 77 (FIG. 5) is mounted adjacent the intermediate or vertical portion of the grain column outer wall 21. This structure consists of sidewall panels 25, and sidewall mounting brackets 78, sealed at the end opposite the blower 40 by an end bulkhead panel 79, FIG. 5. The top is enclosed by adjustable air exhaust panels 27 and panel 127 and the bottom by adjustable cleanout panels 28. At the front end of this duct the return air control door 46 for opening or closing the opening 146, best viewed in FIGS. 4(closed) and 14(open), is used to control the exhaust of hot air. A bulkhead member 81 (FIG. 4) seals around the return air control door 46.
A vitally important and novel part of the exhaust air duct assembly is the exhaust air flow separator valve assembly 7 of FIGS. 4, 5, 13-19, 20 and 24. Althrough this function could be performed by various adjustable valve or duct divider panel means, such as a single open or closed door panel arrangement, the preferred embodiment is designed with a novel butterfly type valve assembly 7 that extends laterally essentially the full length of the exhaust air duct as shown in FIG. 13. The pivotally mounted butterfly valve panel length and pivot position was designed to divide the pervious exhaust wall outlet area into specific desirable increments. A smaller second butterfly segment 17 is slideably disposed on the pivot rod of valve 7 and can be moved with regard to the butterfly valve 7. The purpose of segment 17 is to prevent a build-up of pressure in duct 77 that would reduce the flow of air through pervious panel 21 into duct 77 to an unacceptable level, when the valve 7 is in one of closed positions B or C (FIGS. 13, 15, 16 and 19).
When the valve 7 is rotated such that the top of the panel 7 rests against the pervious exhaust wall of the grain column (FIG. 15), the bottom of the panel rests against the impervious outer wall of the exhaust duct, forming an inclined sealing floor divider panel such that exhaust air flow below the divider panel, position B of FIG. 20, is drawn to the inlet to the blower 41, FIG. 3. The airflow exhausting above the divider panel is released through open top exhaust doors 27, FIG. 15. This provides a condition whereby approximately 1/3 of the airflow is exhausted to atmosphere and about 2/3 of the airflow is recycled to the blower for reuse of the sensible heat.
Conversely, when the pivotal divider or butterfly valve panel 7, FIG. 13, is rotated the opposite direction (position C of FIGS. 14 and 16) such that the bottom of the panel contacts the pervious grain wall and the top side touches the impervious outer wall of the exhaust duct, approximately 2/3 of the exhaust air volume that enters the duct is exhausted to atmosphere and 1/3 is recycled.
A third position that is very important is a centered position A shown in FIGS. 4, 14 and 20 where the butterfly valve 7 is placed vertically or in a neutral position. This position is used when all or nearly all of the airflow is to be recycled (FIG. 14) or when none (FIGS. 17 and 18) of the airflow is to be recycled.
It becomes quite evident of the extremely useful and valuable contribution this valve makes to the efficiency and capacity of the dryer. When medium to high moisture grain is being dried using Mode I drying (pressure heat, suction cool with recycled cooling and exhaust air), butterfly valve position "C" (FIGS. 13, 16 and 20) would probably be selected. Top exhaust doors 27 and 127 would be open, and return air control doors 46 would be open, thus recycling only the lower 1/3 of the airflow from the lower position of the drying zone, and exhausting 2/3 of the air from the vertical sidewall.
When the grain requires low to medium moisture removal, butterfly valve position "B" (FIGS. 15 and 20) would be selected. Top exhaust doors 27 and 127 would be open, and the return air control door 46 would be open, thus recycling approximately 2/3 of the exhaust air and exhausting 1/3 of the air from the lower part of the drying zone.
A third condition may exist during Mode I drying (FIG. 13) when low moisture removal drying yields exhaust air quality from the lower half of the drying zone that is fully reusable. In this situation, butterfly valves are placed in the "A" or vertical position (FIGS. 13, 14 and 20). Top exhaust doors 27 are closed, and top exhaust door 127 is open to provide relief from pressure build-up in the exhaust duct 77. Recycled air control doors 46 are open. Thus, all exhaust air from the lower drying zone is recycled unless excess pressure forces some air through door 127, or excess suction draws some ambient air into the duct.
When grain with combustible oil or dust particles such as safflower, sunflowers or milo (grain sorghum) is being dried, using Mode II drying (pressure heat, pressure cool, full exhaust) all of the air exhausting from the sidewall may be unsuitable for recycling. This valve position "A" (FIGS. 4, 17 and 20) would be selected, top exhaust doors 27 and 127 (FIG. 17) would be open, and return air control doors 46 (FIGS. 4 and 17) would be closed, exhausting all drying airflow. The air splitter door 42 would be partially open depending upon the amount of cooling desired in the lower portion of the air column.
The butterfly valve 7 also has a very important function during "dryeration" or Mode IV drying when both the upper and lower plenums are used for pressure heat drying with the lower portion of the dryer enclosed by impervious siding 60, FIG. 19, such that air exhausting from the lower plenum zone 59 below the drying exhaust ducts 77 can be recycled and the air in the exhaust ducts 77 can be controlled for recycling or exhausting as discussed previously for normal pressure heat, with suction cool drying. FIG. 24 shows the position of exhaust doors 27 and 127, valve 7, and cleanout doors 28 during the FIG. 19 dryeration, Mode IV drying.
When using Mode III drying (FIG. 18, full pressure heat, continuous drying in both plenums with full exhaust) or Mode V drying (same as Mode III, except that the metering rolls 51 are not operating) such as for rice drying, "dryeration", or "combination drying" of safflower, sunflowers or milo when no cooling is needed, the butterfly valves 7 and 17 are placed in position "A", top exhaust doors 27 and 127 are open, and return air control doors 46 are closed.
The blower 40 (FIG. 3) is mounted to the base frame 11 and is connected to the dryer upper or heat plenum chamber 58, and front bulkhead 47 by an airflow transition assembly 37. The airflow transition assembly 90 contains a straight through air duct where air from the outlet of the blower 40 passes across burner 33, heating the air as it passes into heat plenum 58. The bottom of the upper air duct portion of the transition is a hinged panel 42 (FIG. 3) adjustably controlled to selectively position the panel or "air splitter" (see U.S. Pat. No. 4,268,971) to divert a desired portion of the blower outlet air into the air control box below the air splitter panel 42 that makes up the lower portion of the airflow transition assembly. Door panels 45 on the air control box 37 are closed when the air splitter is open and are open when the air splitter is closed. Under certain conditions which will be clearly seen later, both the top 42 and side panels 45 of the air control box may be closed for a specific use, but the dryer is never operated with both panels 42 and 45 open.
A weathershield air duct panel housing 29 with louvers 30, (FIGS. 1, 2 and 3) surrounds the blower and transition structure on all sides and connects to the air duct assembly 77 (FIG. 5) mounted on the sidewall of the dryer to effectively route all exhaust drying air from air duct assembly 77 and all of the suction cooling air from the air control box 37 of the airflow transition assembly 89 (FIG. 3), back to the inlet 41 of the centrifugal blower 40, along with providing control of the amount of cooling airflow from the cooling louvers 30 (FIG. 3). The airflow function can also be carried out by vaneaxial and other types of air moving devices.
A novel method of controlling the thickness of the flow of grain to the metering means from external the dryer while the dryer is operating is illustrated best in FIGS. 8 and 9. This grain flow control apparatus 100 consists of formed channel members 101, mounted end to end the full length of the grain dryer, that are supported and adjusted by bolts or threaded adjusting rods 102 near each of each channel, passing through threaded brackets 107 and pipe sleeves 103, then passing loosely through a hole in the upper flange 105 of the channel 101 and retained by fasteners 104 on each side of the flange 105 that provide an upper and lower bearing surface for the flange 105. The channel's lower flange 106 is slotted to provide a saddle such that the channel web is approximately parallel to the adjusting rod 102 and pipe sleeves 103. The channels 101 are incrementally adjusted by turning the bolt 102 so that as the bolt 102 advances or retreats through the threaded bracket 107 (much like a screwjack). The channel 101 is moved upward or downward along the pipe sleeve 103 causing a widening or narrowing of the gap 111 between the lower channel flange 105, FIG. 8, and the lower outer grain column wall 21 which forms one side of the entrance of the metering hopper adjacent the metering rolls 51. An important design consideration is the ease of removal of the metering gate channel 101 for cleanout of the grain column or removal of large objects. This is easily accomplished by removing the retainer clip or lock nut from the top of the bolt or threaded adjusting rod 102 at each end 105 of the channel 101, then sliding the channel 101 up along the pipe 103 and rotating the top flange 105 of the channel 101 up along the pipe 103 and rotating the top flange 105 of the channel 101 inward and downward toward the unload conveyor 52 in the center of the dryer 10. Replacement is done by reversing the removal process.
Another advantage of this part of the invention is that a clearance gap 109 can be maintained between the grain retainer panel 110, FIG. 8, due to the relationship of the angle of repose of the grain compared to the width of the gap, and the elevation of the top flange of the channel compared to the bottom edge of the grain retainer panel 110. This gap 109 greatly reduces assembly time and the critical fit of components during assembly.
Still another feature of the design is that precise adjustment of each channel section 101 can be made from outside the dryer by measuring the exposed bolt extension from the threaded bracket 107, FIG. 8. This allows the dryer operator to set a uniform metering throat gap 111 throughout the dryer for uniform metering flow, while also having the capability of setting non-uniform settings in sections of the dryer where it is determined that a grain flow of a different rate is highly desirable. These settings can be made within minutes without interrupting the drying operation as compared to conventional adjustments that must be made within the dryer, which requires several dryer shutdowns and cooling of the dryer plenum to achieve precise settings, a process which becomes quite frustrating to the operator, and counterproductive to the drying operation.
A further major advantage of this novel apparatus is that a wide range of opening can be made without modification of the dryer mechanically. This is quite important when drying crops of diverse physical characteristics and physical properties. For example, (1) soybeans, which are large, round, and heavy (60 lbs. per bushel); (2) corn, which is large, rectangular, flat or rounded, and heavy (56-58 lbs. per bushel); and (3) wheat, which is intermediate, tapered, and heavy (60 lbs. per bushel) may be dried by the same dryer as (4) oats, at 32-34 lbs. per bushel, and (5) sunflowers, at 24-32 lbs. per bushel (when immature, 16-20 lbs. per bushel) without modifications. The lightweight, bulky grains dry much faster than the heavier grains, thus requiring a very wide throat gap opening 111 to avoid having to modify the metering drive train, compared to the heavy dense grains. Rice must be handled at a very high throughput rate to keep kernel temperature below critical levels that would greatly impair quality and thus selling price, while maintaining adequate capacity. Rice must be passed through the dryer several times since all the moisture cannot be removed during one pass without severe heat stress cracking and extreme quality loss.
The wet grain in the upper portion of the drying zone can tolerate a higher drying temperature during the "Constant Rate" period of drying than the partially dried grain in the lower portion of the drying zone when moisture removal is decreasing. It is desirable to provide temperature separation, but without adding substantial cost and complexity to the dryer structure. It is also well-known that air within a plenum chamber does not flow in a laminar homogeneous fashion, but is turbulent and has currents that flow in varied fashion through the plenum, varying even between dryers of like make, size, and identical design due to difference in management settings. Thus, merely modifying the burner unit to provide more heat at the top than the bottom of the plenum will not assure that excessive temperatures and hot spots will not occur at various locations in the lower plenum; and, likewise, low temperature spots may occur in the top of the plenum due to air current variations.
To improve the dryer operation by being able to provide segragated drying air temperatures without developing separate air sources, separate burners, and a complete plenum divider structure between the upper and lower drying zones in the heat plenum, which would add substantially to the dryer cost and complicate maintenance, due to difficult access to the upper plenum, a composite design approach was conceived. A burner 135 (FIGS. 21 and 22) was designed to deliver a higher heat output at the top and reducing by stages toward the bottom level of the burner to provide a higher temperature airflow immediately adjacent the top of the burner air duct and a lower temperature near the floor. This can be done simply by providing more or bigger orifices in the burner where more gas (more heat) is desired, or more gas can be supplied to the burners at higher levels by valving the output at each level. An example of the temperature stratification can be seen in the schematic cross-sectional views of the grain column designs in FIGS. 10, 11 and 12.
Then, an adjustable air deflector duct 142 (FIGS. 21 and 22) is used to segregate the airflow from the burner 135 to provide slightly more than the appropriate amount of the air volume to the upper half of the grain column in the upper drying zone. This inclined adjustable deflector duct 142 forces the air through an opening in the partial plenum divider 150, including solidly affixed parts 152 and removable panels 151, which separate the upper part 160 from the lower part 161 of the upper heat plenum zone 58. The partial plenum floor 150 extends to a point near the rear wall of the heat plenum zone chamber 58, leaving an opening 153 to provide for airflow between the upper and lower portions of the upper chamber 58. With a designed and controlled amount of excess air in the upper part 160 above plenum floor 150, the lateral air velocity sweeps grain particles, dust, and other foreign matter to the rear opening 70 where the material is carried downward by the excess airflow to the hopper of the automatic cleanout device 73 (as disclosed in U.S. Pat. No. 4,268,971) for expulsion from the heat plenum 58. Center panels 151 of the upper heat plenum divider 150 are easily removable to facilitate inspection and cleaning of the stationary upper plenum divider panels 152.
In summary, the valves 7 in each exhaust duct 77 are used in conjunction with top and bottom exhaust vent doors 27 and 28 to selectively separate or proportion as desired and therefore contorl the exhaust air for recycling volume and humidity control.
By indepth analysis and computer simulation, the grain column was redesigned to provide optimum use of the blower energy for increased dryer efficiency and capacity. By carefully observing the exhaust air psychrometric state conditions through the length of the drying air exhaust zone, it became apparent that excessive air horsepower is required in the prior art to dry in the upper portion of the heat zone and cool in the cooling zone. The dryer grain column thickness was redesigned and tested to conform the computer simulation; for example, as shown in FIGS. 11 and 12.
A more positive means of control was needed for continuous column grain dryers whereby grains of all densities could be controlled uniformly (while the dryer is operating, if desired). A precision means 100 of setting all sections of the metering gate throat gap was designed to obtain a uniform grain volume from each section of the dryer, or of being able to precisely set an alternate grain flow throat spacing when desired due to variable dryer airflow rate, drying air temperature differences within the drying column, and difference in grain particle size distribution at various stations along the drying columns.
To increase the effectiveness of the increased drying area created by the narrowed upper portion of the grain column (FIGS. 11 and 12), the lower portion 39a of the garner bin 39 or wet grain holding column at the top of the structure was made pervious as an extension of the adjacent outer pervious wall. This was a necessity to offset the increased air pressure produced in the garner bin 39 by the thinner upper grain column, as well as to provide a gentle combination of counterflow and crossflow preheat drying of the thickened grain column in the garner section. This perforated preheat section 39a also greatly minimizes the surging of airflow caused by the rising and falling of the grain in a powered (low profile) garner bin. It also greatly minimizes the potential hazard of moist air being forced up the gravity spouts of bucket elevators where it condenses and runs into other grain storage structures causing spoilage of grain in thos structures. The positioning of this perforated section of the garner bin structure is very important. By positioning it adjacent the pervious outer grain column wall, where it is continually covered by moving grain, the grain acts to automatically and continually "wipe" the inner side of the pervious wall, thus keeping it clean while still allowing it to contain "beeswings" and other light weight foreign material too large to be forced through the openings in the pervious wall section. However, pervious panels placed above the grain level would quickly become coated and sealed over from the inside by the airborne foreign material yielding it totally ineffective for allowing preheat air to pass through the grain. If large openings were placed in the garner panels above the grain level, foreign material would be blown out, polluting the air and surrounding area.
A modified burner 133 designed to burn more fuel in the top of the burner than the bottom, is combined with an adjustable air deflector 142 to route a controlled volume of air into the upper heat plenum above a partial plenum separation panel 150 to provide high temperature drying air for the wet grain and lower final drying air temperature in the lower drying zone. The plenum floor 150 stops short of the rear of the heat plenum so that visual inspection of the upper floor can be made as well as allowing excess air to sweep foreign material to the automatic cleanout hopper 70 at the rear of the heat plenum.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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A cross flow grain drying and conditioning apparatus having an improved grain column configuration wherein the thickness is narrower at the top and bottom thereof than at an intermediate portion thereof for optimumly confining the grain to be dried. A single blower operates to force heated drying air through a first zone of the column of grain and to pull cooling air through a second zone or alternatively to push heated air through both the first and second zones by opening or closing a plenum divider which can be closed to define the zones or opened to combine the zones. An exhaust drying and cooling air recycling structure is provided for regulating the volume of exhaust air versus recycled air in an exhaust area and for blending unsaturated exhaust heated air with incoming cooling air drawn from the second zone or secondly for recycling exhausted drying air from the second zone when using both zones for best drying, or thirdly for exhausting all drying and cooling air when using pressure heating and cool drying. A secondary partial plenum divider and an improved burner also provided for supplying hotter air to the cooler, wetter incoming grain than to the partially dried and warmer grain as such grain moves down through the grain column. The secondary partial plenum divider also includes an opening therein for inspection and for allowing fines to drop out into an automatic cleanout apparatus.
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CROSS-REFERENCE TO RELATED PATENT APPLICATION OR PRIORITY CLAIM
[0001] This application is a Divisional of U.S. patent application Ser. No. 11/901,138, filed Sep. 13, 2007 titled “Cell Delivery Matrices”, which claims priority to U.S. Provisional Patent Application No. 60/846,468, filed Sep. 21, 2006, the contents of which are incorporated herein by reference and in their entirety.
FIELD OF THE INVENTION
[0002] The present disclosure relates generally to compositions and methods for improving the efficacy of cell based therapies through use of a composition that significantly mitigates migration of the cells from the site of delivery. More specifically, the present disclosure relates to cell delivery matrices that localize adipose derived endothelial cells and improve adherence of the endothelial cells to the target tissue, body cavity, or joint.
BACKGROUND OF THE INVENTION
[0003] In recent years, numerous therapies have been developed utilizing a variety of stem cells, presaging an emerging new specialty called regenerative medicine that promises to harness stem cells from embryonic and somatic sources to provide replacement cell therapies for genetic, malignant, and degenerative conditions. Adipose derived endothelial cells are pluripotent stem cells, having the ability to differentiate into smooth muscle or other types of cells, as described in Oliver Kocher and Joseph A. Madri, Modulation of Actin m RNA s in Cultured Vascular Cells By Matrix Components and TGF-β, In Vitro Cellular & Developmental Biology, Vol. 25, No. 5. May 1989, which is incorporated herein by reference in its entirety. As such, these cells are useful in retention or restoration of cardiac function in acute and chronic ischemia. Cells within adipose tissue can differentiate into cells expressing a cardiomyocytic or endothelial phenotype, as well as angiogenic and antiapoptotic growth factors.
[0004] Direct injection or transplantation of cells may effectively restore small areas of damage, but to reconstruct severe damage to injured tissue, resulting from major coronary artery blockage, for example, will require extensive therapy with numerous differentiated cells. Such therapy is enhanced by maintaining endothelial cells at a target site for a therapeutically effective period of time, which may be from hours to days. In some embodiments, a therapeutically effective period of time is weeks to months.
SUMMARY OF THE INVENTION
[0005] Cell delivery matrices are described that maintain local delivery of adipose derived endothelial cells and other therapeutic agents to a target tissue, body cavity, or joint. The cell delivery matrix may be a three-dimensional matrix scaffold comprising fibrin derived from the patient's own body. The cell delivery matrix used in the methods of the invention may be degradable, bioabsorbable or non-degradable. In an embodiment, the cell delivery matrix is an artificial, FDA-approved synthetic polymer. In an embodiment, the cell delivery matrix comprises expanded polytetrafluoroethylene (ePTFE). In another embodiment, the cell delivery matrix comprises polyethyleneterephthalate (PET). The cell delivery matrix may be biocompatible and semi-permeable. The surface of the cell delivery matrix may comprise an immobilized adhesion molecule.
[0006] The present disclosure provides regenerative therapies comprising implanting in the subject cell delivery matrices localizing adipose derived endothelial cells. The cell delivery matrices maintain the adipose derived endothelial cells at the target for a therapeutically effective amount of time. The adipose derived endothelial cells can be allogenic or syngenic to the subject. The endothelial cells may be delivered alone or in combination with other therapeutic agents.
[0007] A skilled artisan will appreciate that the subject of the present invention may be any animal, including amphibians, birds, fish, mammals, and marsupials, but is preferably a mammal (e.g., a human; a domestic animal, such as a cat, dog, monkey, mouse, and rat; or a commercial animal, such as a cow, horse or pig). Additionally, the subject of the present invention may be of any age, including a fetus, an embryo, a child, and an adult.
BRIEF DESCRIPTION OF THE FIGURES
[0008] FIG. 1 depicts a cell delivery matrix. Arrows indicate localized endothelial cells and the semi-porous biomaterial.
DETAILED DESCRIPTION
[0009] Those of ordinary skill in the art will realize that the following detailed description is illustrative only and is not intended to be in any way limiting. Other embodiments will readily suggest themselves to such skilled persons having the benefit of this disclosure.
[0010] As used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the content clearly dictates otherwise. All publication, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. Additionally, the section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described. All references cited in this application are expressly incorporated by reference for any purpose.
[0011] U.S. Pat. No. 5,372,945, incorporated herein by reference in its entirety, discloses methods and devices that may be used for the ready isolation of large quantities of endothelial cells having the ability to differentiate into smooth muscle. According to an embodiment, subcutaneous fat is removed from a patient using modified liposuction techniques and transferred to a self-contained, closed device where the fat can be stored under sterile conditions until needed. The fat is sterilely transferred to a digestion device where it is initially washed to remove red blood cells and other debris, followed by a controlled collagenase digestion for about 20 minutes at about 37° C. The fat slurry is then transferred to an endothelial cell isolation device, again under sterile conditions, where endothelial cells sediment into an isolation device, allowing automatic retrieval of the isolated endothelial cells. The cell suspension is then sterilely transferred to a processing unit wherein the cells are rapidly filtered onto the graft surface under sterile conditions. The endothelial cell isolation and deposition process requires only about 40 minutes for completion. Following an incubation period, the graft is ready for implantation into the patient. The system yields endothelial cell product in numbers acceptable for subsequent high density seeding, e.g., in a range of about 5.14×10 6 to 4.24×10 7 cells from 50 cc of fat, and adherence to the graft surface. The apparatus deposits cells along the entire length and diameter of the graft consistently, with no significant difference in cell concentration as compared by analysis of variance.
[0012] As depicted in FIG. 1 , after isolation these cells may then be localized by a cellular matrix. The cell delivery matrix that localizes the endothelial cells may be a three-dimensional culture, which is liquid, gel, semi-solid, or solid at 25° C. The three-dimensional culture may be biodegradable or non-biodegradable.
[0013] The cell delivery matrix used in the methods of the invention may be comprised of any degradable, bioabsorbable or non-degradable, biocompatible polymer. Exemplary three-dimensional culture materials include polymers and hydrogels comprising collagen, fibrin, chitosan, MATRIGEL, polyethylene glycol, dextrans including chemically crosslinkable or photocrosslinkable dextrans, and the like. In an embodiment, the three-dimensional culture comprises allogeneic components, autologous components, or both allogeneic components and autologous components. In an embodiment, the three-dimensional culture comprises synthetic or semi-synthetic materials. In an embodiment, the three-dimensional culture comprises a framework or support, such as a fibrin-derived scaffold. The term scaffold is used herein to include a wide variety of three-dimensional frameworks, for example, but not limited to a mesh, grid, sponge, foam, or the like.
[0014] The term “polymer” is also used herein in the broad sense and is intended to include a wide range of biocompatible polymers, for example, but not limited to, homopolymers, co-polymers, block polymers, cross-linkable or crosslinked polymers, photoinitiated polymers, chemically initiated polymers, biodegradable polymers, nonbiodegradable polymers, and the like. In other embodiments, the prevascularized construct comprises a polymer matrix that is nonpolymerized, to allow it to be combined with a tissue, organ, or engineered tissue in a liquid or semi-liquid state, for example, by injection. In certain embodiments, the prevascularized construct comprising liquid matrix may polymerize or substantially polymerize “in situ.” In certain embodiments, the prevascularized construct is polymerized or substantially polymerized prior to injection. Such injectable compositions are prepared using conventional materials and methods know in the art, including, but not limited to, Knapp et al., Plastic and Reconstr. Surg. 60:389 405, 1977; Fagien, Plastic and Reconstr. Surg. 105:362 73 and 2526 28, 2000; Klein et al., J. Dermatol. Surg. Oncol. 10:519 22, 1984; Klein, J. Amer. Acad. Dermatol. 9:224 28, 1983; Watson et al., Cutis 31:543 46, 1983; Klein, Dermatol. Clin. 19:491 508, 2001; Klein, Pedriat. Dent. 21:449 50, 1999; Skorman, J. Foot Surg. 26:511 5, 1987; Burgess, Facial Plast. Surg. 8:176 82, 1992; Laude et al., J. Biomech. Eng. 122:231 35, 2000; Frey et al., J. Urol. 154:812 15, 1995; Rosenblatt et al., Biomaterials 15:985 95, 1994; Griffey et al., J. Biomed. Mater. Res. 58:10 15, 2001; Stenburg et al., Scfand. J. Urol. Nephrol. 33:355 61,1999; Sclafani et al., Facial Plast. Surg. 16:29 34, 2000; Spira et al., Clin. Plast. Surg. 20:181 88, 1993; Ellis et al., Facila Plast. Surg. Clin. North Amer. 9:405 11, 2001; Alster et al., Plastic Reconstr. Surg. 105:2515 28, 2000; and U.S. Pat. Nos. 3,949,073 and 5,709,854.
[0015] A cell delivery matrix may comprise collagen, including contracted and non-contracted collagen gels, hydrogels comprising, for example, but not limited to, fibrin, alginate, agarose, gelatin, hyaluronate, polyethylene glycol (PEG), dextrans, including dextrans that are suitable for chemical crosslinking, photocrosslinking, or both, albumin, polyacrylamide, polyglycolyic acid, polyvinyl chloride, polyvinyl alcohol, poly(n-vinyl-2-pyrollidone), poly(2-hydroxy ethyl methacrylate), hydrophilic polyurethanes, acrylic derivatives, pluronics, such as polypropylene oxide and polyethylene oxide copolymer, or the like. The fibrin or collagen may be autologous or allogeneic with respect to the patient. The matrix may comprise non-degradable materials, for example, but not limited to, expanded polytetrafluoroethylene (ePTFE), polytetrafluoroethylene (PTFE), polyethyleneterephthalate (PET), poly(butylenes terephthalate (PBT), polyurethane, polyethylene, polycabonate, polystyrene, silicone, and the like, or selectively degradable materials, such as poly (lactic-co-glycolic acid; PLGA), PLA, or PGA. (See also, Middleton et al., Biomaterials 21:2335 2346, 2000; Middleton et al., Medical Plastics and Biomaterials, March/April 1998, at pages 30 37; Handbook of Biodegradable Polymers, Domb, Kost, and Domb, eds., 1997, Harwood Academic Publishers, Australia; Rogalla, Minim. Invasive Surg. Nurs. 11:67 69, 1997; Klein, Facial Plast. Surg. Clin. North Amer. 9:205 18, 2001; Klein et al., J. Dermatol. Surg. Oncol. 11:337 39, 1985; Frey et al., J. Urol. 154:812 15, 1995; Peters et al., J. Biomed. Mater. Res. 43:422 27, 1998; and Kuijpers et al., J. Biomed. Mater. Res. 51:136 45, 2000).
[0016] The surface of the cell delivery matrix may comprise an immobilized adhesion molecule, as described in U.S. Pat. No. 5,744,515, incorporated herein by reference in its entirety. In certain embodiments the immobilized adhesion molecule is selected from the group consisting of fibronectin, laminin, and collagen. The adhesion molecules may be immobilized to the surface, including the pores of the surface, of the matrix by means of photochemistry.
[0017] The cell delivery matrix, in addition to localizing endothelial cells, may localize at least one cytokine, at least one chemokine, at least one antibiotic, such as an antimicrobial agent, at least one drug, at least one analgesic agent, at least one anti-inflammatory agent, at least one immunosuppressive agent, or various combinations thereof. The at least one cytokine, at least one antibiotic, at least one drug, at least one analgesic agent, at least one anti-inflammatory agent, at least one immunosuppressive agent, or various combinations thereof may comprise a controlled-release format, such as those generally known in the art, for example, but not limited to, Richardson et al., Nat. Biotechnol. 19:1029 34, 2001.
[0018] Exemplary cytokines include angiogenin, vascular endothelial growth factor (VEGF, including, but not limited to VEGF-165), interleukins, fibroblast growth factors, for example, but not limited to, FGF-1 and FGF-2, hepatocyte growth factor, (HGF), transforming growth factor beta (TGF-.beta.), endothelins (such as ET-1, ET-2, and ET-3), insulin-like growth factor (IGF-1), angiopoietins (such as Ang-1, Ang-2, Ang-3/4), angiopoietin-like proteins (such as ANGPTL1, ANGPTL-2, ANGPTL-3, and ANGPTL-4), platelet-derived growth factor (PDGF), including, but not limited to PDGF-AA, PDGF-BB and PDGF-AB, epidermal growth factor (EGF), endothelial cell growth factor (ECGF), including ECGS, platelet-derived endothelial cell growth factor (PD-ECGF), placenta growth factor (PLGF), and the like. Cytokines, including recombinant cytokines, and chemokines are typically commercially available from numerous sources, for example, R & D Systems (Minneapolis, Minn.); Endogen (Woburn, Wash.); and Sigma (St. Louis, Mo.). The skilled artisan will understand that the choice of chemokines and cytokines for incorporation into particular prevascularized constructs will depend, in part, on the target tissue or organ to be vascularized or revascularized.
[0019] In certain embodiments, the cell delivery matrix further localizes at least one genetically engineered cell. Descriptions of exemplary genetic engineering techniques can be found in, among other places, Ausubel et al., Current Protocols in Molecular Biology (including supplements through March 2002), John Wiley & Sons, New York, N.Y., 1989; Sambrook et al., Molecular Cloning: A Laboratory Manual, 2.sup.nd Ed., Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., 1989; Sambrook and Russell, Molecular Cloning: A Laboratory Manual, 3.sup.rd Ed., Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., 2001; Beaucage et al., Current Protocols in Nucleic Acid Chemistry, John Wiley & Sons, New York, N.Y., 2000 (including supplements through March 2002); Short Protocols in Molecular Biology, 4.sup.th Ed., Ausbel, Brent, and Moore, eds., John Wiley & Sons, New York, N.Y., 1999; Davis et al., Basic Methods in Molecular Biology, McGraw Hill Professional Publishing, 1995; Molecular Biology Protocols (see the highveld.com website), and Protocol Online (protocol-online.net). Exemplary gene products for genetically modifying the genetically engineered cells of the invention include, plasminogen activator, soluble CD4, Factor VIII, Factor IX, von Willebrand Factor, urokinase, hirudin, interferons, including alpha-, beta- and gamma-interferon, tumor necrosis factor, interleukins, hematopoietic growth factor, antibodies, glucocerebrosidase, adenosine deaminase, phenylalanine hydroxylase, human growth hormone, insulin, erythropoietin, VEGF, angiopoietin, hepatocyte growth factor, PLGF, and the like.
[0020] In certain embodiments, a cell delivery matrix further comprises appropriate stromal cells, stem cells, or combinations thereof. As used herein, the term “stem cells” includes traditional stem cells, progenitor cells, preprogenitor cells, reserve cells, and the like. Exemplary stem cells include embryonic stem cells, adult stem cells, pluripotent stem cells, neural stem cells, liver stem cells, muscle stem cells, muscle precursor stem cells, endothelial progenitor cells, bone marrow stem cells, chondrogenic stem cells, lymphoid stem cells, mesenchymal stem cells, hematopoietic stem cells, central nervous system stem cells, peripheral nervous system stem cells, and the like. Descriptions of stem cells, including method for isolating and culturing them, may be found in, among other places, Embryonic Stem Cells, Methods and Protocols, Turksen, ed., Humana Press, 2002; Weisman et al., Annu Rev. Cell. Dev. Biol. 17:387 403; Pittinger et al., Science, 284:143 47, 1999; Animal Cell Culture, Masters, ed., Oxford University Press, 2000; Jackson et al., PNAS 96(25):14482 86, 1999; Zuk et al., Tissue Engineering, 7:211 228, 2001 (“Zuk et al.”); Atala et al., particularly Chapters 33 41; and U.S. Pat. Nos. 5,559,022, 5,672,346 and 5,827,735. Descriptions of stromal cells, including methods for isolating them, may be found in, among other places, Prockop, Science, 276:71 74, 1997; Theise et al., Hepatology, 31:235 40, 2000; Current Protocols in Cell Biology, Bonifacino et al., eds., John Wiley & Sons, 2000 (including updates through March, 2002); and U.S. Pat. No. 4,963,489.
[0021] Therapeutic agents that can also be localized by the cell delivery matrix may include Transforming Growth Factor beta (TGFβ) and TGF-β-related proteins for regulating stem cell renewal and differentiation.
[0022] Further therapeutic agents that may be used include anti-thrombogenic agents or other agents for suppressing stenosis or late restenosis such as heparin, streptokinase, urokinase, tissue plasminogen activator, anti-thromboxane B 2 agents, anti-B-thromboglobulin, prostaglandin E, aspirin, dipyridimol, anti-thromboxane A 2 agents, murine monoclonal antibody 7E3, triazolopyrimidine, ciprostene, hirudin, ticlopidine, nicorandil, and the like. Anti-platelet derived growth factor may be used as a therapeutic agent to suppress subintimal fibromuscular hyperplasia at an arterial stenosis site, or any other inhibitor of cell growth at the stenosis site may be used.
[0023] Other therapeutic agents that may be used in conjunction with endothelial cells may comprise a vasodilator to counteract vasospasm, for example an antispasmodic agent such as papaverine. The therapeutic agents may be vasoactive agents generally such as calcium antagonists, or alpha and beta adrenergic agonists or antagonists. Additionally, the therapeutic agent may be an anti-neoplastic agent such as 5-fluorouracil or any known anti-neoplastic agent, preferably mixed with a controlled release carrier for the agent, for the application of a persistent, controlled release anti-neoplastic agent to a tumor site.
[0024] The therapeutic agent may be an antibiotic, which may be applied to an infected stent or any other source of localized infection within the body. Similarly, the therapeutic agent may comprise steroids for the purpose of suppressing inflammation or for other reasons in a localized tissue site.
[0025] Additionally, glucocorticosteroids or omega-3 fatty acids may be localized by the cell delivery matrix, particularly for stenosis applications. Any of the therapeutic agents may include controlled release agents to prolong the persistence.
[0026] The therapeutic agent may constitute any desired mixture of individual pharmaceuticals of the like, for the application of combinations of active agents. The pharmaceutical agent may support the survival of the cell (e.g., a carbohydrate, a cytokine, a vitamin, etc.). The cell delivery matrix can be delivered to the target tissue, body cavity, or joint by any local delivery means known in the art. Applicant's provisional application 60/841,009, entitled “Catheter for Cell Delivery,” incorporated herein by reference in its entirety, discloses methods and apparatuses suitable for local delivery of the cell delivery matrices of the present disclosure. In an embodiment, the cell delivery system used to deliver the cells locally comprises a catheter. The catheter may comprise an inner bladder and an outer perforated bladder that permits localized delivery of stem cells. The inner bladder may be expanded through the use of a pressure conduit in order to deploy a stent. Cell matrices comprising endothelial cells may be introduced between the inner and outer bladder. The inner bladder may be further expanded in order to exert pressure on the outer perforated bladder to advance the cells though the apertures of the outer bladder. The inner bladder may remain pressurized to hold the outer bladder against the vessel wall, thereby directing the cells to specific target sites. In an embodiment, a three-dimensional matrix scaffold comprising fibrin is delivered locally without cells, in accordance with the methods disclosed in Application Number 60/841,009.
[0027] Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the invention. It is to be understood that the forms of the invention shown and described herein are to be taken as the presently preferred embodiments. Elements and materials may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the invention may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the invention. Changes may be made in the elements described herein without departing from the spirit and scope of the invention as described in the following claims.
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Cell delivery matrices and methods for facilitating local delivery of adipose derived endothelial cells to a target tissue, body cavity, or joint are described. The cell delivery matrix may be a three-dimensional matrix scaffold comprising fibrin derived from the patient's own body. The cell delivery matrix may be biocompatible and semi-permeable. The cell delivery matrix used in the methods of the invention may be comprised of any degradable, bioabsorbable or non-degradable, biocompatible polymer. Regenerative therapies comprising implanting in the subject cell delivery matrices localizing adipose derived endothelial cells are described. The cell delivery matrices maintain the adipose derived endothelial cells at the target for a therapeutically effective amount of time. The adipose derived endothelial cells can be allogenic or syngenic to the subject. The endothelial cells may be delivered alone or in combination with other therapeutic agents.
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BACKGROUND OF THE INVENTION
The present invention relates to a laser system and a method of use, and more particularly to a method and an apparatus for a high power laser beam capable of thermally reacting with a target of a rigid material to create cuts and apertures of higher symmetry in the material than heretofore achieved.
Method and apparatus for producing high power laser beams have found many uses and applications in the art, including the use of such a device to scribe or cut a target comprised of a rigid material, such as metals, wood, rubber, plastics or ceramics. By scribing or cutting it is meant that the high power laser beam thermally reacts with the target vaporizing the material to create apertures or holes discretely or continuously in said material. Conventionally, such an apparatus has used a CO 2 laser, operating at 10.6 microns, and having a power output of at least 10 watts. The beam output from such a laser is focussed onto the target material. The target material includes rigid materials such as metals, wood, rubber, plastics or ceramics. Heretofore, it has been felt that the polarization of the beam is unimportant in the application of scribing or cutting of the rigid material. In particular, it was believed that the state of polarization of the beam made no difference in the size or shape of the aperture which resulted from the beam thermally reacting with the material.
U.S. Pat. No. 4,116,542 teaches a method and apparatus for reducing the coherence and for smoothing the power density profile of a collimated high power laser beam, in which the beam is focussed at a point on the surface of a target fabricated of material having a low atomic number. In that patent, it was disclosed that the laser beam incident upon the target material, in one example, was shown to be a circularly polarized beam. However, the use of a circularly polarized beam in that patent served the function of reducing the coherence and for smoothing the power density profile of the laser beam. Moreover, the beam was circularly polarized in order that the reflected beam from the target material would not be reflected back into the amplifier section of the laser, thereby overcoming the problem of potential damage to the laser. It is clear, from a reading of that patent, that it does not teach the particular method and apparatus for a high power laser beam thermally reacting with a target of a rigid material to create symmetrically shaped apertures in the material.
In Applied Optics, Vol. 19, page 2688 (1980), and Vol. 18, page 1875 (1979), a quarter wave reflector using multi-layer dielectric material is disclosed. However, the apparatus and method of thermally reacting a high power laser beam with a rigid material is not taught.
In a paper entitled "Cutting With Polarized Laser Beams" by F. O. Olsen, presented at the German Welding Institute Conference in Essen, in May 1980, and published subsequently in the Digest of that meeting, the author described the influence of the plane of polarization of the beam on the shape of the apertures created thereby.
SUMMARY OF THE INVENTION
In accordance with the apparatus of the present invention, a laser system adapted for generating a high power laser beam which is aligned to impinge a target of a rigid material to thermally react with the material to remove a portion therefrom, has a laser means for generating the high power beam of electromagnetic coherent radiation having a state of polarization. The beam is aligned to impinge the material. Controlling means are provided to control the polarization of the beam with respect to the material such that the portion removed is symmetrically shaped.
The present invention also provides a method for using the foregoing apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of one embodiment of the apparatus of the present invention.
FIGS. 2(a-c) are magnified schematic views of apertures of the prior art (FIGS. 2a and 2b) and of the present invention (FIG. 2c), created by thermally reacting the laser beam with a target of rigid material.
FIG. 3 is a schematic side view of another embodiment of the apparatus of the present invention.
FIG. 4 is a schematic view of yet another embodiment of the apparatus of the present invention.
FIG. 5 is an enlarged schematic side view of one component, a reflector having a phase shift, used in the apparatus of the present invention.
FIGS. 6(a-c) are side views of a cavity formed by a stationary beam (FIG. 6a), and cavities developed in time by a moving beam with the direction of polarization parallel and perpendicular to the direction of motion respectively (FIGS. 6b and 6c).
FIGS. 7(a-d) are top and side views of a row of cuts created by a laser whose direction of polarization is parallel to the direction of the cut (FIG. 7a), perpendicular to the direction of the cut (FIG. 7b) and at an oblique angle to the direction of the cut (FIGS. 7c and 7d).
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, there is shown a laser system 10 of the present invention. The system 10 comprises a laser 12, such as a CO 2 laser, capable of generating a high power beam of electromagnetic coherent radiation, typically at 10 watts. The beam is aligned to traverse along path 22. A linear polarizer 14 linearly polarizes the beam. The path 22 then enters into a quarter wave means 16. The quarter wave means 16 comprises a first reflector 18 and a second reflector 20. The beam travels along the path 22 and is aligned to impinge the first reflector 18 at forty-five degrees (45°) from the normal to reflect therefrom, to impinge the second reflector 20 also at forty-five degrees (45°) from the normal and to reflect therefrom. From the quarter wave means 16 the beam travels along path 22 and is focussed by the focussing beams 24, which is simply a focusing lens. The focussing means 24 focusses the beam onto a target 30, which typically is of a rigid material, such as steel, stainless steel or ceramics. The quarter wave means 16 is exactly analogous to a transmissive quarter wave plate. The quarter wave means 16 has an angle of retardation of substantially 90°. Having the properties of a transmissive quarter wave plate, the quarter wave means 16 converts the linearly polarized beam from the linear polarizer 14 into a circularly polarized beam. The linearly polarized beam may also be from the laser 12, which innately may have a direction of linear polarization. In FIG. 1 the quarter wave means 16 is comprised of two identical reflectors, 18 and 20 respectively, each having an angle of retardation of substantially 45°. The particular physical characteristics of the first or second reflectors 18 or 20 respectively and the quarter wave means 16 is the subject of a co-pending patent application by D. Fischer and A. Bloom and assigned to the same assignee as the present application. They will be described hereinafter. From FIG. 1 it is seen that the quarter wave means 16 has at least one reflecting surface, and the beam travelling along the path 22 is aligned to impinge and to reflect from the one reflecting surface.
Referring to FIGS. 2a and 2b, there is shown the apertures, greatly enlarged, created by the laser system of the prior art. The direction of the scribe or cutting is shown by the arrow 50. In FIG. 2a the beam is linearly polarized along the direction shown by arrow 52 which is parallel to the direction of scribing or cutting. The resultant aperture as shown in FIG. 2a is of a hole that is very straight with maximum penetration. In FIG. 2b the incident beam is also linearly polarized. However, the direction of polarization is along an axes shown by the arrow 54 which is perpendicular to the direction of travel as shown by the arrow 50. The resultant aperture as seen in FIG. 2b is of an asymmetric hole which is curved back to the bottom in the direction opposite that of the direction of scribing. In addition, the depth of penetration is not as deep as that shown in FIG. 2a where the direction of polarization is parallel to the direction of travel.
Referring to FIG. 2c, there is shown an enlarged schematic view of the aperture created by the laser system of the present invention. The beam is circularly polarized as shown by the arrows 56. By circularly polarizing the beam, the particular direction of polarization is effectively nulled. Without any preferential direction of polarization, the hole produced would be clean, deep, and symmetrical, just as that produced if the beams were linearly polarized along the direction of travel. Thus, with a circularly polarized beam, the effect of nonalignment of the direction of polarization with the direction of travel is eliminated.
The theoretical basis for this invention is as follows:
When a material is being cut by a focussed beam that's moving relative to the material, the forward edge of the cut intercepts the beam at an oblique angle that depends on the speed of the cut and rate of material removal. The absorption and reflection characteristics for the beam then depend strongly on the orientation of the polarization with respect to the surface of the cut. If the beam is polarized parallel to the direction of beam motion then the electric field vector is nearly normal to the surface being heated and cut. This is the condition that results in high absorption and low reflectivity. The cutting speed will be high for this case as more energy is absorbed on the surface undergoing the cutting reaction and relatively little energy is reflected on through the cut and wasted.
For the case where the polarization is aligned across the cut direction the optical absorption on the surface being cut is relatively low and more of the energy is reflected through and wasted. For this case, the cutting speed is between 50% and 70% of the speed attainable with parallel polarization. Furthermore, the width of the cut (kerf width) is different in the two cases with the maximum kerf width being made by the beam with polarization across the cut direction. This is a further disadvantage for that orientation.
While the two cases described above result in different maximum cutting speeds and different kerf widths, they do at least provide cuts that extend straight through the material in the direction that extends the original direction that the beam propagates. A third case of interest is where the beam is polarized neither along nor across the cut direction but at some intermediate angle. In this case, maximum absorption occurs on one side of the front edge of the cut and minimum absorption of energy occurs at the other side. The result is an undercutting effect on the side where the absorption is high and a cut that is neither perpendicular to the material surface nor aligned with the beam propagation direction. See FIGS. 7(a-c). It is surmised that energy reflected from the one side of the cut is directed back to the other side in wave guide-like fashion to assist in undercutting that side. The polarization after reflection may very well be scattered on reflection, thereby making the absorption of this reflected energy higher on the undercut side. Confirmation of this effect comes when the direction of the cut is reversed as the undercutting occurs on the opposite side of the cut. See FIG. 7d. One manifestation of this effect is that when cutting a closed shape, a circle for example, the part enclosed by the cut will remain captured in the piece it was cut from. By converting a plane polarized beam to circular polarization and using that circular polarization for cutting the disparity in cutting speeds as well as the angled-cut effect is eliminated. In addition, the cutting speeds attainable with circularly polarized light are as high as the highest speed possible with light polarized parallel to the direction of the cut.
LASER SCRIBING
When using high power energy laser for cutting or scribing, the laser outputs a series of pulses. Each pulse of high power energy laser creates a hole or cavity in the rigid material. If the beam is not in motion relative to the ceramic the cavity is symmetrically shaped and is oriented straight into the ceramic, normal to the surface and in-line with the beam propagation direction as shown in FIG. 6(a).
When the beam is in motion relative to the rigid material and is incident on the material as a series of pulses of about 100-300 microsec duration, the beam (or the material) is moving at a speed of about 10 inches per second with pulse repetition rates of between 1500 and 2000 pulses per second, a row of cavities (called the scribe line) with a spacing of from 0.005 inch to 0.007 inch between cavities results. During the period of the pulse the material moves about 0.001-0.003 inch. This keeps the beam impinging on the forward edge of the cavity. If the beam is polarized parallel to the direction of motion the absorption, as previously discussed, is high and the cavity developes in time as shown in FIG. 6(b).
When the polarization is oriented across the direction of motion the absorption is low on the forward side of the cavity and energy is reflected backward as the beam moves forward. Time development of the cavity is then as shown in FIG. 6(c). The backward-reflected energy vaporizes material under the trailing edge of the cavity.
Referring to FIG. 3, there is shown yet another embodiment of the laser system 110 of the present system. The laser system 110 is exactly similar to the laser system 10 of FIG. 1, with the exception of the quarter wave means 116. Similar to the components previously described, the laser system 110 comprises a CO 2 laser 112 emitting a beam of electromagnetic coherent radiation aligned to traverse along path 122 through a linear polarizing means 114. The linearly polarized beam passes through the quarter wave means 116 and is converted to a circularly polarized beam by the quarter wave means 116. The beam is then focussed by focussing means 124 to impinge the target 130. The quarter wave means 116 of FIG. 2 has the same characteristics as the quarter wave means 16 of FIG. 1; namely, the quarter wave means 116 has an angle of retardation of substantially 90°. The quarter wave means 116 comprises a transmissive plate 119 and a reflector 118. The reflector 118 is similar to the reflector 18 shown in FIG. 1. The transmissive plate 119 is similar in characteristics to the reflector 118 in that it has an angle of retardation of substantially 45°. The transmissive plate 119 is in essence a one-eighth wave plate.
Referring to FIG. 4, there is shown yet another embodiment of the laser system 210 of the present invention. With the exception of the quarter wave means 216 of FIG. 4, the laser system 210 is exactly the same as the laser system 110 of FIG. 3 or the laser system 10 of FIG. 1. The quarter wave means 216 comprises a first, second, and third reflecting means, 218, 220, and 226 respectively. Each of the first, second, and third reflecting means 218, 220, and 226 respectively, has an angle of retardation. The sum of the angle of retardation of each of the first, second and third reflecting means 218, 220 and 226 respectively, is substantially 90°. Thus, from the quarter wave means 216 a circularly polarized beam emerges.
It should be self-evident that the quarter wave means in the apparatus of the present invention may comprise a plurality of reflecting means. Furthermore, the quarter wave means may be reflective or transmissive in nature, so long as the quarter wave means creates a circularly polarized beam from an incident linearly polarized beam. Furthermore, additional optical means may be employed in the system 10, 110 or 210 of the present invention to maintain the phase relationship, i.e. optical means that have zero phase shift, to deliver the beam onto the target material. Such optical elements may be placed any where along the beam path 22, 122 or 222. These elements may be used to create articulated joints or other devices to deliver the beam to the target 30, 130 or 230. Examples of optical elements with zero phase shift include: reflecting means in which the beam is incident thereon at near normal incidence; and two reflecting means having equal but opposite amount of angle of retardation with the beam incident upon and reflecting from the two reflecting means, one after another thereby cancelling out the phase shift created by each reflecting means.
Referring to FIG. 5, there is shown a reflecting means 18 used in the quarter wave means 16, 116 or 216. The reflecting means 18 comprises a substrate 40. A plurality of first dielectric material, 41a, 41b and 41c and a plurality of second dielectric material 42a, 42b and 42c are on substrate 40. The first and second dielectric materials, 41 and 42 respectively, are different with the first and second dielectric materials 41 and 42 on the substrate 40 in alternate layers. Typically, the substrate is made from a metal, such as silver or aluminum, with the first dielectric material being Germanium (Ge) or TiO 2 and the second dielectric material being Zinc Sulfide (ZnS), ThF 4 or SiO 2 . The substrate 40 is typically one micron in thickness with the first and second dielectric materials 41 and 42 respectively being also on the order of one micron in thickness. Because of the thinness of the layers, they are typically placed on a support 38. One method of manufacturing the reflecting means 18 is by alternatingly evaporating the first and second dielectric materials 41 and 42 respectively onto the substrate 40, which is on a support 38.
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A laser system adapted for a high power laser beam thermally reacting with a target of a rigid material to remove a portion of the rigid material, has a laser generating a high power beam of electromagnetic coherent radiation. The beam is aligned to impinge the material and is controlled by a controlling means such that the portion removed is symmetrically shaped.
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FIELD OF THE INVENTION
This invention relates to mechanical toothbrushes for personal use and in particular relates to circularly movable electric toothbrushes which are selectively reversible.
BACKGROUND OF THE INVENTION
Review of the Prior Art
Many attempts have been made in the prior art to provide a mechanically operated toothbrush for personal use, most being electrically driven. In U.S. Pat. No. 2,598,275, Lakim discloses an electrically actuated oscillatory toothbrush having a reciprocable shaft driven by an oscillatory or vibratory motor. In U.S. Pat. No. 2,655,674, for example, Grover provides a lip guard and a pair of rotary brushes for cleaning both sides of a row of teeth simultaneously. In my prior U.S. Pat. No. 3,702,487, there is described a mechanical toothbrush having a crank-shaped drive shaft that maintains the bristles disposed at all times toward selected teeth. The present invention provides an alternative means of accomplishing the objectives of my prior patent.
These and other prior art attempts have shown keen awareness of the problems which a toothbrush user commonly encounters in brushing the multi-surfaced teeth and gums without tending to move the gums away from the necks of the teeth or to force food particles therebetween. However, except for my prior patent no known prior art device has effectively solved these problems and provided a mechanically operated toothbrush which cleans the sides of teeth, the cuspidate surfaces thereof, and the interdental areas while selectively able to massage gums as dexterously, efficiently, and sensitively as a hand-operated toothbrush is commonly able to do.
The apparent difficulty is that the sweeping motion generally used in hand operaton of a toothbrush is not effectively simulated by the rotary or reciprocatory motion of the prior art devices. Another difficulty of prior art devices is generally caused by unwanted contact of bristles of rotary toothbrushes with the cheek or gums. The device of the present invention has been found to be as efficient as the hand brushing method.
SUMMARY OF THE INVENTION
Accordingly, it is the object of this invention to provide a mechanically operated toothbrush which moves in a path of revolution to provide a sweeping motion during toothbrushing therewith by a personal user.
It is another object of this invention to orient the bristles of the toothbrush of this invention in a general toothward direction at all times which is generally deemed most beneficial in brushing teeth.
It is a further object of this invention to provide a gradual onset of contact of the bristles with the gums as the bristles approach the necks of the teeth, thereby imparting a compacting type of massage to the gums, and also to provide a means for cleaning crown areas by transverse sweeping thereover.
In satisfaction of the foregoing objects and advantages there is provided by this invention a mechanically driven toothbrush comprising:
A. a handle, comprising a housing which is adaptable for manual clasping, having sides, a top and a bottom, a rotary drive means mounted within said housing, and an externally mounted actuating means for reversibly operating the rotary drive means; B. a revolutionary reversible drive means comprising a drive shaft rigidly connected to the rotary drive means and to a fly wheel, an actuating rod loosely connected on the opposite side of the fly wheel in an off-center position; said actuating rod extending through the top of the housing and connected thereto but permitted to be rotated independently of the housing; and C. a toothbrush having a stem which is interchangeably attached to the upper portion of said actuating rod.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the circularly operated electric toothbrush of this invention partially in section;
FIG. 2 is a sectional view taken in the direction of the arrows 2--2 in FIG. 1, showing details of the construction of the head mount;
FIG. 3 is an alternative embodiment of the head mount;
FIG. 4 is a diagrammatic view showing the motion pattern made by the toothbrush of the invention; and
FIG. 5 is a front-elevation sectional view of the left side of a user's mouth in which the toothbrush stem moves in the direction of the arrows 71, 72, 73 and 74 in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The objectives of the invention are attained by using a handle of convenient shape and size within which is mounted a reversibly operable, rotary drive means, such as a fluid-operable drive means, as disclosed in U.S. Pat. No. 3,273,189 and Re 26, 589, a mechanical motor of spring-drive type, but preferably an electrical motor of conventional design having an armature and conventional field structure such as is disclosed in U.S. Pat. No. 3,274,631 and 3,160,902. The electric motor may be driven by AC current or by batteries of the popular recharging plug receptacle type.
The handle has top, bottom and conventional sides. On one side of the handle, which is suitably made of a tough but resilient plastic such as polypropylene, are switch means for starting and stopping the motor and for selectively reversing its direction of rotation.
The circularly operated electric toothbrush of this invention comprising a handle 10, a sloped head 20, a revolutionary drive means in the form of fly-wheel drive shaft 50 for moving an actuating rod 40 along a path of revolution, and a toothbrush 30 which is interchangeably attached to rod 40, as shown in FIG. 1. The handle 10 comprises a housing, an electric motor 11 mounted therein with drive shaft 12, and switch means 13 for actuating the motor reversibly. The housing, which is adaptable for manual clasping, comprises the sides 14, the bottom 12 and top portion 16. The electric motor 11 may be driven by connection to an electrical outlet by a cord at 17 or the motor may be operated by batteries as is well known. Gear means 18 may be provided as desired and as well known to control the speed of drive shaft 12 by motor 11.
The interchangeable toothbrush 30 comprises the stem 31, the bristles 32, and interchangeable joint means 33. Any commercially available toothbrush 30 may be used as a part of the toothbrush of this invention. Joint means 33 may be of any well known form of construction so long as the toothbrush is removably attached.
An essential novelty of the device of this invention resides in the particular driving means involving use of the fly wheel means 50. In this device, fly wheel 50 is rigidly attached at its bottom center 51 to drive shaft 12 attached to the electric motor and revolves as the motor causes the drive shaft 12 to rotate. It is, of course, to be understood that the speed of rotation of the fly wheel 50 may be regulated or controlled by the use of the gear train 18 as is well known in the art. The fly wheel may, of course, also be an enlarged extension of drive shaft 12 and not merely an additional member. It is only mecessary that the rod 40 be offset from center to provide the pattern of revolution of the invention.
The fly wheel 50 is loosely connected on its opposite side in an off center position and preferably near an edge to an actuating rod 40. The actuating rod 40 is preferably attached to fly wheel 50 by a pin joint 52 or other suitable means so that the rod is permanently attached but retains at least some side to side and up and down movement. Thus, in pin joint 52, sufficient space is provided in the joint to allow the rod 40 to move vertically as necessary to assist in its movement at the head mount 60 as described hereinafter. The relationship of the fly wheel 50, drive shaft 12 and actuating rod 40 may be seen clearly in the views of FIGS. 1 and 2. Actuating rod 40 extends to and beyond head mount portion 60 to connect with the stem 33 of toothbrush 30.
From its connection with fly wheel 50, actuating rod 40 extends upwardly to head mount portion 60, preferably at a slight angle from vertical. The angle of the actuating rod is preferably about 70° to 80° and most preferably about 80° to 85°. The actuating rod extends to and beyond heat mount or joint portion 60 to a point 41 where it is removably attachable to the stem 33 of toothbrush 30. The toothbrush joint of stem 33 and upper portion 41 of rod 40 can be of any desired design so long as the actuating rod 40 and toothbrush handle are maintained in generally rigid but detachable relationship. The well-known snap-on type of connection suitable for attaching the toothbrush. For example, the actuating rod 40 at its upper portion may be provided with a receiving portion at 41 to receive the stem 33 of toothbrush 30. Snap-on connections of this type are well known in the toothbrush art and need not be further described here. For example, see my prior U.S. Pat. No. 3,702,487 where a connection of this type is disclosed.
As indicated, the actuating rod 40 extends to and beyond head mount portion 60 and at the head mount portion 60, connecting means are provided to attach rod 40 to the neck of portion 60 so that rod 40 is well supported and maintained in proper relationship with fly wheel 50 but still is allowed to rotate as fly wheel 50 turns. In one embodiment as shown in FIG. 1 and detailed in FIG. 2, a double countersink connection is utilized comprising countersink 42 and 42' and horizontal guide pin 43. In this embodiment, head mount portion 60 is provided with ring means 61 and rod 40 passes loosely therethrough. Guide pin 43 is rigidly connected at both ends to the top of head mount 60 and thus is maintained in rigid relationship therewith and passes loosely through a hole or opening 45 in the narrow portion 44 of rod 40. While the ends of pin 43 are maintained in rigid relationship with the housing, means must be provided for rod 40 to rotate as fly wheel 50 turns. According to this embodiment, rod 40 is countersunk at 42 and 42' to permit clearance of this portion of rod 40 over pin 43. The hole or opening 45 in the narrow portion 44 of rod 40 through which pin 43 passes is sufficiently large to permit pin 43 to pass loosely therethrough. Thus, when rod 40 is rotated by action of fly wheel 50, the opening in rod 40 is large enough to permit vertical movement of rod 40 as it rotates. This vertical movement is sufficient to permit the rod to move on pin 43 as the fly wheel 50 rotates, the rod also moving vertically at joint 52. Countersunk portions 42 and 42' prevent the remaining portions of rod 40 from hitting the pin 43 as rod 40 moves with the rotation of fly wheel 50. It should be understood that the deeper the countersink portions 42 and 42', the smaller can be opening 45 for pin 43. On the other hand, shallow countersink portions require larger openings for the pin.
While this is a preferred construction of maintaining alignment of rod 40, an alternative construction is shown in FIG. 3. In this construction, ring 61 is attached to head 60 with rod 40 passing therethrough. Ring 61 is attached to head 60 by opposite disposed horizontal pins 62 and 62' which maintain ring 61 in a generally horizontal relationship but still permit the ring to move vertically by movement around the axis of pins 62 and 62'. Rod 40 is loosely attached to ring 61 by pins 63 and 63' which pass from ring 61 to the rod 40. Pins 63 and 63' are located about 90° from each of pins 62 and 62' and are adapted to provide vertical movement of ring 61 with respect to rod 40 via pins 63 and 63'. The double vertical movement of ring 61 with respect to rod 40 by reason of the two sets of pins thus provides rotation of rod 40 within ring 61 somewhat like a universal joint. In the embodiments of FIGS. 2 and 3, the construction is such as to permit sufficient movement or "play" at head mount portion 60 to accommodate movement of rod 40 as fly wheel 50 rotates. It should be understood however that while the specific embodiments of FIGS. 2 and 3 are preferred for the head mounting of the rod, other constructions may also be employed.
These particular connections at head mount 60 are necessary to minimize wear at the point where actuating rod 40 exits head 20 as at this point the angled and turning rod will be subjected to its greatest wear during use. It will also be understood that this construction also provides a unique combination of vertical and circular motion and thus provides the novel action on the teeth and gums when in use.
As may be seen in the diagram of FIG. 4, rotation of the fly wheel 50 will form a circular pattern indicated by the letter a. The combination of the actuating rod 40 and toothbrush 30 forms a generally angular line as indicated by c and c'. Therefore, the pattern of movement of the bristles 32 of toothbrush 30 will be generally as indicated by line b in FIG. 4, which pattern of movement provides the unique cleaning action of the toothbrush of this invention.
Referring now to FIG. 5, where one of the possible of the revolving brush against the teeth is shown as limited by the degree of movement provided by the head mount portion, when the brush stem 31 revolves away from the solid position shown, it moves along the direction 71 so that the bristles 32 penetrate deeply into interdental areas and sweep food particles away. When the stem 31 is in the reverse position 31a, it continues moving along the direction 72. When the stem 31 is in the return position 31b, it moves along the direction 74.
Each of the directions 71, 72, 73 and 74 of FIG. 5 are arcs of a circle limited as indicated above. The bristles 32 of the toothbrush 30, however, maintain alignment at all times and consequently describe an arc because of their width, radius being determined by the angle of the rod 40 while the orientation of the bristles 32 is determined by the diameter of the fly wheel 50.
When a user is operating the toothbrush of this invention with one hand, he is able to direct its operation so that the preferred dental techniques of brushing away from the gums and toward the teeth is readily used. The bristles 32 are able to penetrate between adjacent teeth and are able to follow the striations of the teeth. By bringing the lower and upper teeth 70 and 80, respectively, fairly close together, the bristles 32 compactingly massage the gums 75 of the lower jaw when passing by in the approach position 31c, vigorously brush the necks 76 of the lower teeth 70 when in the brush position, and outwardly sweep over the crowns 83 of the upper teeth 80 when in the reverse position 31a. Subsequently, when executing the circular return operation as shown in return position 31b, the back of the stem 31 moves lightly downward against cheek 77 without any contact of the bristles 32 therewith.
A simple twist of the user's wrist, after selectively reversing the motor by touching the reversible actuating means therefor, is sufficient to repeat this desirable brushing action on the inner sides of the lower teeth 70 or of the upper teeth 80 or to brush directly across the crown bases 73 and 83 of the lower and upper teeth, respectively in transverse or longitudinal sweeping operation. The electric motor in the handle 10 is suitably operated on batteries or on conventional 110 volt AC current. A small spotlight may be attached to the side 11' of the housing so that it is collimated to shine directly on the bristles 32 when in the brushing position.
It should be understood that the circularly operated toothbrush cited hereinbefore may be varied as to structure of the toothbrush, the drive means, and the various connection means without departing from the spirit of the invention as disclosed herein, so that it should be understood that the limits of the invention are entirely as defined in the following claims.
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A circularly movable mechanical toothbrush having a fly wheel type drive shaft loosely joined to a rod near one edge thereof. Actuation of the fly wheel causes the rod to rotate in a distinct motion that causes toothbrush bristles to be maintained at all times toward selected teeth, which motion compactingly massages gums during a gradual approach stroke, aligns the bristles with tooth striations and interdental spaces during a sweeping brush stroke, and keeps the bristles disposed away from the user's cheek during a return stroke.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/145,506 entitled “Locomotion Safety and Health Assistant” and filed on Apr. 9, 2015, which is specifically incorporated by reference herein for all that it discloses and teaches.
TECHNICAL FIELD
[0002] The invention relates generally to the field of canes/walking assistance and health maintenance devices, and more particularly to a locomotion safety and health assistant for the elderly and others.
BACKGROUND
[0003] Canes, crutches, walking sticks, and similar locomotion aides have been available to assist the elderly (and others) in walking and otherwise moving about since time immemorial. Relatively recently, canes have been designed to be self-standing, utilizing multiple legs and feet (or ferrules) to enhance the stability of the cane itself and also that of the user thereof For example, a common quad cane is designed with a small rectangular platform attached at the bottom of the shaft and has four ferrules, one at each corner, which extend downwards therefrom and contact the ground.
[0004] However, traditional canes and even the newer enhanced canes (such as the quad cane mentioned above) have a number of limitations. Most canes are simple devices that provide only a supportive structure to help a user balance and/or to allow the user to support some of his or her weight with the arm/hand rather than via the legs/feet. Such simple canes address only one aspect of the locomotion/health care problem: that of unsteady walking. Yet there are many other aspects that can contribute to fall susceptibility for a given person: vision impairment, lessened sensitivity in the feet, lessened sense of balance, and increased susceptibility to changes in pulse rate and blood pressure. Traditional canes can not warn the vision impaired user of approaching obstacles, drop-offs, changes in elevation, etc. Nor do such traditional devices provide light to help the user navigate in dim, treacherous conditions. Additionally, prior art devices do not incorporate other health assistance devices that further facilitate safe locomotion, such as: a pulse rate sensor, logic to determine a safe pulse rate zone, warnings if the pulse rate is out of said zone, health data collection, alerts when it is time to take medication, temperature, blood pressure, oxygen saturation, or other enhancements.
[0005] What is needed is a locomotion safety and health assistant device that can address the above deficiencies.
SUMMARY
[0006] One embodiment of the locomotion safety and health assistant comprises a light-weight quad cane having an integrated suite of sensor(s), microcontroller(s), power source(s), external communication device(s), light(s), tactile communication device(s), alert(s) and activation sensor(s). A plurality of ultrasonic or similar sensors can effectively monitor the terrain ahead of a user, watching for obstacles or changes in elevation. The assistant can provide tactile feedback (or communication via touch/vibration sensing) or other communication with the user to warn of any obstacles or changes in elevation that are sensed. For example, a single vibration of the assistant's handle can alert the user to an approaching drop in elevation of the floor such as a set of stairs leading downwards. Similarly, a double vibration can provide a different alert for an approaching obstacle such as a basketball, a wall, a set of stairs leading upwards, etc. A glow-in-the-dark (or not) switch or force sensor can be incorporated just below the handle of the assistant (or in another handy location) that allows the user to turn on (and off) a light that is directed to the front of the assistant and lights up the terrain ahead. The assistant can include a programmable medication alert which chimes or otherwise communicates with the user when one or more times to take medication(s) have arrived. Additionally, a pulse sensor can be incorporated in the handle of the assistant. The pulse sensor can utilize, as an example, a light sensor that shines into a user's fingertip and measures changes in the reflected light in order to determine changes in blood flow, pulse rate, blood pressure, etc. Other types of sensors for measuring the health indicators of the user (e.g., blood oxygen, temperature, etc.) can be incorporated as well. Such measurements can be compared to safe ranges and the assistant can warn the user if one or more of the health indicators is in an unsafe range; thereby providing warning that it may not be safe to attempt to stand and walk as fall susceptibility is unduly high at present. A sharp three second vibration in the handle, three-pulse vibration, or other type of tactile or other communication (such as a flashing light, audio alarm, etc.) can be used to communicate the situation to the user. Advanced models can incorporate voice recognition and voice interaction to communicate with the user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The aforementioned and other features and objects of the present invention and the manner of attaining them will become more apparent and the invention itself will be best understood by reference to the following descriptions of a preferred embodiment and other embodiments taken in conjunction with the accompanying drawings, wherein:
[0008] FIG. 1 illustrates a side perspective view of an exemplary embodiment of a locomotion safety and health assistant;
[0009] FIG. 2 illustrates a side perspective view of an exemplary embodiment of a locomotion safety and health assistant sensing no nearby obstacles ahead;
[0010] FIG. 3 illustrates a side perspective view of an exemplary embodiment of a locomotion safety and health assistant sensing an obstacle or change in elevation ahead and warning the user thereof;
[0011] FIG. 4 illustrates a side perspective view of an exemplary embodiment of a locomotion safety and health assistant sensing level ground ahead;
[0012] FIG. 5 illustrates a side perspective view of an exemplary embodiment of a locomotion safety and health assistant sensing a drop in elevation ahead and warning the user thereof.
DETAILED DESCRIPTION
[0013] Referring now to the drawings, FIG. 1 illustrates a side perspective view of an exemplary embodiment of a locomotion safety and health assistant 200 . The assistant 200 comprises a quad cane having a base 105 , a lower support 110 , a height adjustment 115 , an upper support 120 , a centering support 125 and a handle grip 130 Enhanced components of the assistant 200 can include a first handle communicator 10 , a second handle communicator 20 , a first force sensor 30 , a health sensor 40 , a second force sensor 50 , a light 60 , a first environment sensor 70 , a second environment sensor 80 , a microcontroller and associated electronics 90 , third force sensor 95 , and a plurality of legs with ferrules 101 , 102 , 103 , and 104 . In another embodiment, the base 105 attaches directly to a cane 100 , the cane comprising potentially one or more of the subcomponents 110 , 115 , 120 , 125 described above. Basically, the cane 100 can comprise any components between the base and the handle grip.
[0014] The assistant 200 can utilize a light-weight quad cane. The cane can have a plurality of legs 101 , 102 , 103 , and 104 . More or fewer legs are contemplated in other embodiments. Integrated into the assistant 200 can be a base 105 that can have therein a microcontroller, battery, Bluetooth (or other wireless technology for exchanging data) controller, and accompanying wires/electronics. These components communicate with the sensors and other components in order to create the ‘smart cane’ assistant of the present invention. They interpret signals from the sensors and initiate communications with the user, control alarms and notifications, power and control the light(s), etc.
[0015] Towards the bottom of the assistant 200 can be integrated a light 60 which can be a bright white LED or other helpful lighting device that is pointed forwards and downwards to help light the terrain and other items ahead. The user can activate the light in various ways and the light switch or force sensor can be glow-in-the-dark to assist the user in locating the activator in dark conditions. In some embodiments, the angle of the light can be adjusted and/or additional lighting features can be integrated into the assistant 200 .
[0016] Near (for example, just below) the handle can be a small button which can comprise the first force sensor 30 . When the first force sensor 30 is pushed, it can activate the health sensor 40 . Alternatively, the first force sensor can operate the light 60 or some other device. In yet another embodiment, a second force sensor 50 can operate the light. Alternatively, the second force sensor 50 can activate the health sensor 40 or some other device (especially in the case when the health sensor 40 is activated by touch or some other means).
[0017] The handle grip 130 can incorporate vibration motors which can be the first handle communicator 10 and the second handle communicator 20 . A small health sensor 40 can be a pulse sensor or other similar sensor that can determine changes in the user's blood flow, pulse rate, blood pressure, etc.
[0018] Two small, cylindrical sensors, about the size of large marbles can be located near the light 60 . They are the PING environment sensors 70 and 80 . These can be two ultrasonic sensors that effectively monitor for obstacles or changes in elevation ahead of their user. The ultrasonic sensors use sound, and its echo, to determine distances (other types of sensors are contemplated, e.g., lasers and light sensors that determine range, such as laser range finders could be used). Triggered by the third force sensor 95 located on the bottom of the assistant 200 , the ultrasonic sensors run every time the cane is placed on the floor (or at other intervals, or even continuously, if needed). One of the ultrasonic sensors points slightly downward, and is used to alert users of potential hazards ahead. The other sensor points straight forward (or even upwards, in some embodiments), measuring distances to larger bodies such as walls and beds. Data from this second ultrasonic sensor cancels any signal from the first, so that a user is not receiving constant warnings about approaching walls or other obvious objects. If approaching stairs, obstacles, or other hazards are imminent, vibration motors in the handle run for two seconds (other time periods are contemplated). Additional communication means and methods are contemplated in other embodiments. The environment sensors 70 and 80 can be set at different angles than described above in order to better sense particular things. For example, if a patient has problems with stairs going or other drops in elevation, then the environment sensors can be adjusted to better sense this particular type of danger.
[0019] The health sensor 40 can be incorporated into the handle grip 130 and can be triggered by a first force sensor 30 that is activated when pressure is applied on the handle by the user's finger. In another embodiment, simply placing the thumb on the health sensor 40 causes activation. If a pulse sensor is used, it works by shining a light into the user's fingertip, and measuring changes in the reflected light. Because fall susceptibility due to changes in blood flow is most likely when an elderly person stands, the pulse sensor can be configured to run only upon initial pressure on the force sensor. If the sensor reads a pulse rate outside of normal parameters for an elderly adult (or for the particular user), the first handle communicator 10 and second handle communicator 20 can vibrate off and on for three seconds to alert their user of the change. Additional communication means and methods are contemplated.
[0020] A Bluetooth connection or other external communicator can be used to record and communicate data gathered from the health sensor and other sensors to be later used by a doctor or caregiver.
[0021] The cane can also incorporate a medication alert, tailored to the timing of the user, to alert them when it is time for them to take their medications. This can be integrated into the microcontroller and electronics 90 or can be inserted elsewhere in the supports 110 and 120 as desired. The microcontroller and associated electronics 90 can incorporate one or more power sources, which can be rechargeable and/or replaceable.
[0022] The quad cane has a base 105 which connects the lower support 110 portion of the cane with the legs. The lower support 110 portion can attach to a height adjustment 115 portion which allows the cane to be lengthened or shortened depending on the needs of the user. An upper support 120 attaches between the adjustment 115 and the centering support 125 . The centering support 125 places the handle grip 130 more directly above the center of the base/legs.
[0023] FIG. 2 illustrates a side perspective view of an exemplary embodiment of a locomotion safety and health assistant 200 sensing no nearby obstacles ahead. The assistant 200 utilizes one or more environment sensors 70 to send out a first sensing beam 72 A. This beam strikes an approaching obstacle wall 74 , but the assistant 200 measures the length of sensing beam 72 A and finds that the sensing beam 72 A is traveling beyond a set safety distance, so no threat is reported. Compare this to the shortened sensing beam 72 B in FIG. 3 . Note that since the upcoming terrain contains no nearby obstacle, no warning is being provided to the user in FIG. 2 . Compare this with FIG. 3 , below, when a warning condition is sensed.
[0024] FIG. 3 illustrates a side perspective view of an exemplary embodiment of a locomotion safety and health assistant 200 sensing an obstacle 74 or change in elevation ahead and warning 135 the user thereof. In this FIG., the obstacle 74 is a short wall and one or more of the first and second handle communicators in the handle 130 are vibrating warning 135 to communicate the danger to the user. The sensing beam 72 B can utilize ultrasound or other radiation, ambient light, etc. Furthermore, the beam 72 B can trigger when an obstacle is found within a certain distance from the assistant. For example, when an obstacle is found within 94 centimeters of the assistant 200 , a warning vibration 135 can be given. Compare the shortened length of 72 B in FIG. 3 with the longer 72 A in FIG. 2 and note that the length of 72 A is beyond the threat distance so no warning is communicated to the user in FIG. 2 , while in FIG. 3 a warning 135 is issued. Also note that the handle can contain more than one handle communicator. In this example, only the upper handle communicator 10 (see FIG. 1 ) is activated. In FIG. 5 , only the lower handle communicator 20 is activated. Other communications are contemplated.
[0025] FIG. 4 illustrates a side perspective view of an exemplary embodiment of a locomotion safety and health assistant 200 sensing level ground ahead. In this case, the level ground is found within a set distance; for example, between 94 and 108 centimeters ahead. Compare this with FIG. 5 , below, when a warning condition is sensed. In FIG. 4 , a second sensing beam 82 A is used by the second environment sensor 80 . Since the ground ahead is level, the length of sensing beam 82 A remains approximately constant during each sensing session, so no threat or warning is communicated to the user in FIG. 4 . However, the user is approaching a step down ahead and the assistant will warn of this soon, see FIG. 5 .
[0026] FIG. 5 illustrates a side perspective view of an exemplary embodiment of a locomotion safety and health assistant 200 sensing a drop in elevation ahead 86 and warning 145 the user thereof. In this FIG., the drop in elevation 86 is a down-step and at least one of the communicators in the handle 130 are vibrating a warning 145 to communicate the danger to the user. The sensing beam 82 B is longer in FIG. 5 than 4 , and hence the assistant 200 can sense the drop. The second environment sensor 80 can utilize ultrasound or other radiation, ambient light, etc. Furthermore, the beam 82 B can trigger when the drop in elevation 86 is found within a certain distance from the assistant 200 . For example, when the drop is found beyond 108 centimeters of the assistant 200 , a warning vibration 145 can be given.
[0027] While particular embodiments have been described and disclosed in the present application, it is clear that any number of permutations, modifications, or embodiments may be made without departing from the spirit and the scope of this disclosure.
[0028] Particular terminology used when describing certain features or aspects of the embodiments should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects with which that terminology is associated. In general, the terms used in the following claims should not be construed to be limited to the specific embodiments disclosed in the specification, unless the above Detailed Description section explicitly defines such terms. Accordingly, the actual scope of the claims encompasses not only the disclosed embodiments, but also all equivalent ways of practicing or implementing the claimed subject matter.
[0029] The above detailed description of the embodiments is not intended to be exhaustive or to limit the invention to the precise embodiment or form disclosed herein or to the particular field of usage mentioned in this disclosure. While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize Also, the teachings of the invention provided herein can be applied to other systems, not necessarily the system described above. The elements and acts of the various embodiments described above can be combined to provide further embodiments.
[0030] Any patents, applications and other references that may be listed in accompanying or subsequent filing papers, are incorporated herein by reference. Aspects of the invention can be modified, if necessary, to employ the systems, functions, and concepts of the various references to provide yet further embodiments of the invention.
[0031] In light of the above “Detailed Description,” the Inventor may make changes to the invention. While the detailed description outlines possible embodiments of the invention and discloses the best mode contemplated, no matter how detailed the above appears in text, the invention may be practiced in a myriad of ways. Thus, implementation details may vary considerably while still being encompassed by the spirit of the invention as disclosed by the inventor. As discussed herein, specific terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated.
[0032] While certain aspects of the invention are presented below in certain claim forms, the inventor contemplates the various aspects of the invention in any number of claim forms. Accordingly, the inventor reserves the right to add additional claims after filing the application to pursue such additional claim forms for other aspects of the invention.
[0033] The above specification, examples and data provide a description of the structure and use of exemplary implementations of the described articles of manufacture and methods. It is important to note that many implementations can be made without departing from the spirit and scope of the invention.
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A locomotion safety and health assistant can utilize a quad cane and have integrated thereon a suite of sensors, microcontrollers, power sources, external communication devices, lights, tactile communication devices, alerts and activation sensors. A plurality of environment sensors can monitor the terrain ahead, watching for obstacles or changes in elevation. The assistant can provide communication with the user to warn of any obstacles or dangers. A switch can allow the user to turn on a light that is directed to the front of the assistant and lights up the terrain ahead. The assistant can include a programmable medication alert. Additionally, a pulse sensor or other health sensor can be incorporated therein. Measurements therefrom can be compared to ranges and warnings communicated when outside of a safe range; thereby providing warning that it may not be safe to stand and walk as fall susceptibility is unduly high at present.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] The instant application claims priority to and is a continuation of U.S. application Ser. No. 13/645,327 filed Oct. 4, 2012, which is incorporated by reference herein for all purposes.
BACKGROUND
[0002] Compressed air energy storage during off-peak periods can efficiently utilize surplus power from renewable and other sources. During periods of peak demand, heat may be applied to the compressed air to generate much more electrical energy than was originally stored. Compressed air energy storage avoids issues associated with battery storage such as limited lifetime, materials availability, or environmental friendliness.
SUMMARY
[0003] An apparatus performs a power cycle involving expansion of compressed air utilizing high pressure (HP) and low pressure (LP) air turbines located upstream of a gas turbine, which may be modified by removal of the gas turbine compressor. The power cycle involves heating of the compressed air prior to its expansion in the HP and LP air turbines. Taking into consideration fuel consumption to heat the compressed air, particular embodiments may result in a net production of electrical energy of ˜2.2-2.5x an amount of energy consumed by substantially isothermal air compression to produce the compressed air supply. Although pressure of the compressed air supply may vary over a range (e.g. as a compressed air storage unit is depleted), the gas turbine may run under almost constant conditions, facilitating its integration with the apparatus. The air turbines may operate at lower temperatures than the gas turbine, and may include features of turbines employed to turbocharge large reciprocating engines.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 shows a simplified diagram of a compressed air energy system according to an embodiment.
[0005] FIG. 2 shows a photograph of a turbine used as a turbocharger.
[0006] FIG. 3 is a temperature-entropy (T-S) diagram for an SGT-100 gas turbine with 200 bar air source pressure.
[0007] FIG. 4 is a T-S diagram for the SGT-100 gas turbine with 40 bar air source pressure.
[0008] FIG. 5 is a T-S diagram of the optional organic Rankine cycle with an SGT-100 gas turbine and an air source pressure of 200 bar.
[0009] FIG. 6 shows how the various power inputs and outputs vary over the range of air source pressures.
[0010] FIG. 7 shows the efficiencies of a system integrating the SGT-100 turbine over the range of air source pressures.
[0011] FIG. 8 plots expander efficiency with the four specific gas turbines at 120 bar air source pressure.
[0012] FIG. 9 plots overall cycle efficiency with the four specific gas turbines at 120 bar air storage pressure.
[0013] FIG. 10 plots overall equivalence ratio of the expansion system for the four specific gas turbines when the air source pressure is 120 bar.
[0014] FIG. 11 shows the ratio of electrical power output to input for the four specific gas turbines, both with and without the ORC option.
[0015] FIG. 12 shows exhaust and combustor inlet conditions for the SGT-100 turbine.
[0016] FIG. 13 shows the variation in pressure ratios of HP and LP air turbines with air source pressure of the compressed air source for the case of the SGT-100 gas turbine.
[0017] FIG. 14 shows the variation in inlet and exit volume flows through the LP and HP turbines.
[0018] FIG. 15 shows a graph of heat rates (in Btu/kWh) of a combined cycle gas turbine plant, versus the rated plant output.
DETAILED DESCRIPTION
[0019] FIG. 1 shows a simplified diagram of a compressed air energy system according to an embodiment. System 100 comprises a source of compressed air 102 , which in this particular embodiment comprises a compressed air storage unit 104 . However, the presence of a compressed air storage unit is not required in all embodiments, and alternative embodiments could feature an air compressor or other source of compressed air.
[0020] Compressed air 105 is flowed into the compressed air storage unit from air compressor 106 . In some embodiments, the air compressor may comprise a multi-stage compressor with intercooling between stages.
[0021] According to certain embodiments, air compressor 106 may function to compress inlet air 108 in a substantially isothermal manner, for example utilizing heat exchange across a gas/liquid interface having a high surface area. Examples of such substantially isothermal compression (as well as substantially isothermal expansion) are described in U.S. Patent Publication No. 2011/0115223 (“the Publication”), which is hereby incorporated by reference in its entirety. It should be appreciated that certain of the designs discussed below may include one or more concepts discussed in the Publication.
[0022] Specifically, FIG. 1 shows the compressed air being fed to the inlet of a high pressure (HP) air heater 120 . This HP air heater may be of tubular design, with high pressure air present inside the tubes 122 , and low pressure exhaust gas being present within the space 124 enclosing the tubes. In particular embodiments, the HP air heater heats the incoming compressed air to about 700° C.
[0023] The hot compressed air then enters the HP air turbine 126 . Therein, the hot compressed air may be expanded with a variable pressure ratio. In certain embodiments this variable pressure ratio may be up to 2.5 or even larger, depending on the pressure in the compressed air energy store. Expansion of the gas serves to drive first generator 127 to produce electricity.
[0024] Next, the partially expanded compressed air enters the low pressure (LP) air heater 128 , where it is reheated before entering the inlet of the LP air turbine. According to some embodiments, the partially expanded compressed air may be reheated to the same temperature (e.g. 700° C. in particular embodiments).
[0025] The hot, partially expanded compressed air then enters the LP air turbine 130 . Therein, the hot air may again be expanded to drive the first generator to produce even more electricity.
[0026] Design for the HP and/or LP air turbines may be inspired in part by turbines employed to turbocharge large reciprocating engines. Specifically, the HP and LP air turbines may also be equipped with variable nozzle geometry, providing greater flexibility to deal with large variations in flow rate and inlet pressure. Moreover, unlike the engine turbochargers which have to cope with dirty engine exhaust gases, the HP and LP air turbines proposed herein could run with clean air, further simplifying their design and operation.
[0027] FIG. 2 shows a variable nozzle ring for a turbocharger manufactured by the ABB Group of Zurich, Switzerland. It can be seen from FIG. 2 that the nozzle vanes can be rotated to achieve the optimum incidence angle of the engine exhaust gas on the moving blades of the turbine. Also, the mechanism to achieve the adjustment of the nozzle vanes is located outside the casing containing the gas flow path, where the temperature is lower.
[0028] In certain embodiments it may be possible to rotate the so-called stationary vanes or nozzles through any angle relative to the flow direction, limited only by the interference between adjacent vanes. The mechanism for rotating the blades is outside the casing of the turbine and can be kept cool.
[0029] The rotation may be performed slowly in order to adjust to the new conditions. Hence these vanes may be effectively considered to be stationary.
[0030] However, the blades attached to the turbine shaft are at a fixed angle relative to the flow direction. These blades rotate at high speed.
[0031] A study of the aerodynamics may determine optimum arrangements with the flexibility to deal with the range of conditions expected. In certain embodiments, the HP turbine may comprise a single stage of adjustable stationary vanes, and its associated rotor comprising blades with a fixed flow angle.
[0032] By contrast, in certain embodiments the LP turbine may need to cope with a pressure ratio of six. The LP turbine may have two stages, with two rows of adjustable stationary vanes alternating with two rows of rotating blades of fixed angle.
[0033] In various embodiments the compressed air may be configured to exit the LP turbine at a pressure and temperature corresponding to the normal inlet conditions of the gas turbine combustor. This facilitates integration of the instant apparatus with an existing gas turbine without its compressor.
[0034] To achieve this compatibility, the LP turbine may also exhibit a variable pressure ratio. In particular embodiments, this pressure ratio may vary between about 2.5-6.
[0035] Some of the compressed air supplied to the gas turbine may not be used for combustion. Instead, the compressed air may be used for internal cooling of the stationary and moving blades of the gas turbine.
[0036] In order to retain the original cooling performance of the existing gas turbine, the temperature of the supplied compressed air may not exceed that which would have been provided from the compressor element of the gas turbine.
[0037] It is noted that under certain circumstances, the avoidance of a compressor element may reduce the cost of the gas turbine. And, where the gas turbine is of a single shaft design, it may be possible to remove the gas turbine compressor blades from the shaft and use the existing gas turbine combustor and turbine rotor.
[0038] It is further noted that in some embodiments, the application of the gas turbines to the present cycle may call for a modest increase in back pressure. However this adjustment is similar to that encountered when a heat recovery steam generator is added into a conventional combined cycle system.
[0039] After performing the required cooling on the initial blade row(s) of the gas turbine, the portion of the compressed air used for turbine blade cooling, passes out of small holes in the turbine blades and mixes with the main combustion gas flow through the downstream blade rows.
[0040] After leaving the gas turbine, the hot exhaust combustion gas 132 flows to the LP burner. Additional fuel is added to raise the exhaust gas temperature in order to heat the compressed air in the LP heater. For example, the exhaust gas temperature of the LP air heater may be raised to 720° C., where the compressed gas carried by the tubes is being reheated to 700° C.
[0041] After leaving the LP heater, the combustion gases are reheated (e.g. to 720° C.) once more in the HP burner. The heated combustion gases are then flowed to the enclosed space of the HP heater in order to heat the compressed air that is flowing through the tubes therein.
[0042] It is noted that in this particular embodiment, both the LP and HP burners are duct burners. In such duct burners, additional fuel is burned in the low pressure environment (e.g. the low pressure exhaust gas of the gas turbine). As duct burners are established technology, the expense and complexity of developing fuel combustion at high pressures can be avoided.
[0043] As previously noted, in this embodiment the compressed air is supplied from a compressed air storage unit. As the supply of compressed air is depleted in the unit, the pressure of the compressed gas may drop.
[0044] When the pressure of the stored compressed air drops below a certain amount (e.g. 100 bar), it may no longer be appropriate to have both the high and low pressure air turbines in operation. Under these conditions, the apparatus may be configured to route the heated high pressure air to the LP turbine, bypassing the HP air turbine. This selective routing of the compressed gas may be accomplished, for example, by the use of valving 135 .
[0045] Since additional heat would not be added by the LP burner when the HP turbine is bypassed, it is not necessary for the air to go through the LP heater tubes. To minimize pressure drop and heat losses, it may be desirable for the compressed air (below 100 bar) to bypass the LP heater tubes as well as the HP turbine, and flow directly from the outlet of the HP heater to the LP air turbine. In certain embodiments this may be accomplished via multi-way valving scheme 138 .
[0046] FIG. 1 shows only particular embodiment, and others are possible. For example, there are several ways of configuring valves or other flow-switching devices in order to make the transition from two air turbines, two burners, and two air heaters, to a single air turbine, burner, and air heater.
[0047] Thus alternative embodiments offer the choice of diverting not only the high pressure compressed air, but also the low pressure exhaust gas. The HP burner and HP air heater could be bypassed, and all the flow occurring through the LP burner and air heater.
[0048] Ultimately, the specific design employed in particular embodiments could represent a balance of factors. For example, a design could represent a compromise between the cost and complexity of the valve arrangement, versus minimization of the pressure drop in both the compressed air and in the combustion gas.
[0049] FIG. 1 indicates a mechanism 139 allowing the HP air turbine to be de-coupled from the air turbine shaft. Again, this may be desirable in operation modes where the compressed gas is provided at low pressure and bypasses the HP air turbine.
[0050] At the conclusion of the power cycle, the exhaust combustion gas is outlet from the enclosed space of the HP air heater. It is noted that the heat capacity of the combustion gases in the LP heater and the HP heater, is higher than that of the incoming compressed air. Thus, the temperature difference between the combustion gas and the compressed air can widen from the 20° C. difference that may occur at the outlets of the LP and HP burners.
[0051] One possible result of this widening in temperature difference is that the exhaust combustion gas temperature at the outlet of the HP heater may increase, for example to about 200° C. or more. In certain embodiments, the energy represented by this heat can be recovered and converted to electric power utilizing a simple organic Rankine cycle.
[0052] An organic Rankine cycle (ORC) is used for low temperature applications such as power generation from geothermal water, and heat recovery from industrial waste heat and from biomass-fired combined heat and power plants. The organic fluid is usually a hydrocarbon or a refrigerant.
[0053] Organic fluids have a lower boiling point than water. In addition, organic fluids have a lower latent heat relative to their specific heat. As a result, organic fluids may be more suitable than water for extracting sensible heat at moderate temperatures (e.g. less than about 300° C.) from a waste gas or liquid, in which the temperature falls as the heat is extracted.
[0054] Accordingly, organic Rankine cycles are usually much simpler than steam Rankine cycles. Organic Rankine cycles do not need multiple feed-heating stages or multiple boiler pressures. Neither do ORCs require re-heat stages. This greater level of simplicity results in organic Rankine cycles being suited for smaller systems, in which the complex configurations of a large steam plant (e.g. combined cycle plant) may not be cost justified.
[0055] FIG. 1 shows the inclusion of a separate ORC apparatus 150 that is configured to receive the exhaust gas outlet from the enclosed space of the HP air heater. Heat from the exhaust gas is exchanged with an organic fluid circulated by a pump through a condenser and a turbine. The energy from the turbine is used to drive a generator to output electricity.
[0056] The use of a back-end ORC installation is not required and is an optional feature that can serve to enhance the performance of an already-efficient system. Such enhancement is discussed in connection with certain examples given below.
[0057] In order to quantify possible performance of the apparatus according to an embodiment, a model for the proposed air expansion circuit was created. First, certain commercially available gas turbines were characterized in a gas turbine sub-model using publicly available information. The sub-model is a simplified representation of an actual gas turbine, based upon the information available. The parameters of pressure ratio, air mass flow, efficiency and exhaust gas temperature were represented.
[0058] In particular, turbine information can be found in sources such as the Gas Turbine World Handbook, manufacturers' websites, or in published papers. Parameters which may typically be found from such sources include electrical power output, compressor pressure ratio, the compressor air flow rate, the heat rate (or thermal efficiency), and the exhaust gas temperature.
[0059] The characterization is performed by a computer model of the original gas turbine using published information in combination with informed assumptions concerning some parameters, for which no published data is available. The gas turbine sub-model assumes that the air which is used for cooling of the turbine blades, is mixed in with the main flow just after the first row of moving turbine blades. This reduces the gas temperature for the downstream parts of the turbine.
[0060] The model is used to predict the gas turbine performance, adjusting assumptions to obtain the best fit with the available information. The following Table 1 shows the main results of the characterization exercise for sub-models of four single-shaft simple cycle gas turbines. Published data on net electrical power, gas turbine electrical efficiency and gas turbine exit temperature are compared with the values calculated by the gas turbine sub-model, resulting in close agreement.
[0000]
GAS TURBINE
CHARACTERIZATION
Manufacturer
Siemens
Kawasaki
Solar
GE
Gas turbine name
SGT-100
M7A-03
Taurus 70
7FA
Published net electrical
5400
7830
7965
215769
power (kW)
Calculated net electrical
5392
7842
7682
215835
power (kW)
Published electrical
31.0%
34.1%
34.3%
38.6%
efficiency (%)
Calculated gas turbine
31.3%
34.0%
34.3%
38.2%
efficiency (%)
Published turbine exit
531
520
510
599
temperature (° C.)
Calculated turbine exit
533
520
510
599
temperature (° C.)
[0061] The gas turbine sub-model which was used to characterize the unmodified commercial gas turbine was then incorporated in the model of the overall system shown in FIG. 1 . The following Table 2 shows the additional input data to model the circuit incorporating the SGT-100 gas turbine. The first data column shows input data for the maximum air pressure of 200 bar. The second data column shows input data for the minimum air pressure of 40 bar.
[0000]
Max air
Min air
pressure
pressure
Gas turbine manufacturer
Siemens
Siemens
Gas turbine type
SGT-100
SGT-100
Maximum air inlet temperature to gas turbine
410.54
410.54
(° C.)
Gas turbine air flow rate (kg/s)
20.235
20.235
Compressed air storage exit pressure (bar)
200
40
Pressure ratio of HP air turbine
2.45
1.00
Compressed air storage exit temp (° C.)
30
30
Isothermal compressor efficiency
85%
85%
HP air heater secondary DP (%)
1%
1%
LP air heater, secondary DP (%)
2%
2%
HP and LP air heater minimum DT (° C.)
20
20
HP and LP gas burner efficiency (%)
99.7%
99.7%
LP burner DP (%)
3%
3%
HP burner DP (%)
3%
3%
Inlet temperature of HP air turbine (if not
700
—
bypassed) (° C.)
Inlet air temperature of LP air turbine (° C.)
700
564
LP air heater primary side DP (%)
3%
3%
HP air heater primary side DP (%)
3%
3%
Gas LHV calorific value, MJ/m 3 (at 1 atm,
34.82
34.82
15° C.)
Gas density (at 1 atm, 15° C.)
0.723
0.723
Stoichiometric ratio of CO 2 (by vol) to fuel gas
1.04
1.04
Stoichiometric ratio of H 2 O (by vol) to fuel gas
2.021
2.021
Isentropic efficiency of HP air turbine
87.0%
87.0%
Isentropic efficiency of LP air turbine
87.0%
87.0%
LP and HP air turbine mechanical & electrical
97.0%
97.0%
efficiency
Atmospheric pressure, bar
1.01325
1.01325
Atmospheric air temperature (° C.)
15
15
Atmospheric humidity
60%
60%
[0062] Although the operating conditions of the gas turbine within the system are nearly the same as that of the stand-alone gas turbine, there are some minor differences. In particular, the presence of the heat exchangers (air heaters) downstream of the gas turbine causes a rise in the back-pressure, which reduces the output and raises the gas turbine outlet temperature. Also, there are some conditions under which the temperature of the air entering the gas turbine combustor is reduced below the normal value. This causes a small increase in the amount of fuel required to achieve the design operating temperature. The gas turbine sub-model takes these effects into account.
[0063] Table 2 shows the input data for the various parts of the system, including heat exchanger pressure losses, minimum temperature differences in the heat exchangers, and the isentropic efficiencies of the HP and LP turbines. The feature of bypassing the HP air turbine when the air storage pressure drops below 100 bars, is represented in the model by inputting a value of 1.0 for the pressure ratio of the HP turbine.
[0064] As shown in Table 2, the same fractional pressure losses have been assumed for low pressure operation of the circuit as for high pressure operation even though there is a possibility of bypassing some elements of the circuit during low pressure operation. It is also seen from Table 2 that when the air source pressure is reduced to 40 bars, the air inlet temperature of the LP air turbine is reduced below the 700° C. figure, which is assumed at 200 bar air source pressure. This avoids too high an air inlet temperature to the gas turbine combustor. When the air source pressure is low, the pressure ratio of the LP air turbine is reduced and so the temperature drop in the LP air turbine is also reduced.
[0065] FIG. 3 and FIG. 4 are temperature-entropy (T-S) diagrams for the SGT-100 gas turbine at the maximum air source pressure of 200 bar and at the minimum pressure of 40 bar. The figures show the change from two- to one-air turbine expansion, as the air source pressure is reduced.
[0066] The model also allows for analysis of the gas turbine and air turbine expansion circuit of FIG. 1 , including the performance of the optional organic Rankine cycle. The following Table 3 shows input data used for the calculation with the Siemens SGT-100 gas turbine, both at a maximum air pressure of 200 bar and a minimum air pressure of 40 bar.
[0000]
Maximum
Minimum
INPUT DATA - Organic Rankine cycle
Air Pressure
Air Pressure
Organic working fluid
neopentane
neopentane
Boiler saturation temp (° C.)
140.0
105.0
Minimum acceptable pinch point temp
20.0
20.0
difference (° C.)
Gas side pressure drop in ORC heat
3.00%
3.00%
exchanger (%)
Condenser saturation temperature (° C.)
25.00
25.00
Required exhaust gas dew-point margin
10.00
10.00
(° C.)
Turbine isentropic efficiency (%)
85.0%
85.0%
Turbine generator electrical efficiency (%)
96.0%
96.0%
Feed pump isentropic efficiency (%)
80.0%
80.0%
Feed pump motor electrical efficiency (%)
95.0%
95.0%
Turbine exit pressure (bar)
1.720
1.720
[0067] The modeling revealed that neopentane served as one possible option for a suitable organic fluid for the gas turbines and the proposed operating conditions. Table 3 indicates that it may be beneficial to reduce the pressure and hence the saturation temperature of the organic fluid, as the storage pressure of the compressed air falls.
[0068] FIG. 5 is a T-S diagram of the optional organic Rankine cycle with an SGT-100 gas turbine and an air source pressure of 200 bar. This figure shows good temperature matching on the two sides of the heat exchanger. FIG. 5 also indicates reduction of the final exhaust temperature from over 200° C. down to about 60° C.
[0069] Various performance calculations were made utilizing the model. FIG. 6 shows power inputs and outputs for the SGT-100 gas turbine, over a range of air source pressures.
[0070] FIG. 6 shows how the various power inputs and outputs vary over the range of air source pressures. It is seen that the gas turbine power output is relatively constant throughout this range. The power demand of the isothermal compressor increases with the air storage pressure, as a constant compressor efficiency of 85% relative to ideal isothermal compression is assumed.
[0071] The LP air turbine output increases over the range from 40-100 bar air source pressure. Then, there is a slight dip and the LP air turbine power output is constant above 100 bar air storage pressure.
[0072] The HP air turbine power output reduces from about 4000 kW to about 1000 kW as the air source pressure reduces from 200 bar to 100 bar. Below 100 bar, the HP air turbine is bypassed and therefore produces no power.
[0073] FIG. 6 also shows that the total power output is not much less than the total thermal input to the expansion cycle. This indicates a high thermal efficiency of the expansion process.
[0074] FIG. 7 shows the efficiencies of a system integrating the SGT-100 turbine over the range of air source pressures. The overall cycle efficiency is calculated by subtracting the compression power from the expander power output, and then dividing by the total thermal input.
[0075] From FIG. 7 it is seen that the thermal efficiency of the expander system is at or slightly above 90% over the whole range of air source pressures even without the organic Rankine cycle. If an ORC is included, then the expander efficiency is at or slightly above 92% over the whole range. The overall cycle efficiency is close to 50% without the ORC, and is increased by 1.5 to 2% points if the ORC is added.
[0076] Modeling of systems integrating the other three gas turbines listed in Table 1, was also performed. Some differences between the different gas turbines resulting from this modeling are now discussed.
[0077] FIG. 8 plots expander efficiency with the four specific gas turbines at 120 bar air source pressure. It is seen that the efficiency (with ORC) increases from about 92.5% for the 5MW SGT-100, to 93.5% for the 8 MW M7A-03 and the Solar Taurus 70. However, little further change in expander efficiency is achieved as the size and power of the gas turbine increases to 216 MW. This is because expander efficiency is already high with the small gas turbines.
[0078] FIG. 9 plots overall cycle efficiency with the four specific gas turbines at 120 bar air storage pressure. In contrast with FIG. 8 , this plot of overall cycle efficiency reflects a steady improvement as the size and power of the gas turbine increases. It is seen that the overall cycle efficiency (with ORC) reaches 57% in the case of GE-7FA gas turbine, whose power output per unit of air flow, is significantly improved.
[0079] FIG. 10 plots overall equivalence ratio of the expansion system for the four specific gas turbines when the air source pressure is 120 bar. This equivalence ratio includes the fuel used in the gas turbine and in both HP and LP burners. There is a significant increase as the size and power of the gas turbine increases.
[0080] FIG. 11 shows the ratio of electrical power output to input for the four specific gas turbines, both with and without the ORC option. It is seen that this ratio increases for the larger gas turbines which have higher turbine firing temperatures (i.e. the gas temperature at the inlet to the moving blades of the gas turbine), and higher isentropic efficiencies.
[0081] Specifically, FIG. 11 shows that the ratio of power output to power input increases substantially in line with the increase in the equivalence ratio. The increase in power output per unit mass of air indicates that the proportion of the expansion power, which is required for compression, is reduced. Therefore the overall cycle efficiency improves, even though there is little increase in the expansion efficiency.
[0082] The increase in equivalence ratio is not necessarily related to the size of the gas turbine, since some relevant factors are the gas turbine firing temperature and the isentropic efficiency of the gas turbine expansion. For example, the gas turbine firing temperature is determined by the blade material and by the blade cooling technology, rather than the physical size of the gas turbine. It is noted that the assumed turbine firing temperature of the GE-7FA is about 1300° C. compared to temperatures of 1100 to 1160° C. for the smaller gas turbines.
[0083] A high isentropic efficiency may also influence the equivalence ratio since this gives a larger temperature drop for a given pressure ratio. Consequently more fuel can be added in the downstream duct burners. Larger gas turbines tend to achieve higher isentropic efficiencies partly because leakage and other turbine blade end effects are smaller in proportion to the total power output.
[0084] The effects of operational conditions on gas turbine and air turbines were also modeled. As previously mentioned, the increase in turbine back pressure due to the downstream heat exchangers causes the gas turbine exhaust temperature to be raised slightly above the standard operating conditions in a simple cycle configuration. This effect is also observed with gas turbines in a conventional gas and steam combined cycle.
[0085] FIG. 12 shows exhaust and combustor inlet conditions for the SGT-100 turbine. FIG. 12 shows that the gas turbine exhaust temperature is increased by about 25° C. It is also seen that the temperature of the air supplied to the gas turbine combustor (and to the blade cooling system) is the same as the standard combustor inlet temperature over nearly all the air source pressure range.
[0086] There is, however, a small reduction in this inlet temperature in the pressure range between 80 bar and 100 bar air source pressure. This reduction arises because the HP air turbine is bypassed below 100 bar, so the LP air turbine has a high pressure ratio.
[0087] The air inlet temperature to the air turbine is limited to 700° C., so the high pressure ratio causes a reduction in the air temperature leaving the LP air turbine. It is not expected that significant issues would arise from this small reduction in the combustor air inlet temperature.
[0088] FIG. 13 shows the variation in pressure ratios of HP and LP air turbines with air source pressure of the compressed air source for the case of the SGT-100 gas turbine.
[0089] FIG. 14 shows the variation in inlet and exit volume flows through the LP and HP turbines. The exit volume flow of the LP air turbine is almost constant, since this matches the inlet volume flow to the gas turbine.
[0090] Overall performance of the proposed power cycle may be compared with that of a conventional combined cycle gas turbine (CCGT) having a steam Rankine cycle. The performance of CCGTs is dependent on the size of the plant. This is partly because large gas turbines are more efficient than small ones.
[0091] The dependence of CCGT performance on size is also a consequence of the fact that the efficiency of a steam Rankine cycle is dependent on its complexity. In particular, the efficiency of a steam plant used for gas turbine heat recovery is increased if it has three boiler pressures, and if the steam is reheated after expansion in the HP steam turbine. The increased complexity of the steam cycle can only be justified for large plants.
[0092] FIG. 15 shows a graph of heat rates (in Btu/kWh) of a combined cycle gas turbine plant, versus the rated plant output. Modeled heat rates of the proposed gas turbine and air turbine plants are also superimposed on the graph. These heat rates refer to the complete cycle including the compression.
[0093] FIG. 15 shows the heat rate for the complete cycle involving the General Electric 7FA gas turbine is comparable with corresponding combined cycle gas turbines of similar output. However, the heat rates for cycles involving the three smaller gas turbines are all significantly lower than for the corresponding size of combined cycle systems.
[0094] Particular embodiments of the proposed power cycle may be employed to store cheap off-peak energy, which may be provided by renewable energy sources, such as wind. On the other hand, the power obtained from expansion is delivered at such times when the electricity demand is high and power prices are also high.
[0095] Thus, if renewable sources are used to provide the off-peak power, then the high expansion efficiency of over 90% allows substantial reduction in the production of carbon-dioxide per kWh as compared to the most efficient combined cycle plants, which in general have an efficiency of about 60%.
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An apparatus performs a power cycle involving expansion of compressed air utilizing high pressure (HP) and low pressure (LP) air turbines located upstream of a gas turbine. The power cycle involves heating of the compressed air prior to its expansion in the HP and LP air turbines. Taking into consideration fuel consumption to heat the compressed air, particular embodiments may result in a net production of electrical energy of ˜2.2-2.5x an amount of energy consumed by substantially isothermal air compression to produce the compressed air supply. Although pressure of the compressed air supply may vary over a range (e.g. as a compressed air storage unit is depleted), the gas turbine may run under almost constant conditions, facilitating its integration with the apparatus. The air turbines may operate at lower temperatures than the gas turbine, and they may include features of turbines employed to turbocharge large reciprocating engines.
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TECHNICAL FIELD
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/391,797 filed Jun. 27, 2002, hereby incorporated by reference. The present invention relates generally to a cutting insert to be placed into a tool holder for boring holes into metals. More specifically, the invention relates to a cutting tool insert having a specialized spur point geometry at the center of the insert which facilitates the cutting of workpieces, for example, relatively thinner workpieces and workpieces that are at a distance from the cutting machine.
BACKGROUND OF THE INVENTION
[0002] Drilling systems are frequently used to provide cylindrical holes in metallic workpieces. The cutting or boring action of the drill system may be carried out by an elongated, substantially cylindrical drilling tool, such as a combination of a tool holder and a drill insert, which is selectively attached thereto. Such an arrangement may then be used in an application wherein one end of the tool holder is securely mounted in a driving apparatus, which rotates the holder about its longitudinal axis. At the opposite end of the elongated tool holder, the cutting insert engages the material to be cut. Alternatively, the workpiece may be made to rotate relative to the holder and cutting insert, such as in positioning the holder in the tail stock of a lathe or the like. Further, the tool and workpiece may be made to rotate relative to one another. The use of cutting inserts allows for quick changing of the insert upon wear of the cutting surfaces instead of the entire tool, and allows for one tool to be used for a variety of different boring applications by simply changing the insert and not the entire drill assembly.
[0003] However, one particular application which provides problems for prior art cutting tools involves drilling holes through the web portion of structural steel I beams, for example. The flanges of the I-beam require the tool to reach a significant distance to the web of the I-beam. The reach distance can cause a severe instability problem for the tool when attempting to cut a hole through the web. As a result, the tool may wobble or “walk” resulting in an oversize hole, run-out, bellmouthing, and/or an off location hole. Another problem is that the web in these applications are typically relatively thin. During the drilling process, the drill pressure pushes against the thin wall of material allowing it to deflect. As the tool breaks through the material, the material snaps back to its original position, resulting in an irregular shaped hole. Still another problem presented by this and similar applications is that a large burr is produced on the backside of the material. As the tool breaks through the material, the built up drilling pressure causes the tool to lunge through the drilled hole which results in the creation of a burr on the backside of the material. This typically requires an added de-burring process to the machining operation in order to remove the burr. In applications such as with structural steel it is critical that not only the hole be round, but that there is no burr to interfere between the register surfaces of beams and connector plates which must lay flat when they are being connected. A burr can result in an improper connection length and also decrease the strength of the connection by preventing a proper preload of the fastener used to connect the beams.
SUMMARY OF THE INVENTION
[0004] The present invention provides a spur point insert for a drilling tool which has increased stability and reduces tool lunge on break through. These and other advantages of the present invention are provided by a drill insert comprising a drill insert body having at least a first side and a second side, wherein the first side of the drill body comprises a generally planar surface, wherein the second side comprises a first cutting portion formed on a first insert diameter and a second cutting portion formed on a second insert diameter, wherein the first cutting portion comprises at least two cutting edges forming a primary included angle and wherein the cutting edges of the first cutting portion extend from opposite ends of a chisel point to the first insert diameter, wherein the second cutting portion comprises at least two cutting edges forming a secondary angle, wherein the cutting edges of the second cutting portion extend from the first insert diameter to the second insert diameter.
[0005] These and other advantages of the present invention are also provided by a drilling tool assembly comprising a holder having first and second ends and a rotational axis, wherein the second end is adapted to be fixedly attached in a drilling machine, and the first end comprises a holder slot having a bottom seating surface over at least a portion of the holder slot, the holder slot also including a locating boss extending from the bottom seating surface; and a drill insert body having at least a first side and a second side, wherein the first side of the drill body comprises a generally planar surface, wherein the second side comprises a first cutting portion formed on a first insert diameter and a second cutting portion formed on a second insert diameter, wherein the first cutting portion comprises at least two cutting edges forming a primary included angle and wherein the cutting edges of the first cutting portion extend from opposite ends of a chisel point to the first insert diameter, wherein the second cutting portion comprises at least two cutting edges forming a secondary angle, wherein the cutting edges of the second cutting portion extend from the first insert diameter to the second insert diameter and wherein the first side is adapted to have at least a portion thereof positioned in the holder slot in seating engagement with the bottom seating surface and including a locating slot formed in the first side of the drill insert body which cooperates with the locating boss of the bottom seating surface to allow the insert to be seated against the bottom seating surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The invention and developments thereof are described in more detail in the following by way of embodiments with reference to the drawings, in which:
[0007] [0007]FIG. 1 is an exploded assembly view of the drill tool assembly according to a preferred embodiment;
[0008] [0008]FIG. 2 is a partial perspective view of the holder associated with the assembly;
[0009] FIGS. 3 A- 3 D are a variety of different views of an insert according to a first embodiment of the present invention having a 180 degree secondary included angle; and
[0010] FIGS. 4 A- 4 D are a variety of different views of an insert according to a second embodiment of the present invention having a secondary included angle less than 180 degrees.
DETAILED DESCRIPTION OF THE INVENTION
[0011] Turning now to a preferred embodiment of the invention, FIG. 1 illustrates a drill tool assembly 10 generally indicated. Drill tool assembly 10 comprises a holder 12 , which has a body 14 and head portion 16 associated therewith. In the preferred embodiment, holder 12 has, in general, a cylindrical shape with a first end 20 and second end 22 . As shown in FIG. 2, the first end 20 of holder 12 has a clamping or holder slot 30 , which may extend across the entire diameter of the head portion 16 or, at least, over a center portion thereof at the general location of the rotational axis 18 of holder 12 . The holder slot 30 has a bottom wall 32 positioned in substantially perpendicular orientation relative to the rotational axis 18 of the holder 12 . In the preferred embodiment, the assembly 10 may further include a locating boss or dowel pin 24 , which is positioned precisely with respect to the axis 18 and extends from the bottom wall 32 of the holder slot 30 . The pin 24 may be positioned within a hole 26 extending downwardly from the bottom wall 32 of slot 30 along the axis 18 of the holder body in a press fit relationship to position pin 24 . Alternatively, the locating boss, which, in the preferred embodiment, comprises pin 24 , may be configured in another manner to achieve the corresponding functionality of pin 24 , such as an integral member extending from bottom wall 32 . Within the holder slot 30 , a drill insert 35 is precisely positioned with respect to the holder 12 to perform the desired drilling function in conjunction therewith. As will be hereinafter described in more detail, the insert 35 has a spur point geometry comprising a plurality of cutting surfaces, which are precisely positioned with respect to the axis 18 of the holder 12 to minimize errors in a resulting drilling operation using assembly 10 .
[0012] More particularly, the preferred embodiment of holder 12 is shown in FIG. 2, and may be configured to include at its first end 20 a pair of clamping arms 34 , which extend about holder slot 30 . The clamping arms 34 preferably include apertures 36 , which accommodate screws 38 (see FIG. 1) to secure the drill insert 35 in its position within the holder slot 30 . In the preferred configuration, the holes 36 are threaded to engage screws 38 , and mate with screw holes formed in the drill insert 35 in a predetermined manner to precisely locate the drill insert in a predetermined location within holder slot 30 , as will be described in more detail. Each of the clamp arms 34 may also include a lubrication vent 28 , which allows the application and flow of lubrication adjacent the cutting surfaces of the drill insert to facilitate the drilling operation. The clamp arms 34 may also include angled or curved surfaces, which facilitate chip removal via chip evacuating grooves 37 on each side of the holder 12 . The seating surface 32 is also shown to be designed as a planar surface, which corresponds to the planar bottom portion of the preferred drill insert 35 , although another configuration of bottom surface 32 may be employed and is contemplated herein.
[0013] Turning to FIGS. 3 A- 3 D, a first embodiment of the spur point drill insert 35 is shown. The spur point drill insert 35 is a spade-type drill blade, with side edges 60 including margins 63 of the blade being generally parallel with the rotational axis 18 of the holder 12 once the insert 35 is positioned and secured with holder 12 . When secured with holder 12 , drill insert 35 will also have a rotational axis, which desirably is coaxial with axis 18 of holder 12 . The drill insert 35 will also have a width 71 , which, upon being rotated with holder 12 , forms an outside diameter 71 of the assembled tool. The drill insert 35 comprises a first spur cutting potion 64 having a minor diameter or spur diameter 61 and a second blade cutting portion 74 having a major diameter or blade diameter equivalent to the insert width 71 .
[0014] The spur cutting portion 64 includes cutting edges 66 on its upper surface in the form of a V-shape having a first or primary included angle θ. Cutting edges 66 are formed on parallel planes on opposite sides of the drill insert 35 and extend generally radially inward and terminate on opposite ends of a chisel 90 formed across the web 92 of the insert 35 . The cutting edges 66 extend along parallel planes generally radially outward to the spur diameter 61 . For most applications, the best performance is achieved when the spur diameter 61 is generally half to one fourth the size of the blade diameter 71 . However, it is contemplated that other ratios may also be used and the spur diameter 61 is not intended to be limited to any particular ratio with respect to the blade diameter 71 .
[0015] The second blade cutting portion 74 includes cutting edges 76 on its upper surface. Cutting edges 76 may either be perpendicular to the rotational axis and having a 180 degree angle as shown in FIGS. 3 A- 3 D or in the form of a V-shape having a second or secondary included angle Φ as shown in FIGS. 4 A- 4 D. Cutting edges 76 are formed on parallel planes on opposite sides of the drill insert 35 and extend generally radially outward from the spur diameter 61 to the blade diameter 71 .
[0016] The cutting edges 66 , 76 may include a plurality of cutting components, which cooperate together to provide the desired cutting surface 66 for the material and/or drilling application. These cutting components may include, but are not limited to, chip breakers, corner clip, corner radius, edge treatments, etc.
[0017] In general, the insert 35 is designed to cut when rotationally driven in conjunction with holder 12 in a predetermined direction, and is not reversible, although such drilling blade configurations are known to those skilled in the art and could be used in conjunction with the present invention if desired. The drill insert 35 further preferably includes apertures 70 , which cooperate with the apertures 36 in clamp arms 34 to secure insert 35 within holder slot 30 and seated against seating surface 32 . Additionally, each of the apertures 36 and 70 are preferably formed with countersunk portions formed as a bearing surface adapted to be engaged by a corresponding tapered or like surface on the screws or other fastening mechanism 38 . The enlarged clamping head of the screws 38 may be of any convenient shape, such as conical, ball-shaped, or in another form to correspond with the similar surfaces in the tool holder 12 and insert 35 . In a typical fashion, by offsetting the axes of the apertures 36 and 70 , upon securing insert 35 within slot 30 by means of screws 38 , the planar bottom portion 59 of insert 35 will be forced downwardly against the seating surface 32 . Insert 35 may include a locating slot 65 , which allows positioning of the locating pin 24 therein. This connection is further described in co-owned U.S. Pat. No. 5,957,635, which is herein incorporated by reference.
[0018] In operation, the spur cutting portion 64 , or spur, aggressively engages the material to be cut and helps center the tool during the initial cut. As the spur 64 is formed at a minor diameter 61 or spur diameter that is smaller than the major diameter 71 or width of the cutting tool 10 , there is less deflection of the workpiece when the spur 64 is engaged. When the spur 64 breaks through the opposite side of the workpiece, a significant portion of the built up drill pressure is released. In addition, the margins 63 of the drill insert 35 are typically fully engaged with the material hole diameter at the time when the spur 64 breaks through the opposite side of the workpiece which provides additional stability to the cutting operation. Therefore the stability of the cutting tool 10 is retained and the secondary or blade cutting edges 76 are in effect milling the remaining workpiece material in the hole. The reduction of built up drill pressure also results in a significant reduction of lunge upon completion of drilling the hole, resulting in a minimization of the creation of unacceptable burrs.
[0019] Turning to FIGS. 4 A- 4 D, a second embodiment of the spur point drill insert 35 ′ is shown. Drill insert 35 ′ is similar to drill insert 35 except that drill insert 35 ′ comprises a second blade cutting portion 74 ′ having a secondary included angle Φ which is less than 180 degrees and the spur diameter 61 ′ is about a fourth the size of the blade diameter 71 .
[0020] It is contemplated that the drill insert 35 , 35 ′ is made of a sintered metallic hard material such as carbide, cermet, ceramic, monocrystalline and polycrystalline diamond, or boron nitride. However, the drill insert may also be comprised of high speed steel.
[0021] Although the present invention has been described above in detail, the same is by way of illustration and example only and is not to be taken as a limitation on the present invention. Accordingly, the scope and content of the present invention are to be defined only by the terms of the appended claims.
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A cutting tool insert having a specialized spur point geometry at the center of the insert. The insert comprises a spur point cutting portion and a blade cutting portion wherein the spur point provides stability by providing a spot and allowing a flexible workpiece to partially spring back when the spur breaks through. The spur point insert facilitates the cutting of relatively thinner workpieces and workpieces requiring the tool to have a longer reach to the hole, while minimizing the burr resulting from the drilling operation.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part of co-pending U.S. patent application, Ser. No. 10/236,787, filed Sep. 6, 2002 now U.S. Pat. No. 6,791,306, entitled: “Synthetic Ripple Regulator,” by M. Walters et al (hereinafter referred to as the '787 patent application), assigned to the assignee of the present application and the disclosure of which is incorporated herein.
FIELD OF THE INVENTION
The present invention relates in general to power supply circuits and components therefor, and is particularly directed to an arrangement for synchronizing a plurality of synthetic ripple generators that generate artificial or synthesized ripple waveforms to control switching operations of a multiphase DC—DC converter.
BACKGROUND OF THE INVENTION
As described in the background section of the above-referenced '787 patent application, electrical power for integrated circuits is typically supplied by one or more direct current (DC) power sources. In a number of applications the circuit may require plural regulated voltages that are different from the available supply voltage, which may be relatively low e.g., on the order of three volts or less, particularly where low current consumption is desirable, such as in portable, battery-powered devices. (This architecture may achieve a much high voltage difference in portable applications, for example an input voltage on the order of 4.5-25V and an output voltage Vo on the order of 0.5V-3.7V.) Moreover, in many applications the load current may vary over several orders of magnitude. To address these requirements it has been common practice to employ ripple generator-based converters, such as a hysteresis or ‘bang-bang’ converter of the type shown in FIG. 1 .
Such a ripple regulator-based DC—DC voltage converter employs a relatively simple control mechanism and provides a fast response to a load transient. The switching frequency of the ripple voltage regulator is asynchronous, which is advantageous in applications where direct control of the switching frequency or the switching edges is desired. For this purpose, the ripple voltage regulator of FIG. 1 employs a hysteresis comparator 10 , that switchably controls a gate drive circuit 20 , respective output drive ports 22 and 23 of which are coupled to the control or gate drive inputs of a pair of electronic power switching devices, respectively shown as an upper P-MOSFET (or PFET) device 30 and a lower N-MOSFET (or NFET) device 40 . These FET switching devices have their drain-source paths coupled in series between first and second reference voltages (Vdd and ground (GND)).
The gate drive circuit 20 controllably switches or turns the two switching devices 30 and 40 on and off, in accordance with a pulse width modulation (PWM) switching waveform (such as that shown at PWM in the timing diagram of FIG. 2 ) supplied by comparator 10 . The upper PFET device 30 is turned on and off by an upper gate switching signal UG applied by the gate driver 20 to the gate of the PFET device 20 , and the lower NFET device 30 is turned on and off by a lower gate switching signal LG applied by the gate driver 20 to the gate of the NFET device 30 .
A common or phase voltage node 35 between the two power FETs 30 / 40 is coupled through an inductor 50 to a capacitor 60 , which is referenced to a prescribed potential (e.g., ground (GND)). The connection 55 between the inductor 50 and the capacitor 60 serves as an output node, from which an output voltage Vout (shown as triangular waveform Output in FIG. 2 ) is derived. In order to regulate the output voltage relative to a prescribed reference voltage, the output node 55 is coupled to a first, inverting (−) input 11 of the hysteresis comparator 10 , a second, non-inverting (+) input 12 of which is coupled to receive a DC Reference voltage.
In such a hysteretic regulator, the output PWM signal waveform produced by hysteresis comparator 10 transitions to a first state (e.g., goes high) when the output voltage Vout at node 55 falls below the reference voltage Reference (minus the comparator's inherent hysteresis voltage Δ). Conversely, the comparator's PWM output transitions to a second state (e.g., goes low) when the output voltage Vout exceeds the reference voltage plus the hysteresis voltage Δ. The application of or increase in load will cause the output voltage (Vout) to decrease below the reference voltage, in response to which comparator 10 triggers the gate drive to turn on the upper switching device 30 . Because the converter is asynchronous, the gate drive control signal does not wait for a synchronizing clock, as is common in most fixed frequency PWM control schemes.
Principal concerns with this type of ripple voltage regulator include large ripple voltage, DC voltage accuracy, and switching frequency. Since the hysteretic comparator 10 directly sets the magnitude of the ripple voltage Vout, employing a smaller hysteresis Δ will reduce the power conversion efficiency, as switching frequency increases with smaller hysteresis. In order to control the DC output voltage, which is a function of the ripple wave shape, the peak 71 and the valley 72 of the output ripple voltage (Output, shown in FIG. 2 ) is regulated. For the triangular wave shape shown, the DC value of the output voltage is a function of the PWM duty factor. The output voltage wave shape also changes at light loads, when current through the inductor 50 becomes discontinuous, producing relatively short ‘spikes’ between which are relatively long periods of low voltage, as shown by the DISCON waveshape in FIG. 2 . Since the ripple voltage wave shape varies with input line and load conditions, maintaining tight DC regulation is difficult.
In addition, improvements in capacitor technology will change the ripple wave shape. In particular, the current state of ceramic capacitor technology has enabled the equivalent series resistance or ESR (which produces the piecewise linear or triangular wave shape of the output voltage waveform shown in FIG. 2 ) of ceramic capacitors to be reduced to very low values. At very low values of ESR, however, the output voltage's ripple shape changes from triangular to a non-linear shape (e.g., parabolic and sinusoidal). This causes the output voltage to overshoot the hysteretic threshold, and results in higher peak-to-peak ripple. As a result, the very improvements that were intended to lower the output voltage ripple in DC—DC converters can actually cause increased ripple when used in a ripple voltage regulator.
In accordance with the invention disclosed in the '787 application, shortcomings of conventional ripple voltage regulators, including those described above, are effectively obviated by the synthetic ripple voltage regulator shown in FIG. 3 . This synthetic ripple voltage regulator generates an auxiliary voltage waveform, that effectively replicates or mirrors the waveform ripple current through the output inductor 50 , and uses this auxiliary voltage waveform to control toggling of the hysteretic comparator 10 . Using such a reconstructed current for the purpose of ripple voltage regulation results in low output ripple and simplified compensation.
More particularly, the synthetic ripple voltage regulator of FIG. 3 employs a transconductance amplifier 110 , the output of which is coupled to a ‘ripple voltage’ capacitor 120 . The transconductance amplifier 110 produces an output current I RAMP proportional to the voltage across inductor 50 , which is interconnected between a node 35 common with the upper and lower MOSFETs (respective gate drives 21 and 22 for which are produced by a gate drive circuit 20 ), and an output node 55 . The ripple voltage capacitor 120 transforms this output current ramp into an inductor current-representative voltage having the desired waveform shape. A benefit of synthesizing the ripple waveform based on inductor current is the inherent feed-forward characteristic. For a step input voltage change, the current I RAMP produced by the transconductance amplifier 110 will change proportionally to modify the conduction interval of the power switching devices.
For this purpose, transconductance amplifier 110 has a first, non-inverting (+) input 111 coupled to the phase node 35 and a second, inverting (−) input 112 coupled to output voltage node 55 at the other end of inductor 50 , so that the transconductance amplifier 110 effectively ‘sees’ the voltage across inductor 50 . The output voltage node 55 is further coupled to a first terminal 121 of capacitor 120 and to the inverting (−) input 141 of an error amplifier 130 inserted upstream of the hysteresis comparator 10 . Error amplifier 130 serves to increase the DC regulation accuracy, providing high DC gain to reduce errors due to ripple wave shape, various offsets, and other errors. Error amplifier 130 has a second, non-inverting (+) input 132 thereof coupled to receive the voltage Reference, while its output 133 is coupled to the non-inverting (+) input 12 of hysteresis comparator 10 . In the configuration of FIG. 3 , the output of the error amplifier 130 follows the load current. The transconductance amplifier 110 has its output 113 coupled to a second terminal 122 of the capacitor 120 and to inverting (−) input 11 of the hysteresis comparator 10 .
The operation of the synthetic ripple voltage regulator of FIG. 3 may be understood with reference to the set of waveform timing diagrams of FIG. 4 . As a non-limiting example, the regulator voltage may be set at a value of Reference=1 VDC and the hysteresis comparator 10 may trip with +/−100 mV of hysteresis. The inductance of inductor 50 is 1 μH and the output capacitance is 10 μF. The line M 1 (at the 30 μsec time mark) in FIG. 4 represents a change in input voltage from a value on the order of 3.6 VDC prior to M 1 to a value on the order of 4.2 VDC at M 1 and thereafter.
The upper waveform 501 corresponds to the ripple voltage generated across the ripple voltage capacitor 120 ; the middle waveform 502 is the current through inductor 50 , and the lower waveform 503 is the output voltage at node 55 . The similarity of the respective ripple and inductor current waveforms 501 and 502 is readily apparent, as shown by respective step transitions 511 / 521 and 512 / 522 therein, at t=20 μs and t=50 μs. As shown by waveform 502 , the converter is initially supplying an inductor current on the order 100 mA for an input supply voltage of 3.6 VDC. This inductor current is discontinuous and the switching frequency has a relatively stable value on the order of 900 kHz.
At the transient 521 (t=20 μs) in waveform 502 , there is a stepwise (×10) increase in the load current from 100 mA to a value on the order of 1 A, and the switching frequency increases to a frequency on the order of 1.5 MHz. From the output voltage waveform 503 , it can be seen that the amount of ripple 531 occurring at this transient is relatively small (on the order of only +/−3 mV, which is well below that (+/−100 mV) of the prior art regulator of FIG. 1 , during discontinuous operation, where load current=100 mA, and then drops to +/−1.5 mV).
At the M 1 or t=30 μs time mark, there is a stepwise increase in input voltage from 3.6 VDC to 4.2 VDC, and the switching frequency increases to almost 2.3 MHz, yet the levels of each of waveforms 501 , 502 and 503 remain stable. Subsequently, at t=50 μs, there is a step transient 512 in the inductor/load current waveform 501 , which drops back down from 1 A to 100 mA, and the switching frequency settles to a value on the order of 1.3 MHz. As can be seen in the output voltage waveform 503 , like the ripple 531 occurring at the t=20 μs transient, the amount of ripple 532 for this further transient is also relatively small (on the order of only +−3 mV and dropping to +/−1.5 mV), so that the output voltage may be effectively regulated at a value on the order of the voltage Reference of 1 VDC.
SUMMARY OF THE INVENTION
In accordance with the present invention, the functionality of the transconductance amplifier and hysteretic comparator architecture disclosed in the '787 application is applied to a multiphase DC—DC voltage generator, to realize a new and improved circuit arrangement for synchronizing a plurality of synthetic ripple voltage generators, that generate artificial or synthesized ripple voltage waveforms for controlling switching operations of a multiphase DC—DC voltage converter. The synthetic ripple voltage regulator of the invention has a variable frequency that is a function of the input voltage, output voltage and load.
For this purpose, the invention comprises a master hysteretic comparator that is referenced to upper and lower voltage thresholds. The master hysteretic comparator monitors a master ripple voltage waveform that is produced across a capacitor by a current proportional to the difference between the output voltage and either the input voltage or a reference voltage (ground). The proportionality current is produced by a transconductance amplifier pair. The output of the master hysteretic comparator serves as a master clock signal that is sequentially coupled to PWM latches, the states of which define the durations of respective components of the synthesized ripple voltage. A respective PWM latch has a first state thereof initiated by a selected master clock signal produced by the hysteretic comparator and terminated by an associated comparator that monitors a respective phase node voltage.
As noted above, the synthetic ripple voltage regulator of the invention has a variable frequency that is a function of the input voltage, output voltage and load. In accordance with an alternative approach, a comparator and one-shot are used to generated a master clock signal having a fixed, steady-state frequency, with the difference between Vlower and Vupper being set proportional to the output voltage Vo. In an alternative methodology for producing produce the output signal PWM 1 , the output signal from the sequence logic causes the output port signal PWM 1 to change state (e.g., go high), and a switch is turned on. The ripple capacitor voltage across a ripple capacitor is thereby increased by a charge current proportional to (Vin−Vo). The phase 1 ripple voltage crosses the upper voltage threshold Vupper, and a comparator resets the output flip-flop from which PWM 1 is produced. This causes the PWM 1 output to change state (go low). During the interval between opposite peaks in the phase 1 ripple capacitor voltage, the voltage across the capacitor decreases by a discharge current proportional to Vo.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 diagrammatically illustrates the general architecture of a conventional ripple regulator-based DC—DC voltage converter;
FIG. 2 is a timing diagram showing PWM and output voltage waveforms associated with the operation of the ripple regulator-based DC—DC voltage converter of FIG. 1 ;
FIG. 3 diagrammatically illustrates an implementation of the synthetic ripple voltage regulator in accordance with the invention disclosed in the '787 application;
FIG. 4 is a timing diagram showing waveforms associated with the operation of the synthetic ripple voltage regulator of FIG. 3 ;
FIG. 5 diagrammatically illustrates a multiphase synthetic ripple voltage regulator in accordance with the present invention;
FIG. 6 contains a set of timing diagrams associated with the operation of the multiphase synthetic ripple voltage regulator of FIG. 5 .
FIG. 7 shows the use of a single comparator and one-shot to generate a master clock signal;
FIG. 8 is a timing diagram associated with the operation of FIG. 7 ;
FIG. 9 illustrates an alternative circuit arrangement for producing an output signal PWM 1 ;
FIG. 10 is a timing diagram associated with the operation of FIG. 8 ;
FIG. 11 is a timing diagram of upper and lower voltages associated with a load step;
FIG. 12 shows a master clock pulse train associated with the transient increase of FIG. 11 ; and
FIG. 13 graphically illustrates the change in frequency between a first relatively steady state, followed by a transition to a higher frequency and then a return to a further steady state frequency.
DETAILED DESCRIPTION
Before describing a non-limiting, but preferred embodiment of the multiphase synthetic ripple voltage regulator synchronization scheme of the present invention, it should be observed that the invention resides primarily in an arrangement of conventional circuit components, and the manner in which they may be incorporated into a multiphase hysteretic controller of the type described above. It is to be understood that the invention may be embodied in a variety of other implementations, and should not be construed as being limited to only the embodiment shown and described herein. Rather, the implementation example shown and described here is intended to supply only those specifics that are pertinent to the present invention, so as not to obscure the disclosure with details that are readily apparent to one skilled in the art having the benefit of present description. Throughout the text and drawings like numbers refer to like parts.
Attention is now directed to FIG. 5 , which diagrammatically illustrates the general architecture of a multiphase synthetic ripple voltage regulator in accordance the present invention for a two phase regulator. It will be readily appreciated from the description to follow that the architecture and functionality of the present invention may be readily expanded to additional phases as desired. A two phase implementation has been shown as a reduced complexity multiphase example for purposes of reducing the complexity of the drawings and their attendant description.
The multiphase synthetic ripple voltage regulator of FIG. 5 is shown as comprising a ‘master’ hysteretic comparator 200 formed of upper and lower threshold comparators 210 and 220 , outputs of which are respectively coupled to the SET and RESET inputs of a SET/RESET flip-flop 230 . A first, inverting (−) input 211 of comparator 210 is coupled to receive an upper threshold voltage Vupper, while first, non-inverting (+) input 221 of comparator 220 is coupled to receive a lower threshold voltage Vlower, that is some prescribed offset ΔV/2 lower than the upper threshold voltage Vupper. Each of the second, non-inverting input 212 of comparator 210 and the second, inverting (−) input 222 of comparator 220 are coupled to a common terminal 241 of a controlled switch 240 , and also to a capacitor 245 , which is referenced to ground. Switch 240 is controlled by the Q output of flip-flop 230 .
A first input terminal 242 of switch 240 is coupled to the output of a transconductance amplifier 250 , while a second input terminal 243 of switch 240 is coupled to the output of a transconductance amplifier 260 . Transconductance amplifier 250 has a first, non-inverting (+) input 251 coupled to receive the input voltage Vin to the regulator, while a second, inverting (−) input 252 thereof is coupled to receive the output voltage Vo of the regulator (namely, the voltage at output node 55 of the circuits of FIGS. 1 and 3 , for example). Transconductance amplifier 250 produces an output current proportional to the difference between its inputs, namely proportional to Vin−Vo. Transconductance amplifier 260 has a first, non-inverting (+) input 261 coupled to ground, while a second input 262 thereof is coupled to receive the output voltage Vo. Transconductance amplifier 250 produces an output current proportional to the difference between its inputs, namely proportional to 0−Vo.
The QBAR output of flip-flop 230 is coupled to a sequence logic circuit 270 . Sequence logic circuit 270 , which may be implemented as a counter, has N outputs corresponding to the number of phases being generated. In the present two phase example, sequence logic circuit 270 has a first output 271 coupled to the SET input of a SET/RESET flip-flop 280 and a second output 272 coupled to the SET input of SET/RESET flip-flop 290 . For this purpose, sequence logic 270 may be implemented as a flip-flop for a two-phase application, or a shift register in more than a two-phase application. The RESET input of flip-flop 280 is coupled to the output of a comparator 300 , while the RESET input of flip-flop 290 is coupled to the output of a comparator 310 .
Comparators 300 and 310 have first, non-inverting (+) inputs 301 and 311 respectively coupled to receive the upper threshold voltage Vupper. The inverting (−) input 302 of comparator 300 is coupled to receive a phase 1 ripple voltage waveform that is developed across a capacitor 305 , as a result of current supplied to capacitor 305 by a phase 1 transconductance amplifier 320 . The inverting (−) input 312 of comparator 310 is coupled to receive a phase 2 ripple voltage that is developed across a capacitor 315 , as a result of current supplied to capacitor 315 by a phase 2 transconductance amplifier 330 .
Phase 1 transconductance amplifier 320 has a first, non-inverting (+) input 321 coupled to receive a phase 1 voltage Vphase 1 and a second, inverting (−) input 322 coupled to receive the output voltage Vo. The phase 1 voltage Vphase 1 corresponds to the voltage at node 35 of the converter circuit associated with a first phase output voltage, and controllably gated in accordance with the PWM 1 waveform output of output flip-flop 280 . Thus, transconductance amplifier 320 generates a voltage Phase 1 ripple proportional to Vphase 1 −Vo. Similarly, phase 2 transconductance amplifier 330 has a first, non-inverting (+) input 331 coupled to receive a phase 2 voltage Vphase 2 , and a second, inverting (−) input 332 coupled to receive the output voltage Vo. The phase 2 voltage Vphase 2 corresponds to the voltage at node 35 of the converter circuit associated with a second phase output voltage, and controllably gated in accordance with the PWM 2 output of output flip-flop 290 . Thus, transconductance amplifier 330 generates a voltage Phase 2 ripple proportional to Vphase 2 −Vo.
Operation of the multi-phase synthetic ripple voltage regulator of the present invention may be readily understood with reference to the timing diagrams of FIG. 6 . The uppermost portion of FIG. 6 shows a master ripple waveform 400 , which exhibits a sawtooth behavior with respect to the upper and lower thresholds Vupper and Vlower, respectively. The middle portion of FIG. 6 shows phase 1 and phase 2 ripple waveforms, which exhibit a sawtooth behavior with respect to the upper threshold Vupper. It is to be noted that the two instances of the Vupper threshold are in actuality at the same level. However, they have been separated in FIG. 6 in order to facilitate an illustration of the various ripple waveforms and, in particular, the times of occurrence of various events for those waveforms. This avoids a superimposed cluttering of the phase 1 and phase 2 waveforms by the master ripple waveform. Finally, the lowermost portion of FIG. 6 shows a master clock (clk) signal that is produced at the QBAR output of flip-flop 230 , and the PWM 1 and PWM 2 waveforms produced at the Q outputs of output flip-flops 280 and 290 , respectively.
Considering initially, the master ripple and the master clock waveforms, at time t 0 , the master ripple waveform is shown as decreasing and crossing the lower threshold Vlower. During the interval leading up to t 0 , the common terminal 241 of switch 240 is connected to input terminal 243 , so that a current proportional to ground (0V)−Vo, or simply −Vo is applied to capacitor 245 . Namely, the voltage V 245 across capacitor, which is the master ripple voltage, is decreasing during this interval. When (at time t 0 ) this decreasing voltage crosses the lower threshold Vlower which is applied to the input 221 of comparator 220 , comparator 220 is tripped and resets flip-flop 230 . The latency between the actual crossing of the lower threshold Vlower and time t 1 when flip-flop 230 resets (its QBAR output goes high) is due to second order circuit effects. When the QBAR output of flip-flop 230 goes high, the master clock (Master clk) goes high, and sequence logic 270 couples this output to the set input of the PWM 1 output flip-flop 280 , so that its Q output 281 (which represents the PWM 1 waveform) goes high at time t 1 .
The change in state in the QBAR output of flip-flop 230 switches the connection of switch 240 to input 242 , so that the output of transconductance amplifier 250 is monitored by the hysteretic comparator circuitry. During a time interval beginning with t 1 , transconductance amplifier 250 produces an output current that is proportional to the difference between its inputs, namely proportional to Vin−Vo. This current is applied to capacitor 245 , so that as capacitor 245 is charged, its voltage (Master ripple) increases, as shown between time t 1 and t 2 . Eventually, the increase in the master ripple voltage will exceed the upper threshold Vupper, causing comparator 210 to trip and set flip-flop 230 . It may be again noted that due to second order latency effects, the time t 2 associated with the resetting of flip-flop 230 is slightly delayed relative to the actual instant at which the master ripple voltage crosses the upper threshold voltage Vupper.
With flip-flop 230 now set, its QBAR output goes low at time t 2 , and remains there until it is again reset by comparator 220 , as described above. During the interval subsequent to time t 2 , with flip-flop 230 being set, switch 240 connects input 243 to its common terminal 241 , so that a negative current proportional to −Vo is again supplied to capacitor 245 by transconductance amplifier 260 , causing the master ripple voltage across capacitor 245 to decrease, as shown by the negative slope of the master ripple waveform. Eventually, at time t 4 , the master ripple waveform again crosses the lower threshold Vlower, so that comparator 220 is again tripped and resets flip-flop 230 . When the QBAR output of flip-flop 230 goes high, sequence logic 270 couples this output via output port 272 to the set input of the PWM 2 output flip-flop 290 , so that its Q output 291 (the PWM 2 waveform) goes high at time t 4 .
The reset state of flip-flop 230 switches the connection of the common terminal 241 of switch 240 to its input 242 , so that the output of transconductance amplifier 250 is now monitored by the hysteretic comparator circuitry. During a new time interval beginning with time t 4 , transconductance amplifier 250 produces an output current that is proportional to the difference between its inputs, namely proportional to Vin−Vo. Again, as described above, this current is applied to capacitor 245 , so that capacitor 245 is charged causing its voltage Master ripple to increase, as shown in the interval between times t 4 and t 5 . Eventually, this increase in Master ripple voltage will exceed the upper threshold Vupper, causing comparator 210 to trip, setting flip-flop 230 .
With flip-flop 230 again set, its QBAR output goes low at time t 5 , and remains there until it is once again reset by comparator 220 , as described above. During the interval subsequent to time t 5 , with flip-flop 230 set, switch 240 reconnects input 243 to its common terminal 241 , so that a negative current is again supplied to capacitor 245 by the transconductance amplifier 260 , causing the master ripple voltage across capacitor 245 to decrease, as shown by the negative slope of the master ripple waveform during the time interval t 5 -t 7 . Eventually, at time t 7 , the master ripple waveform crosses the lower threshold Vlower, so that comparator 220 is again tripped and resets flip-flop 230 . When the QBAR output of flip-flop 230 again goes high, sequence logic 270 recouples this output via output port 271 back to the set input of the PWM 1 output flip-flop 280 , so that its Q output 281 (and thereby the PWM 1 waveform) goes high at time t 7 . This above process is repeated for subsequent cycles, as shown.
Although the master ripple generator portion of the circuit directly controls the generation of the master clock and the rising edges of the PWM 1 and PWM 2 waveforms, its does not directly control the falling edges of the PWM 1 and PWM 2 waveforms. The falling edges are controlled by the phase 1 and phase 2 ripple waveforms, as will described below. It should be noted, however, that the master ripple generator serves to control the frequency of the master clock and thereby the ripple voltages, since its generation is dependent upon the input and output voltages. Increasing the input voltage Vin increases the magnitude of the current (Vin−Vo) supplied by transconductance amplifier 250 to capacitor 245 , and thereby reduces the time required for the master ripple voltage across capacitor 245 to reach the upper threshold voltage Vupper. Conversely, decreasing the output voltage Vo not only increases the magnitude of the current (Vin−Vo) supplied by transconductance amplifier 250 , but increases the magnitude of the negative current supplied by transconductance amplifier 260 , the latter being effective to reduce the time required for the master ripple voltage across capacitor 245 to reach the lower threshold voltage Vlower.
As pointed out above, transconductance amplifiers 320 and 330 produce output currents Phase 1 ripple and Phase 2 ripple that are respectively proportional to Vphase 1 −Vo and Vphase 2 −Vo, with the voltages Vphase 1 and Vphase 2 corresponding to the voltages at nodes 35 of the converter circuits associated with respective phases of the multiphase DC—DC converter. Considering first the Phase 1 ripple waveform, the phase 1 ripple waveform is shown as decreasing and the waveform continues to decrease until the master ripple voltage crosses the lower threshold, at time t 0 , so that comparator 220 is tripped and resets flip-flop 230 . As described above, due to second order latency effects, flip-flop 230 is reset at time t 1 , at which time sequence logic 270 drives the set input of the PWM 1 output flip-flop 280 , so that its Q output 281 and thereby the PWM 1 waveform goes high. With the PWM 1 waveform going high, the Vphase 1 voltage at node 35 of its associated DC—DC converter is driven high, so that transconductance amplifier 320 begins to charge capacitor 305 with a current proportional to Vphase 1 −Vo, whereby the voltage across capacitor 305 increases, as shown by the positive slope portion of the phase 1 ripple voltage beginning at time t 1 . Eventually, this increasing phase 1 ripple voltage, which is applied to the inverting (−) input 302 of comparator 300 crosses the upper threshold voltage Vupper, which is applied to the non-inverting input 301 of comparator 300 . When this happens, and taking into account second order latency effects, comparator 300 is tripped at time t 3 , and therefore drives the reset input of PWM 1 output flip-flop 280 . With flip-flop 280 being reset by comparator 300 at time t 3 , the Q output 281 of flip-flop 280 is now driven low, causing the PWM 1 waveform to go low. The PWM 1 waveform will remain low until flip-flop 280 is again set at time t 7 as described above. During the interval from t 3 to t 7 , the relatively low phase 1 voltage derived from phase node 35 causes transconductance amplifier 320 to apply a negative current (on the order of −Vo) to capacitor 305 , so that the phase 1 ripple voltage waveform is continuously decreasing until the next cycle for PWM 1 .
The Phase 2 ripple waveform operates in the same manner as the Phase 1 waveform, described above, except that it is every other master clock cycle relative to the Phase 1 waveform. Namely, just prior to time t 4 , the phase 2 ripple waveform is decreasing and the phase 2 ripple waveform continues to decrease until the master ripple voltage crosses the lower threshold, so that comparator 220 is tripped and resets flip-flop 230 . As described above, due to second order latency effects, flip-flop 230 is reset at time t 4 , at which time sequence logic 270 drives the set input of the PWM 2 output flip-flop 290 , so that its Q output 291 and thereby the PWM 2 waveform goes high. With the PWM 2 waveform going high, the Vphase 2 voltage at node 35 of its associated DC—DC converter is driven high, so that transconductance amplifier 330 begins to charge capacitor 315 with a current proportional to Vphase 2 −Vo, which increases the voltage across capacitor 315 , as shown by the positive slope portion of the phase 2 ripple voltage beginning at time t 4 . Eventually, this increasing phase 2 ripple voltage, which is applied to the inverting (−) input 312 of comparator 310 crosses the upper threshold voltage Vupper, which is applied to the non-inverting input 311 of comparator 310 . When this happens, and taking into account second order latency effects, comparator 310 is tripped at time t 5 , and therefore drives the reset input of PWM 2 output flip-flop 290 . With flip-flop 290 being reset by comparator 310 at time t 5 , the Q output 291 of flip-flop 290 is now driven low, causing the PWM 2 waveform to go low. The PWM 2 waveform will remain low until flip-flop 290 is eventually again set by the next alternating cycle of the master clock, subsequent to that occurring between t 7 and t 8 . During the next interval beginning with time t 6 , the relatively low phase 2 voltage derived from the phase node 35 causes transconductance amplifier 330 to apply a negative current (on the order of −Vo) to capacitor 315 , so that the phase 2 ripple voltage waveform is continuously decreasing until the next cycle for PWM 2 .
In accordance with a first alternative approach, the master ripple waveform produced across capacitor 245 may be created by a discharge and reset technique, using a single comparator as shown in FIG. 7 , and the associated timing diagram of FIG. 8 . At a time to, capacitor C 245 is discharged by a current proportional to Vo. When the voltage across capacitor C 245 drops below or crosses the threshold Vlower at t 1 , the output of comparator 80 and a one-shot 82 , shown as MSLCK, close the switch and reset the voltage across capacitor C 245 to the value of the upper voltage rail Vupper during the interval from t 3 to t 4 . It should also be noted that a pair of master ripple capacitors may be employed in the place of the signal master capacitor C 245 . In this case the two capacitors alternately discharge from Vupper to Vlower, which serves to eliminate the reset interval (from t 3 to t 4 ).
FIGS. 9 and 10 diagrammatically illustrate an alternative technique to produce the output signal PWM 1 . This same circuit may be applied to any of the other phases in a multiphase application. At time t 0 in the timing diagram of FIG. 9 , the signal CLK 1 ( 271 ) from the sequence logic causes the output port (PWM 1 ) of flip-flop 280 to go high, and a switch 350 is turned on. The ripple capacitor voltage across capacitor C RIP increases by a charge current that is proportional to (Vin−Vo). At time t 1 , the phase 1 ripple voltage crosses the upper voltage threshold Vupper, and the comparator RRCMP resets flip-flop 280 , causing the PWM 1 output to change state (go low). During the interval from t 1 -t 2 , the voltage across capacitor C RIP decreases by a discharge current proportional to Vo.
A beneficial feature of the present invention, particularly in connection with multiphase systems, is the fact that it varies the converter's switching frequency in response to load changes, something which the prior art does not do. In contrast, the prior art hysteretic converter of FIG. 1 , described above, actually slows down the switching frequency during a load step (increase). This load step causes a depressed output voltage, which has the effect of turning on the high side or upper FET 30 , and leaves that FET on, until the output voltage at node 55 increases to the upper hysteretic set point, shown at 71 in FIG. 2 . This means that such a control method is problematic in a multiphase system, where a single converter channel must pick up the full load current unit it can drive the output voltage above the upper hysteretic set point. As a consequence, a full load transient applied to a multiphase converter (such as a three-phase converter) results in one power channel having to deliver three times its steady state power.
In accordance with the present invention, this problem is obviated by increasing the converter's switching frequency in response to a load step. This may be understood with reference to the block diagrams of FIGS. 3 and 5 , described above, and the timing diagrams of FIGS. 11 , 12 and 13 . In particular, for a load step (increase), the voltage at the output node 55 will initially decrease, which is fed back to input 131 of the error amplifier 130 . This decrease in the voltage at error amplifier 131 creates a larger differential across the error amplifier input and therefore a higher Vupper value produced at its output 133 . This transitional increase in the value of Vupper applied to input 211 of amplifier 210 in FIG. 5 (and that of its associated voltage value Vlower applied to the input 221 of amplifier 220 ) is shown in FIG. 11 . As can be seen therein, the master ripple will now encounter the Vupper and Vlower references more frequently, so that the Q output of flip-flop 230 will produce a master clock more frequently, as shown in FIG. 12 . FIG. 13 graphically illustrates the change in frequency between a first relatively steady state having a frequency on the order of 289 KHz, followed by a transition (during the transient state) to a frequency on the order of 560 KHz which, in turn, is followed by a further steady state frequency on the order of 300 KHz.
It may be noted that the master clock signal initiates the PWM pulse which turns on the upper FET of the next successive power channel of the multiphase system, with the next power channel being selected by the sequence logic 270 . Increasing the switching frequency means each successive power channel will pick up the load sooner than it does during steady state, so that all of the power channels participate in picking up a power of the transient load current.
An additional advantage of this method results for transient load steps that are less than full load. This may be contrasted with having to synchronize all of the power channels to turn-on the upper FET in each power channel in response to a load transient. With a less than full load transient, the resulting voltage is likely to overshoot the target regulation voltage. The present invention provides a relative smooth response to any magnitude transient.
As will be appreciated from the foregoing description, by applying functionality of the transconductance amplifier and hysteretic comparator architecture disclosed in the above-referenced '787 application to a multiphase DC—DC voltage generator, the present invention is able to realize a new and improved circuit arrangement for synchronizing a plurality of synthetic ripple voltage generators, that generate artificial or synthesized ripple voltage waveforms for controlling switching operations of a multiphase DC—DC voltage converter.
While we have shown and described an embodiment in accordance with the present invention, it is to be understood that the same is not limited thereto but is susceptible to numerous changes and modifications as known to a person skilled in the art, and we therefore do not wish to be limited to the details shown and described herein, but intend to cover all such changes and modifications as are obvious to one of ordinary skill in the art.
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A multiphase ripple voltage regulator generator employs a hysteretic comparator referenced to upper and lower voltage thresholds. The hysteretic comparator monitors a master ripple voltage waveform developed across a capacitor supplied with a current proportional to the difference between the output voltage and either the input voltage or ground. The output of the hysteretic comparator generates a master clock signal that is sequentially coupled to PWM latches, the states of which define the durations of respective components of the synthesized ripple voltage. A respective PWM latch has a first state initiated by a selected master clock signal and terminated by an associated phase voltage comparator that monitors a respective phase node voltage.
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FIELD OF THE INVENTION
The present invention relates to retractable blade knives. In particular, the retractable blade knife of the present invention relates to a knife providing a blade that is protected within a handle when the blade is not in use, and where the handle is orthogonal to the blade. The invention also provides a new cutting edge for knives that presents a series of cutting segments that are at angles with respect to adjacent cutting segments, where the angles vary over a range of values within a series of cutting segments on a blade.
BACKGROUND OF THE INVENTION
Knives with mechanisms for protecting the knife blade when not in use are known. Some of these knives are of a folding variety, with a blade that pivots from an open position to a folded position where the blade is protected within an opening in the knife handle. Another variety of protecting mechanism allows for retraction of the knife blade. In this variety the knife blade can be moved from an open position which has the blade extended from the knife handle, to a closed position which has the blade disposed within an opening within the knife handle, and where the movement of the knife is substantially linear. An example of the first variety of knife is the common folding pocketknife. An example of the second variety is the common utility knife.
These knives have limitations in their use however, because they are basically gripped in the same manner. There remains a need in the art for a convenient, retractable knife that is comfortable to hold and use, and yet is suitable for cutting uses such as those for which utility knives are used. Knives are known that have blades which are substantially in line with the knife handle. Although these knives are suited to some cutting tasks, other cutting tasks are accomplished more readily with knives having blades at an angle to the knife handle. A need exists in the art for a knife that can be held in positions other than with the knife blade extending from the axis defined by a clenched fist. For cutting a sheet material such as linoleum for example, it is common to use a knife having its blade at an angle other than zero degrees to its handle. This angle allows the knife blade to be pulled through linoleum while clearance for the user's knuckles above the surface of the floor is provided. Thus, some cutting tasks are better suited to a knife with a blade in a different orientation than that found in common knives. That is, some cutting tasks would be more easily accomplished with a knife whose cutting edge would be presented in a particular orientation with respect to the hand holding the knife. Fatigue to the hand being used to hold the knife can be avoided, and safety of use can result from such a change in orientation of the blade. In particular a need exists in the art for a knife that has a blade orthogonal to the knife handle. A need also exists in the art for a knife having a blade orthogonal to its handle, and whose knife blade is also retractable. The retractable blade knife of the present invention as described herein meets these needs.
As disclosed in U.S. Pat. No. 2,359,098 to Engle, a knife is known that has a blade that is orthogonal to its handle. The blade arrangement taught in this patent does not provide for retraction of the blade, although it does provide a mechanism for adjustment to the size of a user's hand. The blade of the knife taught in this patent is always exposed, there being no retraction mechanism. The use of a knife as taught in this patent has a potential safety problem for a careless user. The knife as taught by the present invention addresses this problem by providing for retraction of its blade.
U.S. Pat. No. 1,322,775 to Fallon discloses a bladed military weapon whose blade is held in line with a user's forearm, and orthogonal to the axis of the user's clenched fist. This weapon is taught as having an extension that grips the forearm of the user. This weapon is taught as having a pivoting mechanism for the blade that allows the blade to be pivoted from a service position to a folded position above the forearm. The arrangement taught by Fallon does not provide any structure that receives a blade to protect a user against accidental cuts. Also, the weapon as taught by Fallon does not provide any means for retracting the blade of the weapon.
U.S. Pat. No. 5,025,560 to Townsend discloses an ergonomic knife that has a blade that is held orthogonal to a clenched fist of a user when in use for cutting. This knife also has a mechanism for pivoting the blade into a range of cutting positions relative to an extended support member that reaches part way up the forearm and is attached to the forearm of a user. For use, the knife disclosed requires attachment to the forearm, which can be an inconvenience and shortcoming in use. Another shortcoming is that the knife as taught by Townsend has no mechanism for retraction of its blade to a protecting position that would protect a user from accidental cuts.
Another knife having a blade orthogonal to its handle as used was disclosed in United States Design Patent D301,048 to Hollinshead. This particular knife design teaches a knife whose blade is not retractable. The blade of this knife does not extend directly to the handle, but is attached to the knife handle with two blade extension members whose attachment point to the handle are spaced apart by at least two finger widths. This knife also lacks a mechanism for retraction of its blade.
U.S. Pat. No. 4,096,629 to Levine discloses a claw weapon that has multiple retractable blades. This claw weapon has blades that while in use, project outwardly between adjoining fingers of a user's hand. The claw weapon comprises a tubular grip member that contains the blades when the blades are in a retracted position. As taught in the Levine patent, the fingers of a user are in very close proximity to the cutting edges of the multiple blades. An inadvertent shifting of the fingers of a user could expose the fingers to cuts from the blades as such a weapon is being used. This is a serious shortcoming with a weapon according to this teaching. The weapon taught by this patent also lacks a locking mechanism for retaining its blades in an extended position.
U.S. Pat. No. 2,741,025 to Stewart discloses a weapon having a pointed dagger element fixed orthogonal to a gripping member; and also having a tubular sheath of soft elastic material disposed around the dagger element, for protecting a user from the pointed dagger element in storage and for slidably exposing the dagger element in use as a weapon. This weapon does not have a blade. The use of a soft elastic sheath as taught by Stewart would be impractical with a knife blade having edges along the blade's length, because the sheath would be expected to be cut by the knife edges during handling and damaged, if pressure were brought to bear on the sides of the soft elastic sheath. Moreover, the use of a soft elastic material for a sheath around a knife blade would expose the fingers of a user to cuts if the fingers should push against the soft material. These are shortcomings for the weapon as taught by Stewart.
A need exists therefore for a knife with a blade that is orthogonal to its handle, and where the blade is also retractable. A need also exists for this blade to be easily retractable without binding of the retraction mechanism. A further need exists for a knife with such an orthogonal, retractable blade where the blade can be locked in an extended position. Still another need exists for a retractable blade knife where the blade will be enclosed while retracted to protect the user, and where the blade while extended will avoid having a cutting edge in close enough proximity to the fingers of a user to endanger the fingers.
As shown in A. G. Russell Catalog of Knives Spring 1999, p. 51, April, 1999, knives with blades having an irregular edge are known. Such blades appear to be made of materials that are easily fractured and flaked, such as flint or obsidian. These knives with an irregular edge have been used for many years and have been found particularly useful for cutting some materials. These knives have blades that lack certain strengths such as the ability to bend and cut without breaking across the width of the blade however. This lack of certain strengths is a serious shortcoming for the knives with flint or obsidian blades. A need therefore exists for a blade with an edge that is similar to an irregular edge, but that is made of a metal and that can be reproducibly manufactured.
To overcome such shortcomings, a blade edge is disclosed here that provides a cutting edge somewhat similar in appearance to the irregular edge used on flint or obsidian blades, but that is also suited for use with a metal knife blade.
To overcome the shortcomings of known knives above, and to satisfy the outstanding needs outlined above I have now discovered a new retractable knife. I have also discovered a new knife edge that can be used with the new retractable knife, or with other knives or other cutting implements.
SUMMARY OF THE INVENTION
Briefly, the invention is a knife with a retractable blade where the blade is orthogonal to the knife handle. The new knife comprises a handle with two handle elements. One element is a palm gripping member. The other element is a finger gripping member that has a slot extending through it, and that is parallel to the palm gripping member. An elongated blade is fixed at one of its ends to the palm gripping member and the blade extends through the slot, the slot being sized to accommodate passage of the blade. A biasing, member having two ends is fixed at its first end to the palm gripping member, and is fixed at its second end to the finger gripping member. The biasing member is substantially orthogonal to both of the gripping members. The biasing member is also sized and shaped to receive the blade within the biasing member. That is, the biasing member surrounds the blade, or can hold the blade within itself. The blade is retractable from a first extended position to a second retracted position in response to biasing extension of the biasing member. A stabilizer bar, depending from the finger gripping member, slides in a longitudinal slot in the blade. The finger gripping member has at least two openings through it, the openings sized and shaped to receive fingers of a user. The finger openings are preferably spaced apart sufficiently to permit the blade passing slot and the blade to be disposed between the finger openings. This arrangement then ensures that the fingers of a user are separated from the blade by portions of the finger gripping, member.
Preferably, the biasing member comprises either one or two coiled springs. It is preferred that the biasing member have an oval transverse section for more readily accommodating the blade. The biasing member surrounds the blade in a retracted position, thereby protecting the user from accidental cuts.
A new cutting edge for use on knife blades is also disclosed here. By edge here is meant the region of a blade that is adapted for use as the cutting side of a blade. The new edge comprises a series of cutting segments along a blade. The cutting segments are each substantially linear, and are in end to end relationship for forming the edge. Each of the cutting segments is disposed at a selected angle of up to about 25 degrees from the line of a contiguous cutting segment. That is, when any pair of contiguous cutting segments is considered, one of the pair forms an angle of up to about 25 degrees with respect to the other of the pair. A cutting segment deviates from the line of a contiguous cutting segment up to about 25 degrees however with the proviso that the overall width of the blade edge so formed is no more than about 3 mm (millimeters). In effect then, the cutting edge of the invention is made up of a series of very small edge portions, the cutting segments. The visual effect of this arrangement when viewed from the plane of the blade is that of a meandering edge, having the general appearance of a flint knife's edge. The visual effect when viewed from the side of the blade is also that of a meandering edge with this same general appearance.
The new knife edge can have these cutting segments each sharpened to present a bevel such as is commonly found on the blades of ordinary knives. Preferably, the edge comprises cutting segments with two substantially parallel opposed sides and a face distal from the blade body that supports the cutting edges. The preferred length of the cutting segments is from about 0.2 mm to about 1 cm (centimeter), and the preferred thickness between the opposed sides is from about 0.5 mm to about 1.5 mm and is most preferred to be about 1 mm.
The form of the new knife edge can be used on a particular knife blade by itself or in combination with a conventional edge such as a bevel. That is, an edge of a particular knife may be divided into regions, one region of which has a conventional bevel, and the other region of which is composed of the end to end cutting segments as disclosed herein. A particular knife may also have an edge that is divided into two regions where one region has a conventional serrated edge profile, and the other region is composed of the end to end cutting segments disclosed herein.
The new knife edge can also have cutting nodules distributed along the cutting segments, where the cutting nodules are pieces of a material that is sufficiently hard to resist being readily worn down during use of the knife edge, and where the cutting nodules project from the cutting segments. Preferably, the nodules are substantially hemispherical in overall shape and have a sharp, jagged, irregular surface texture for providing a component of abrasion to the cutting effect of the edge. The nodules may be made of a metal or a ceramic material. If made of a metal, the metal may be the same as that used for the rest of the blade or a different metal may be used.
A knife according to the present invention can have one blade edge that was ground to present a conventional bevel, and can have a second blade edge with the latter being the inventive knife edge comprised of the cutting segments in end to end relationship at varying angles to one another. An advantage to having both the inventive knife edge and a conventional bevel edge in a single knife blade is that a user can select whichever cutting edge is best suited to a given cutting task at hand. The knife according to the present invention can be rotated in the user's hand to allow the selection of the better of two cutting edges for the given task.
It is accordingly an aspect of the invention to provide a retractable blade knife where the blade is orthogonal to the handle.
It is another aspect of the invention to provide a retractable blade knife having a biasing member that biases the blade to a retracted position.
It is another aspect of the invention to provide a retractable blade knife with a locking mechanism that allows the blade to be locked in an extended position.
It is yet another aspect of the invention to provide a new cutting edge for use on knives and other cutting tools, where the new cutting edge has characteristics of a meandering edge for aggressively cutting difficult materials.
It is yet another aspect of the invention to provide a new manmade cutting edge for use on knives and other cutting tools, where the new cutting edge roughly imitates the overall appearance of a flaked stone knife, but which is distinguished by having distinct and well defined dimensional constraints for a series of cutting segments.
It is still another aspect of the invention to provide a retractable blade knife that comprises the new cutting edge.
These aspects, and others set forth more fully below are achieved by the present invention. In particular, a new knife is disclosed that reduces fatigue for the user, has a retractable blade, can provide an optional locking mechanism for the blade, and that preferably has an inventive blade for providing aggressive cutting action.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of a front elevation view of a first embodiment of a knife according to the invention, with the blade in an extended position.
FIG. 2 is an illustration of a front elevation view of the first embodiment, with the blade in a retracted position.
FIG. 3 is an illustration of a front elevation view of a finger gripping member of the first embodiment.
FIG. 4 is an illustration of a front elevation view of a palm gripping member of the first embodiment.
FIG. 5 is an illustration of a front elevation view of a second embodiment of a knife according to the invention, this embodiment having a locking mechanism.
FIG. 6 is an illustration of an edge elevation view of the second embodiment.
FIG. 7 is an illustration of a top view of the extension member of the first embodiment.
FIG. 8 is an illustration of a pair of coil springs from the extension member of FIG. 7.
FIG. 9 is an illustration of an edge elevation view of a blade according to the invention.
FIG. 10 is an illustration of an enlargement of a section of FIG. 9, showing details of the blade edge according to the teaching of the invention.
FIG. 11 is an illustration of a set of possible edge profiles for cutting segments according to the teaching of the invention.
FIG. 12 is an illustration of a set of possible edge profiles according to the teaching of the invention, having cutting nodules disposed along the edge.
FIG. 13 is an illustration of the elevation view of a cutting nodule according to the teaching of the invention.
DETAILED DESCRIPTION OF THE INVENTION
I have developed a new and improved retractable blade knife, well suited for use as a utility knife. I have also developed a new and improved cutting edge for use on knives and other cutting implements. The knife and cutting edge will be understood more clearly by reference to the accompanying drawings.
With reference to these drawings, wherein like reference numerals designate similar parts throughout the various views, 12 designates the palm gripping member of the knife embodiment 10 depicted in FIG. 1. The number 14 designates the finger gripping member, and 16 designates the blade. A biasing member 18 connects the palm gripping member 12 and finger gripping member 14. The biasing member 18 is orthogonal to the palm gripping member 12 and fastened to it by a pair of stays 22. The biasing member 18 is orthogonal to the finger gripping member 14 as well, and is fastened to it by a pair of stays 24. The blade 16 has a first end 26 fastened to the palm gripping member 12 at region 28. The second end 32 of the blade 16 extends through a slot 34 through the finger gripping member 14. The finger gripping member 14 for the embodiment shown has four openings 36 for receiving fingers. It is to be understood that the finger openings 36 could be merged into three or into only two finger openings of appropriate dimensions without losing their function as gripping points for fingers of a user. It is also to be understood that the finger openings 36 could be arranged at various angles to make a particular user's grip more comfortable without deviating from the teachings of the invention.
The finger gripping member 14 comprises a stabilizer bar 38 that depends from a side of the finger gripping member 14 into the slot 34 through the member 14. the blade 16 has a longitudinal slot 42 mortised into it that is dimensioned to receive and slidably engage the stabilizer bar 38 for motion within the slot 42.
The biasing member 18 in the embodiment shown comprises a pair of coiled springs, having oval cross sections, the springs being coaxial and intertwined. The biasing member 18 is shown in more detail in an end view, showing a preferred oval shape, in FIG. 7. As shown, the two springs are coils with opposite handedness, one being right handed and one being left handed. In FIG. 8 can be seen an elevation view of the two springs, 52 and 54, that make up the biasing element 18. Other arrangements of springs are also to be recognized as suitable for practicing the invention such as a pair of springs which are coaxial, but of slightly different diameters. This particular alternate arrangement provides a spring that can fit into the cavity of the second spring while the springs still have a common axis. Constant force springs are known in the art and are also to be recognized as capable of use in the inventive knife.
It is to be understood that the biasing member 18 can comprise a single coiled spring of appropriate size and shape. It has been found however that two coiled springs as shown in FIG. 1 and FIG. 8 are preferable for the smooth operation of a knife according to the teaching of the invention.
The openings 36 through the finger gripping member 14 may be sized, shaped, angled and positioned at various locations in the finger gripping member to allow fingers of various sizes to conveniently grip the new knife. For example, two oval openings (not shown) can be substituted for the four openings shown, each oval opening accommodating fingers. This latter arrangement is to be considered as still within the teaching of the present invention. By having the user's fingers received within the openings of the finger gripping member, protection from the blade edges is afforded to the fingers by the separation of the fingers from the edges.
In FIG. 2 may be seen the knife embodiment of FIG. 1, where the knife is in a retracted position. By relaxing the user's grip on the knife, the biasing element 18 is allowed to urge the finger gripping and palm gripping members 14, 12 to become spaced apart. This allows the biasing member 18 to surround the blade 16. The user's hand is thereby protected from the first edge 56 and second edge 58 of the blade. It is preferable that the inventive knife 10 be dimensioned so that when the biasing element 18 is fully extended, the blade 16 will be fully retracted into the biasing element 18 and the second end 32 of the blade 16 will be enclosed within the biasing element 18.
The blade 16 has a longitudinal slot 42 mortised into it that receives a stabilizer bar 38 that depends from the finger gripping member 14. The length of the longitudinal slot 42 may be selected to limit the spacing apart of the finger gripping member 14 and palm gripping member 12 that is achieved by the biasing member's extension.
FIG. 3 depicts a finger gripping member 14 and shows more clearly the stays 24 that may be used to fix the biasing member 18 to the finger gripping member 14. Also shown is the stabilizer bar 38 that depends from the finger gripping member 14 into the slot 34.
In FIG. 4 may be seen a palm gripping member 12 and the stays 22 that are used to fix the biasing member 18 to it.
Turning to FIG. 5, an alternate embodiment 20 of the inventive knife may be seen. The construction of this embodiment is similar, but this embodiment further comprises at least one transverse slot 46 in the blade, and a locking member 44 that is disposed along the finger gripping member 14 and that is adapted for removably engaging with the transverse slot 46. This engagement restricts the sliding motion of the blade 16 through the slot 34, and retains the blade 16 in a selected position. Proper positioning of at least one transverse slot 46 in proximity to the first end 26 of the blade 26 allows the user to lock the blade in the extended position for use in cutting. Positioning of at least one additional transverse slot 46 in proximity to the second end 32 of the blade allows the user to lock the blade 16 in the retracted position. The shape of the locking member 44 is not critical to the operation of the knife 20 as long as it can be removably engaged with the slot 46 by being closely received within the slot 46.
FIG. 6 depicts an edge elevation view of the embodiment 20 seen in FIG. 5. The locking member 44 may be seen more clearly there.
The knife of the present invention can be made with conventional bevel edges on the blade. A conventional serrated edge or a conventional saw tooth edge can also be used on the blade. It is preferred that the inventive knife have at least one edge of a type that is disclosed herebelow. The embodiments shown in FIG. 2 and FIG. 5 are depicted with their blades having a first edge 56 with a conventional bevel, and having a second edge 58 with an edge of the type disclosed here.
A new edge design has been discovered that is superior to those hitherto known for cutting certain kinds of materials. An edge elevation view of the blade 16 is illustrated in FIG. 9. The inventive edge 58 consists of a series of nearly random, substantially linear cutting segments, segments 62 and 64 being examples of such segments. These segments may vary in length and form the blade edge 58 by the segments being oriented in end to end relationship, where the angle a first segment deviates from the line of a second segment can vary substantially at random up by to about 25 degrees. That is, a pair of contiguous segments forms an angle that can be as large as about 25 degrees. The length of the cutting segments can vary substantially at random from about 0.2 mm to about 1 cm. The cutting segments then meander from the plane of the blade and within the plane of the blade.
The edge formed from such a series of cutting segments can have each cutting segment formed into a bevel edge. An edge embodiment as so described will effectively be composed of a series of very small "bladelets" which can be viewed as forming a meandering path down the blade as a whole. In FIG. 10 may be seen an example of such an edge. The cutting edge is seen as twisting from side to side along the blade, but the inventive edge is formed with the proviso that the maximum width of the edge is up to about 3 mm.
In a preferred embodiment, the inventive edge comprises cutting segments where each cutting segment is also of 0.2 mm to 1.0 cm in length, and where the angle each cutting segment deviates from the line of a contiguous cutting segment varies substantially at random to about 25 degrees. And, in addition, the cutting segments have two substantially parallel opposed sides 66 and a face 68 distal the supporting blade, provided that the thickness of each of the cutting segments is about 1 mm. The distal face may have a jagged, irregular profile. In FIG. 11 are illustrated examples of the possible jagged, irregular profiles that can be encompassed by the design of the inventive blade. The parallel opposed sides 66 are referenced for one of the examples shown, and the distal face 68 is referenced for another example. By "jagged, irregular" is meant that the profile of each cutting segment varies substantially randomly in height and shape over the face of the profile, in a direction normal to the distal face.
The cutting segments may form a regular repeating pattern to make up a cutting edge, however it is preferred that the cutting segments not form a regular repeating pattern in forming a cutting edge. That is, the set of cutting segments used for a given knife edge should present to the eye of a user an irregular pattern. If a regular repeating pattern of cutting segments is present, the pattern should repeat over a distance sufficiently long to not have the repetition readily apparent to a viewer without close inspection. In this latter case, the appearance of irregularity will be present. The inventive cutting edge is not completely irregular however, but is distinctly described by the limitations disclosed here.
A more highly preferred embodiment of the inventive edge for cutting is similar to the one just disclosed above, but farther comprising cutting nodules disposed along the edge. It is preferred that these cutting nodules be substantially hemispherical in shape and from about 0.05 mm to about 0.4 mm in diameter.
The cutting nodules should have a sharp, jagged, irregular surface. The cutting nodules may be made of the same material as the bulk of the blade, such as a steel, titanium, tungsten carbide, or a metal alloy containing either iron, titanium or tungsten. Alternatively, the cutting nodules may be made of a ceramic material.
FIG. 12 illustrates examples of profiles for cutting segments which are encompassed by the invention, where the cutting segments have disposed along them cutting nodules 72. FIG. 13 illustrates the type of cutting nodule 72 suited for use with the present invention, having a sharp, jagged, irregular surface. The nodules selected for use in practicing the invention should have sharp surfaces, suitable for use as an abrasive. The quantity of nodules that should be used on a given blade edge may be selected by a manufacturer according to the type of material to be cut and the cost associated with the addition of nodules to the blade.
A knife edge with the structure disclosed here will be useful for aggressive cutting of a variety of materials usually found difficult to cut with conventional knife edges, and will have the advantage of a pleasing appearance that suggests irregularity to a viewer of the knife edge while not being completely irregular.
The palm gripping member, finger gripping member, and spring stays of the device are preferably constructed of plastic, wood, or metal. The blade can be made of a steel, but is preferably constructed of a metal such as tungsten carbide. The spring is preferably constructed of steel. A blade according to the teaching of the invention is preferably made by a casting process, as would be known to one skilled in the art of metal casting. The edges of the blade can also be ground using a conventional knife sharpening method to provide a conventional cutting edge.
Conventional knives use blades with an edge that is usually sharpened to present a thin bevel section for cutting, uniform along the length of the blade. Some blades have been used that have a serrated edge, where the edge has been ground in a regular series of scallops. A blade with such serrations or scallops can be more aggressive for cutting than a straight edge. This increased aggression presumably occurs because the edge is effectively made up of a linear array of very small blades, and using such a blade subjects the workpiece to be cut with many small blades that attack the workpiece at different angles. Irrespective of any theory of cutting, knives with a serrated edge are frequently viewed as more efficient cutting tools than knives with a straight edge.
In the present invention, a blade is disclosed that has advantages over a blade with a conventional serrated edge, or a conventional saw tooth edge. In particular, it has now been discovered that by having a blade edge composed of an array of cutting segments that twist and turn at varying angles as viewed down the edge of the blade, a knife is provided with an edge that can cut more efficiently through some materials than can conventional serrated edges.
It has also been discovered that the inventive cutting edge is improved substantially for use in cutting certain materials by having sharp, jagged, irregular distal surfaces and by having the cutting nodules described here distributed along the cutting edge.
It is to be understood that the blade used in the knife of the present invention may be permanently fixed to the palm gripping member, or may be removably fixed. In the latter case, the knife may be adapted to utilize user replaceable blades.
The present invention is not to be limited in scope by the embodiments disclosed herein, which are intended as single illustrations of one aspect of the invention, and any which are functionally equivalent are within the scope of the invention. Indeed, various modifications of the invention, in addition to those shown and described herein, will become apparent to those skilled in the art from the foregoing description. Such modifications are intended to fall within the scope of the appended claims. All patents and any publications mentioned herein are hereby incorporated by reference.
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A retractable blade knife is described, which has a handle composed of two parallel members connected by biasing spring assemblies and a blade orthogonal to the handle members. A cutting edge comprising cutting segments connected at varying angles to one another is disclosed, the cutting edge providing a visual effect similar to a flaked cutting edge.
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PRIORITY CLAIM
[0001] The present application claims the benefit of copending U.S. Provisional Patent Application Ser. No. 61/561,534, filed Nov. 18, 2011, which application is incorporated herein by reference in its entirety.
BACKGROUND
[0002] This application generally relates to ultrasonic transducers. The application further relates to ultrasonic transducers used for medical imaging.
[0003] A trade-off in medical ultrasound imaging is depth of penetration and spatial resolution. Higher ultrasound imaging frequencies enable higher spatial resolution at the expense of depth of penetration. Lower ultrasound imaging frequencies enable deeper penetration at the expense of spatial resolution. It would be useful if a single ultrasound imaging device was able to image across a broad range of frequencies in order to operate at a higher frequency for better spatial resolution and at a lower frequency for deeper penetration.
[0004] Broad bandwidth ultrasound imaging devices may include use of high sensitivity materials (e.g., single crystal piezoelectric composites), use of multiple matching layers, use of multiple transducers, and use of multiple devices. These approaches can be expensive and be difficult to implement from a manufacturing perspective, particularly for small, single-use, high-frequency ultrasound devices that are used in relatively high volumes (e.g., intravascular ultrasound catheters).
[0005] It would be advantageous to have an ultrasound transducer structure and corresponding manufacturing process that enables broadband imaging performance for small, single-use, high-frequency ultrasound devices. It would be further advantageous if the transducer is cost effective and easy to manufacture.
SUMMARY
[0006] In one embodiment, an ultrasonic transducer includes a backing element, an active element overlying the backing element, and a matching element overlying the active element. The matching element having an inner surface that contacts the active element and an outer surface with a non-homogenous texture and/or material composition.
[0007] The matching element may be a single matching layer where the outer surface has a first region with a first texture and a first material composition and a second region with a second texture and a second material composition. The first texture differs from the second texture and/or the first material composition differs from the second material composition.
[0008] The first and second textures of the matching layer may be coarse or rough. The first and second regions may have a reduced thickness in the matching layer. The first and second textures may be formed by ablation. The first and second textures may be formed by abrasion.
[0009] Alternatively, the matching element may include a plurality of matching regions having different thicknesses. The matching regions may be arranged side-by-side on the active element. At least two of the matching regions may be overlapping.
[0010] Furthermore, the matching layer may include a plurality of discrete matching regions of a first material over the active element. The matching element may further include a fill-in matching region of a second material with a different composition from the first material deposited between the discrete matching regions over the active element. The discrete matching regions of the first material and the discrete matching regions of the second material may be of the same thickness thereby forming a matching layer formed from two materials with different compositions.
[0011] In a further embodiment, a method of making an ultrasonic transducer includes the steps of providing a backing element, providing an active element overlying the backing layer, and forming a matching element over the active element, the matching element having an inner surface that contacts the active element and an outer surface with a non-homogeneous texture and/or material composition.
[0012] The matching element may be a single matching layer and the forming step may include providing the outer surface with a first region having a first texture and a first material composition and a second region having a second texture and a second material composition. The first texture differs from the second texture and/or the first material composition differs from the second material composition.
[0013] The matching layer has a thickness, and the step of providing the outers surface with first and second regions includes a step of reducing the thickness of the matching layer. The reducing step may include ablation. The reducing step may include abrasion.
[0014] The forming step may include providing the matching layer with a plurality of matching regions. The step of providing the matching layer with a plurality of matching regions may include arranging the matching regions side-by-side on the active element. The step of providing the matching layer with a plurality of matching regions may include overlapping at least two of the matching regions.
[0015] The forming step may include depositing a plurality of discrete matching regions of a first material on the active element. The forming step may further include forming a fill-in matching region of a second element between the discrete matching regions of the first material deposited on the active element. The method may further include the further step of causing the discrete matching regions of the first material and the discrete matching regions of the second material to have the same thickness.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The following drawings illustrate some particular embodiments of the present invention and therefore do not limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. Some embodiments will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.
[0017] FIG. 1 is a perspective view of a prior art transducer stack in accordance with an embodiment.
[0018] FIG. 2 is a section view of a transducer stack with a matching element having two matching regions in accordance with an embodiment.
[0019] FIG. 3 is a section view of a transducer stack with a matching element having more than two matching regions in accordance with an embodiment.
[0020] FIG. 4 illustrates laser ablation of a matching element of a transducer stack in accordance with an embodiment.
[0021] FIG. 5 is a perspective view of a transducer stack with a laser-ablated matching element in accordance with an embodiment.
[0022] FIG. 5A is a section view of the transducer stack shown in FIG. 5 .
[0023] FIG. 6 illustrates micro-abrasive blasting of a matching element of a transducer stack in accordance with an embodiment.
[0024] FIG. 7 is a perspective view of a transducer stack with a laser-ablated and micro-abrasive blasted matching element in accordance with an embodiment.
[0025] FIG. 7A is a section view of the transducer stack shown in FIG. 7 .
[0026] FIG. 8 illustrates a time-domain response of an ultrasonic transducer stack before ablation in accordance with an embodiment.
[0027] FIG. 9 illustrates a frequency-domain response of a transducer stack before ablation in accordance with an embodiment.
[0028] FIG. 10 illustrates a time-domain response of a transducer stack after ablation in accordance with an embodiment.
[0029] FIG. 11 illustrates a frequency-domain response of a transducer stack after ablation in accordance with an embodiment.
[0030] FIG. 12 illustrates a time-domain response of a transducer stack after ablation that is excited at a first frequency in accordance with an embodiment.
[0031] FIG. 13 illustrates a frequency-domain response of a transducer stack after ablation that is excited at a first frequency in accordance with an embodiment.
[0032] FIG. 14 illustrates a time-domain response of a transducer stack after ablation that is excited at a second frequency in accordance with an embodiment.
[0033] FIG. 15 illustrates a frequency-domain response of a transducer stack after ablation that is excited at a second frequency in accordance with an embodiment.
[0034] FIG. 16 is a top view of a matching element stencil in accordance with an embodiment.
[0035] FIG. 17 is a section view of a transducer stack having matching regions formed from a first material based on the stencil shown in FIG. 16 .
[0036] FIG. 18 is a section view of a transducer stack having a second material formed over matching regions formed from a first material based on the stencil shown in FIG. 16 .
[0037] FIG. 19 is a section view of a transducer stack having matching regions formed from a first material and a matching region formed from a second material based on the stencil shown in FIG. 16 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides some practical illustrations for implementing some embodiments of the present invention. Examples of constructions, materials, dimensions, and manufacturing processes are provided for selected elements, and all other elements employ that which is known to those of ordinary skill in the field of the invention. Those skilled in the art will recognize that many of the noted examples have a variety of suitable alternatives.
[0039] For example, this application provide certain examples of a transducer stack appropriate for use in an intravascular ultrasound (IVUS) catheter having an ultrasound transducer disposed within the catheter sheath. These examples are given for illustrative purposes only and do not limit the application of the invention to only IVUS catheters.
[0040] FIG. 1 illustrates a prior art ultrasound transducer stack 100 having a backing layer 104 , an active element 101 that includes a single active layer 102 , and a matching element 105 that includes a single matching layer 106 . Transducer stack 100 is illustrated as having rectangular shape. In other examples, the transducer stack 100 may have other shapes, including square, circle, and oval. Transducer stack 100 may also include at least one electrode layer (not shown), which may be formed from metal, including gold and chrome. In one example, the transducer stack 100 may include two electrode layers located on the top and bottom surfaces of active element 101 , respectively. The electrode layer generally facilitates electrical excitation of the active layer. Transducer stack 100 may be electrically connected to a signal generator (not shown) to electrically excite the transducer stack. Transducer stack 100 may also be electrically connected to a receiver (not shown) to detect pressure fields that are converted to electrical signals by the transducer stack.
[0041] FIG. 1 shows active element 101 which includes active layer 102 . Active layer 102 may also be referred to as a piezoelectric layer. In other examples, active element 101 may include multiple active layers. Active layer 102 may be composed of a ceramic material such as lead zirconate titanate, commonly known as PZT. The thickness of active layer 102 determines the thickness resonance of the layer. For example, a 36 μm Motorola 3203HD material has a thickness resonance of approximately 63 MHz. Alternatively, active layer 102 may be composed of a composite material such as lead magnesium niobate-lead titanate single crystal, commonly known as PMN-PT and polymer, wherein a resonance is determined by a longitudinal length mode rather than a thickness mode.
[0042] Backing layer 104 may be composed of an electrically conductive epoxy, such as a tungsten-loaded epoxy. In the example of a transducer stack for use in an IVUS catheter, the thickness of backing layer 104 may be 200 μm or greater. In other examples, the appropriate thickness of backing layer 104 should be sufficiently thick to attenuate ultrasonic vibrations from active element 101 in the backwards direction (toward backing layer).
[0043] FIG. 1 also illustrates matching element 105 which includes matching layer 106 . Matching layer 106 may be composed of an electrically conductive epoxy, such as a silver-loaded epoxy. Matching layer 106 provides a better acoustic impedance match between active element 101 and the medium in which transducer stack 100 is located. Matching layer 106 may have a uniform thickness that is equal to one quarter of the wavelength at the nominal center frequency of transducer stack 100 and is commonly referred to as a quarter-wave matching layer. Matching element 105 improves the efficiency of the transducer stack to transmit ultrasound vibrations into the surrounding medium and to receive ultrasound vibrations from the surrounding medium. While transducer stack 100 is shown for illustrative purposes in FIG. 1 to have matching element 105 having only one matching layer 106 , in other examples, matching element 105 may have more than one matching layer to further improve efficiency.
[0044] FIGS. 2 and 3 are section views of transducer stacks that illustrate matching elements having side-by-side matching regions. FIG. 2 shows transducer stack 120 which includes backing layer 104 , active element 101 including active layer 102 , and matching element 122 . Matching element 122 includes a quarter-wave matching region 124 tuned to a first wavelength 1 1 with a thickness equal to λ 1 /4. Matching element 122 also includes a quarter-wave matching region 126 tuned to a second wavelength λ 2 with a thickness equal to λ 2 /4. Matching regions 124 , 126 may be formed from the same material, such as a silver-loaded epoxy. In other examples, matching regions 124 , 126 may be formed from materials with different composition. For example, matching region 124 may be formed from a silver-loaded epoxy having a first volume concentration of silver, while matching region 126 may be formed from a silver-loaded epoxy having a second volume concentration of silver. The volume concentration of silver may affect mass density and speed of sound of matching element 122 which in turn affect the corresponding wavelength at a given ultrasound frequency. The first and second regions of matching regions 124 , 126 may then exhibit different corresponding quarter wavelengths. The volume concentration of silver may also affect acoustic impedance of matching element 122 . Matching regions 124 , 126 may exhibit different efficiencies at different ultrasound frequencies to transmit ultrasound vibrations into the surrounding medium and to receive ultrasound vibrations from the surrounding medium.
[0045] FIG. 3 illustrates transducer stack 130 having matching element 132 which includes a plurality of matching regions 134 - 138 . As can be appreciated, matching regions 134 - 138 of matching element 132 may be formed from the same material or different materials. Matching regions 134 - 138 of the matching element 132 may then exhibit different corresponding quarter wavelengths. The portions of transducer stack 120 having matching regions 134 - 138 of matching element 132 may exhibit different efficiencies at different ultrasound frequencies to transmit ultrasound vibrations into the surrounding medium and to receive ultrasound vibrations from the surrounding medium.
[0046] This application discloses a transducer stack having a matching layer that is matched at more than one ultrasound frequency to improve the transmit and receive efficiency of the transducer stack for a broader range of ultrasound frequencies. There are a number of techniques that may be used to form a matching element that is matched at more than one ultrasound frequency. Subtractive techniques like machining, grinding or etching may be used to modify the thickness profile of a matching layer in a matching element. Other subtractive techniques such as laser ablation or micro-abrasive blasting modify the thickness of the matching element and may also modify the composition profile of the matching element. For example, when a matching layer formed from silver-loaded epoxy is laser ablated or abrasively blasted, more of the softer epoxy may be removed compared to the silver. This would change the mass density of the ablated/blasted regions which may have an effect on the ultrasonic properties of the matching element. Generally, subtractive techniques will also increase the effective surface area of the matching element which can impact on the ultrasonic properties of the matching element.
[0047] These subtractive techniques may be used individually, or in combination to form a matching element with a coarse or roughened surface. The coarse or roughened surface of the matching element creates a varying and non-uniform thickness allowing the matching element to match to more than one ultrasound frequency. Furthermore, the coarse or roughened surface of the matching element results in an increased effective surface area of the matching element, can impact the ultrasonic properties of the matching element. Precise control of the matching element modification process will provide further improvements. An ultrasound transducer stack having a matching element with finely controlled, coarseness or roughness enables balancing the amount of transducer area matched to different ultrasound frequencies.
[0048] One example of a subtractive technique that may be used to form a matching element able to match at more than one ultrasound frequency is laser ablation. FIG. 4 illustrates a laser system 200 ablating a surface of matching element 105 of transducer stack 300 . Laser system 200 includes a light source (not shown) that may operate in the near-infrared spectrum wherein the optical wavelength can vary between 800 nm and 2500 nm. Exemplary laser sources that operate in the near-infrared spectrum include neodymium-doped yttrium aluminum garnet (or ND:YAG) lasers, laser diodes, and fiber lasers. The light source generates laser beam 202 that may be directed through lens 204 . Focused laser beam 206 ablates a surface of matching element 105 to form an ablated region (see FIG. 5 ). Laser system 200 may be repeatedly translated to ablate multiple regions of a surface of matching element 105 . Alternatively, transducer stack 300 may be translated relative to the laser system 200 . The ablated region size and depth for a given laser system may be controlled by the laser system pulse energy, pulse duration and laser beam diameter.
[0049] FIG. 5 illustrates transducer stack 300 having matching element 105 including matching layer 306 . Matching element 105 is shown to have five (5) ablated regions 310 - 318 . FIG. 5A shows a section view of transducer stack 300 including ablated regions 310 , 312 . In the example of a transducer stack for use in an IVUS catheter, the number of ablated regions may range from one (1) to 40, wherein the diameter of the ablated regions may range from 50 μm to 500 μm. The ablated regions may be distributed uniformly or unevenly across the face of the matching layer. In other examples, the appropriate size, number and location of laser-ablated regions on the matching element may vary depending on the specific application of the transducer stack.
[0050] Another example of a subtractive technique that may be used to form a matching element able to match at more than one ultrasound frequency is micro-abrasive blasting. FIG. 6 illustrates micro-abrasive blasting system 400 that is ablating matching element 305 . Micro-abrasive blasting system 400 includes abrasive nozzle 401 . Micro-abrasive blasting system 400 delivers a stream of abrasive particles 403 to matching element 305 of transducer stack 500 typically using a pressurized gas such as nitrogen or dry air. In the example of a transducer stack for use in an IVUS catheter, the size of the abrasive particles may range from 10 μm to 200 μm and include soft abrasives such as wheat starch or sodium bicarbonate; the depths of the ablated regions generally range between 0.1 μm and 10 μm; the pressure of the pressurized gas may range between 40 PSI and 140 PSI; and the area of the abrasive-blasted region is generally the entire surface area of the matching element. In other examples, the appropriate size and hardness of the abrasive particles, depth of ablated regions, pressure of the pressurized gas, and area of abrasive blasting may vary depending on the specific application of the transducer stack.
[0051] Subtractive techniques may be used in combination to further increase the transmit and receive efficiency of a transducer stack over a broader range of frequencies. FIG. 7 illustrates transducer stack 500 having an abrasive-blasted and a laser-ablated matching element 505 . The surface of matching element 505 is shown to have laser-ablated regions 510 - 518 . FIG. 7A shows a section view of transducer stack 500 that includes ablated regions 510 , 512 that have been laser-ablated and abrasive-blasted.
[0052] FIGS. 8 to 11 illustrate the effect of matching layer ablation on pulse-echo time-domain and frequency-domain responses of an ultrasonic transducer stack to a short-time electrical excitation. Measurement of the pulse-echo time-domain and frequency-domain responses of an ultrasonic transducer stack are known to those skilled in the art of ultrasound imaging. FIG. 8 shows a time-domain pulse-echo response 402 of the transducer stack 300 before ablation of the matching layer 106 , as illustrated in FIG. 4 . FIG. 9 shows a pulse-echo (frequency-domain) power spectrum 404 that corresponds to the time-domain pulse-echo response 402 of the transducer stack 300 before ablation of a matching layer 106 . FIG. 10 shows a time-domain pulse-echo response 412 of the transducer stack 500 after laser ablation and abrasive blasting of the matching layer 506 , as illustrated in FIG. 7A . FIG. 11 shows a pulse-echo (frequency-domain) power spectrum 414 that corresponds to the time-domain pulse-echo response 412 of the transducer stack 500 after laser ablation and abrasive blasting of the matching layer 506 . The effects of matching element ablation on pulse-echo time-domain and frequency-domain responses of the ultrasonic transducer stack are decreased time-domain pulse length, increased center frequency, and increased bandwidth. These effects generally provide improved image quality of ultrasound devices.
[0053] The increased bandwidth further enables imaging at more than one frequency. FIGS. 12 to 15 show the pulse-echo time-domain and frequency-domain responses of transducer stack 500 having an ablated matching element 506 , as illustrated in FIG. 7 . FIGS. 12 and 13 respectively show a pulse-echo time-domain response 422 and a pulse-echo (frequency-domain) power spectrum 424 of a short-time electrical excitation having a first frequency. FIGS. 14 and 15 respectively show a pulse-echo time-domain response 432 and a pulse-echo (frequency-domain) power spectrum 434 of a short-time electrical excitation having a second frequency, wherein the second frequency is lower than the first frequency. The pulse-echo time-domain response 422 of the transducer to the first-frequency, short-time, electrical excitation is shorter than the pulse-echo time-domain response 432 of the transducer to the second-frequency, short-time, electrical excitation. The pulse-echo power spectrum 424 of the transducer to the first-frequency, short-time, electrical excitation has a higher center frequency than that of the pulse-echo power spectrum 434 of the transducer to the second-frequency, short-time, electrical excitation. A transducer operating with a shorter time-domain pulse and higher center frequency will generally enable imaging with better spatial resolution and a smaller depth of penetration. Conversely, a transducer operating with a longer time-domain pulse and lower center frequency will generally enable imaging with a larger depth of penetration and lower spatial resolution.
[0054] Deposition techniques may also be used to increase the transmit and receive efficiency of a transducer stack over a broader range of frequencies. In one technique, one or more stencils may be used to form a matching layer of a matching element, the matching layer having multiple matching regions formed from materials with different compositions. Stencils can be developed from metals, such as stainless steel. Stencil patterns can be fabricated using known processes, such as photochemical machining. A stencil includes at least one cut-out hole that may be of a variety of shapes, including circle, rectangle, or triangle. In the example of a transducer stack for use in an IVUS catheter having a width of approximately 0.5 mm and a length of approximately 0.75 mm, the thickness of the stencil may range from 0.05 mm to 1 mm, and the cut-out holes may vary in size from approximately 0.025 mm to 0.5 mm. In other examples, the dimensions of the stencil and the size and shape of the cut-out-holes may vary depending on the specific application of the transducer stack.
[0055] FIG. 16 illustrates a top view of an example of a stencil 600 that may be used to deposit a first material on a transducer stack that may be used in an IVUS catheter. The stencil length is approximately 0.75 mm, width is approximately 0.5 mm, and thickness is approximately 0.05 mm. The stencil 600 includes five (5) cut-out holes 610 - 618 wherein the cut-holes are circular in shape and have diameters of approximately 0.15 mm.
[0056] FIG. 17 shows a section view of transducer stack 700 including matching element 705 having partial matching layer 706 . Partial matching layer 706 includes matching regions 710 , 712 formed from a first material. Matching regions 710 , 712 are formed by aligning stencil 600 , shown in FIG. 16 , with the top surface of transducer stack 700 . The first material, such as an epoxy containing a first volume fraction of silver, is then applied to transducer stack 700 . Excess first material may be removed by scraping the top surface of stencil 600 using a razor blade or other sharp-bladed instrument after the first material is applied. Stencil 600 may then be removed from the top surface of transducer stack 700 thereby forming matching regions 710 , 712 formed from the first material. Matching regions 710 , 712 may then be permitted to cure before depositing additional materials.
[0057] FIG. 18 shows a section view of transducer stack 700 after having a second material 714 , having a different composition from the first material, deposited on the top face of transducer stack 700 that include matching regions 710 , 712 formed from the first material. The second material 714 may then be permitted to cure before applying a subtractive technique to reduce the thickness of matching layer 706 to a target thickness. The thickness of matching layer 706 can be reduced by a variety of techniques, for example machining. FIG. 19 shows a section view of the transducer stack 700 having a matching element 705 with a matching layer 706 , the matching layer 706 including matching regions 710 , 712 formed from the first material and matching region 714 formed from the second material. It can be appreciated that in other examples, a matching element may include a matching layer formed from more than two materials, each material having a different composition.
[0058] This application discloses a number of subtractive and deposition techniques, each method may be used individually to increase the transmit and receive efficiency of a transducer stack over a broad range of frequencies. It can be appreciated, that any of these methods may also be used in combination with each other to further increase the efficiency of a transducer stack. For example, as noted above, FIG. 7 shows a transducer stack 500 having a matching element having been both laser-ablated and abrasive-blasted. In another example, the transducer stack 700 , as shown in FIG. 19 , may have its matching element 705 coarsened or roughened using either laser ablation, abrasive blasting, or both. In yet another example, these techniques may be performed on transducer stack 120 and 130 as shown in FIGS. 2 and 3 , respectively.
[0059] Furthermore, the subtractive and deposition techniques disclosed in this application may be used individually or in combination on varying transducer stacks. For example, these techniques may be performed on transducer stack 100 shown in FIG. 1 which includes backing layer 104 , active element 101 having a single active layer 102 , and matching element 105 having a single matching layer 106 . In another example, these techniques may be performed on a transducer stack including a backing layer, an active element having one or more active layers, and a matching element having one or more matching layers. In yet another example, using FIG. 19 as a reference, these techniques may be applied to a transducer stack 700 having an active element 101 with more than one active layer, and a matching element 705 with more than one matching layer, where one of those layers is similar to matching layer 706 .
[0060] In some embodiments, an ultrasonic transducer is provided. The transducer can include an active element having a first side and a second side. The transducer can include a backing element attached to the first side of the active element. The transducer can include a matching element attached to the second side of the active element. The matching element may have a surface that is coarse or roughened causing the matching element to have a non-uniform thickness.
[0061] Such an ultrasonic transducer can include a variety of characteristics. In some embodiments, the coarse or roughened surface of the matching element may include a plurality of concavities. In such embodiments, the concavities may be ablated regions. In some embodiments, the ablated regions may have diameters ranging between 50 μm and 500 μm. In some embodiments, by use of micro-abrasive blasting, the ablated regions may cover up to the entire surface of the transducer. In some embodiments, the matching element may include at least two matching layers. In some embodiments, the active element may further comprise two active layers.
[0062] In some embodiments, an ultrasonic transducer is provided. The transducer can include an active element having a first side and a second side. The transducer can include a backing element attached to the first side of the active element. The transducer can further include a matching element attached to the second side of the active element. The matching element may include at least one matching layer. At least one of the matching layers may include at least a first matching region formed from a first material and a second matching region formed from a second material. The first and the second materials can be formed from materials having different compositions.
[0063] Such an ultrasonic transducer can include a variety of characteristics. In some embodiments, a surface of the matching element may be coarse or roughened. In such embodiments, the matching element may have a non-uniform thickness. In some embodiments, the coarse or rough surface may include a plurality of concavities. In such embodiments, the concavities may be ablated regions. In some embodiments, the ablated regions may have diameters ranging between 50 μm and 500 μm. In some embodiments, by use of micro-abrasive blasting, the ablated regions may cover up to the entire surface of the transducer. In some embodiments, the matching element may include at least two matching layers. In some embodiments, the active layer may include at least two active layers.
[0064] Some embodiments provide a method of manufacturing an ultrasonic transducer. Some embodiments involve providing an active element having a first side and a second side. Some embodiments involve providing a backing element on the first side of the active element. Some embodiments involve forming a matching element on the second side of the active element. Some embodiments include forming a surface of the matching element such that the surface is coarse or roughened. In such embodiments, the matching element has a non-uniform thickness.
[0065] Such a method to form an ultrasonic transducer can include a variety of steps. In some embodiments, at least one subtractive technique may be used to form the matching element. In some embodiments, the at least one subtractive technique may include laser ablation. In some embodiments, the at least one subtractive technique may include micro-abrasive blasting. In some embodiments, the at least one subtractive technique may include both laser ablation and micro-abrasive blasting. In some embodiments, the at least one subtractive technique may include machining, grinding, or etching. In some embodiments, forming the active element may include forming at least two active layers. In some embodiments, forming the matching element may include forming at least two matching layers.
[0066] In some embodiments, a method of manufacturing an ultrasonic transducer. Some embodiments involve providing an active element having a first side and a second side. Some embodiments involve providing a backing element on the first side of the active element. Some embodiments involve forming a matching element on the second side of the active element. In such embodiments, the matching element may include a first matching layer. In such embodiments, the first matching layer may include a first matching region formed from a first material, and a second matching region formed from a second material having a different composition than the first material.
[0067] Such a method to form an ultrasonic transducer can include a variety of steps. In some embodiments, a first deposition technique may be used in forming the first matching layer. In such embodiments, the first deposition technique may include aligning a first stencil adjacent to the second side of the active element. In such embodiments, the stencil may have at least one cut-out-hole. In some embodiments, a first material may be applied to the first stencil. In some embodiments, the first stencil is removed and the first material is allowed to cure. In such embodiments, the cured first material forms the first matching region. In some embodiments, the first deposition technique may be repeated for a second stencil. In some embodiments, a second deposition technique may be used in forming the first matching layer. In such embodiments, the second deposition technique may include applying a second material to a surface of the matching element and allowing the second material to cure. In such embodiments, the cured second material forms the second matching region. In some embodiments, a first subtractive technique is used in forming the first matching layer. In such embodiments, the first subtractive technique may include reducing the thickness of the first matching layer until the thickness of the first and second matching regions are equal. In some embodiments, the first subtractive technique may include machining, grinding, or etching. In some embodiments, a second subtractive technique is used to form the matching element. In such embodiments, the matching element may have a surface that is coarse or rough. In such embodiments, the matching element may have a non-uniform thickness. In some embodiments, the second subtractive technique may include laser ablation. In some embodiments, the second subtractive technique may include micro-abrasive blasting. In some embodiments, the second subtractive technique may include both laser ablation and micro-abrasive blasting.
[0068] Thus, embodiments of the invention are disclosed. Although the present invention has been described in considerable detail with reference to certain disclosed embodiments, the disclosed embodiments are presented for purposes of illustration and not limitation and other embodiments of the invention are possible. One skilled in the art will appreciate that various changes, adaptations, and modifications may be made without departing from the spirit of the invention and the scope of the appended claims.
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An ultrasonic transducer includes a backing element, an active element overlying the backing layer, and a matching element overlying the active element, the matching element having an inner surface that contacts the active element and an outer surface with a non-homogeneous texture and/or material composition. The matching element may be formed by subtractive or deposition techniques.
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FIELD OF THE INVENTION
This invention relates to the health and sense of well-being of people of all ages, especially the aged and those having a sedentary lifestyle. More particularly it relates to a glider type support designed to permit the user to exercise the lower body in a progressive manner according to the individual's needs and desires.
BACKGROUND OF THE INVENTION
A decrease in lower body and leg strength is a common medical finding in the aged, in patients restricted by arthritis or other medical illnesses, and in any person with a sedentary lifestyle.
Lower body weakness results in fatigue on walking and climbing, and increase the risk for injury and falls. Weak legs contribute to lower back instability, chronic back pain, and a cycle of inactivity and depression.
Strength is a function of exercise. A recent study showed that even in the very elderly, leg strength could be greatly improved with a program of regular exercise. The same study also showed, however, that all gains in leg strength were lost within two weeks when exercise was discontinued.
Low back and leg strength can only be maintained with regular exercise, and that exercise must be continued indefinitely.
Thus, there is need for a device for safe and effective lower body exercise and that is particularly suitable, but not limited for use by, any sedentary person, specifically those with arthritis, heart disease, or any similarly restricting medical condition. Such device should offer an attractive method of regaining and maintaining lower body and leg strength, and a general feeling of well-being for persons of all ages.
In order to meet the foregoing requirements, the device should have the following attributes:
a. Suitable for all family members;
b. Useable independently of the weather;
c. Provide an increase in knee strength and stability;
d. Strengthen and tone the leg and hip muscles;
e. Increase endurance for walking or climbing;
f. Contribute to neck and lower back stability;
g. Suitable for those with poor vision or sense of balance;
h. Suitable for those with weak or painful backs;
i. Require minimal cardiovascular effort;
j. Permit the user to be seated thereby avoiding a rise or fall in blood pressure; and
k. May be varied or stopped at any time.
In addition, the device should be suitable under medical conditions such as arthritis, osteoporosis, after surgery, chronic back, hip or leg weakness and during convalescence from medical illness or treatment. Such device should also provide relaxation, reactivation and stress management of the individual.
HISTORY OF THE RELATED ART
Gliders with spring stabilizers have been known in the prior art as for example in the United States patents to Williams U.S. Pat. No. 1,885,663, Wolf U.S. Pat. No. 1,974,396, McGowen U.S. Pat. No. 2,037,333, and Pearlstein U.S. Pat. No. 2,959,210.
A child's amusement device that functions similarly to a glider and with springs at the front and rear is shown in the U.S. Pat. No. to Rosenberg 1,275,757.
The U.S. Pat. No. to Breunig 4,700,946 discloses an exercise device which allows the user to exercise against a resistance proportional to his own weight. Thus in column 4, lines 42-58, is a statement that a bar may be so mounted that the user may push the user support assembly up inclined tracks in order to exercise.
The U.S. Pat. No. to Degen 4,793,009 discloses a mounting for a bed which permits it to oscillate and in FIG. 8 discloses a damping arrangement.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an exercise glider to meet the needs and having the attributes discussed in the foregoing background section.
It is a further object of the invention to provide an exercise glider in which provision is made for adding resistance to the motion of the chair, thereby creating a chair with dual usage, that is for relaxation and as an exercise machine.
It is a further object of the invention to provide an exercise glider in which a seated person pushing backward with his legs must overcome a spring resistance, and thereby accomplishes an exercising function.
A further object is a provision of a friction damping mechanism which is associated with the resistance mechanism of the chair to reduce the rate of the glider return, thereby modifying the exercise dynamics.
It is a further object of the invention to provide a resistance to the chair movement which also affords self-centering of the chair on its base.
A further object of the invention is an exercise glider in which the resistance to motion is progressive in order that the user may adapt it to his own needs, either for exercising or merely for relaxation.
These and other objects of the invention will become apparent from the following description in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective of an exercise glider in accordance with the present invention.
FIG. 2 is a side elevation.
FIG. 3 is a section on the line 3--3 of FIG. 2, with portions omitted for clarity.
FIG. 4 is a front elevation with portions broken out to show the spring mounting.
FIG. 5 is a section on the line 5--5 of FIG. 4.
FIG. 6 is a side elevation of a modification showing apparatus for adjustment of the damper belt.
FIG. 7 is a section on the line 7--7 of FIG. 6.
FIG. 8 is a section on the line 8--8 of FIG. 7.
FIG. 9 is a side elevation with parts broken out illustrating the manner of use when the seat is in a backward position.
FIG. 10 is a side elevation with parts broken out illustrating the manner of use when the seat is in a forward position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With further reference to the drawings, the exercise glide of the present invention includes a seat support assembly 10, base assembly 11, a seat pad 12, arms 13, and back 14. These are constructed and arranged so as to provide optimal comfort and support for a user of the chair.
The base assembly 11 has left and right foot members 15, 16 connected by front and rear crossbars 17 and 18. The foot members 15 and 16 are preferably provided with plates or outriggers 19 for the purpose of further stabilizing the chair, particularly against tilting.
At the upper central portion of each of the foot members a side plate 20 is mounted and extends upwardly for connection to a side rail 22, the side rail extending substantially parallel with the foot members 15, 16 and longitudinally of the chair.
The side rails 22 are connected by crossbar 24 at their forward portion forwardly of the side plate member 20, and by a crossbar 26 which is positioned rearwardly of the side plate member 20.
The base structure described thus far including the foot members, the upright side plate members 20, the rails 22, and the crossbars 24, 26, comprise a fixed rigid assembly.
The seat support assembly 10 includes a horizontal frame portion having side members 28 and front and rear cross members 30 providing a frame on which the cushion is mounted. Extending downwardly from the cross member 30 are front and rear aprons 32, 33. Side panels 34, 35 extend downwardly from the left and right side members 28 and are connected together, just above the foot members 15 and 16, by crossbars 36, 37.
In order to mount the seat support assembly on the base assembly, a rocker arm assembly is provided.
The rocker arm assembly includes front rocker arms 40, 41 each of which has an upper crank arm 42 that is received in a roller bearing 43 in the side rail 22 of the base assembly. Each of the rocker arms is substantially U-shaped and has a web portion 44 with a central hub 45. The lower portion of each of the rocker arms has a crank arm 46 that is received in a roller bearing 47 in a side member 32 of the chair seat support. The hubs 45 are rigidly joined by connector 48. Similarly, at the rear of the chair, the rocker arms 51 have crank arms 52 received in a bearing 53 in the base assembly, the other crank arm 55 being received in a bearing 56 in the side member of the seat assembly, the rear rocker arms being joined by connector 58.
In accordance with the structure described thus far, the base assembly side rail 22 rotatably supports the upper crank arms of the front and rear rocker arms, the lower crank arms being rotatably received within the side panels 34, 35 of the seat support assembly 10, thus permitting the chair to glide back and forth with a rocking motion.
In order to modify the exercise dynamics in accordance with the present invention, a spring and damper assembly is provided. The spring assembly includes a coil spring assembly 60, 61 having an end of each attached centrally to an eyebolt 62 which is mounted on the base assembly crossbar 24 and extending just above said rail. At its outer ends the spring 60, 61 are connected to eyebolts 63, 64 which are mounted on the inner sides of side rails 65 of the seat assembly 10.
A damper assembly is provided to dampen the return of the seat after its rearward movement. This includes a relatively light take-up spring 66 which is connected at one end to a forward central portion of the base, such as to the eyebolt 62, and at its other end to the end 67 of a belt 68, the belt passing around the crossbar 26 and then returning above its lower run to a fastener 68 just beneath the seat front cross member 30 where its front end is connected. Crossbar 26 preferably is round and has a polished sleeve 70 around the portion thereof which the belt 68 engages in order to reduce the friction and the noise associated with the rubbing of the belt around the crossbar. It is understood that the material of the belt, its frictional characteristics, and those of the sleeve 70 may be selected to produce the desired dampening effect, in accordance with the needs of the users of the device.
The tension of the spring 60, 61 may be selected so as to require a reasonable amount of effort from a sedentary person to move the seat backwardly when he pushes his feet against the floor. The tension in the take-up spring 66 is such as to maintain the belt 68 in contact with the sleeve 70 so that the desired damping action is obtained. It is understood that the chair may be used for exercise not only by pushing rearwardly but also by pulling forwardly as indicated in FIGS. 9 and 10.
It will also be understood that blocks or boxes may be placed under the user's feet in order to elevate them in order to vary the positioning of the user's body.
In the operation of the chair as thus described, a person initially pushes or pulls with his feet against the floor in order to move the chair rearwardly or forwardly against the tension of the springs 60, 61. After the chair has reached the extent of the its movement as caused by the person using the chair, then the springs tend to return it to its initial at rest or dead center position. However, a simple oscillating motion due merely to the springs is prevented by reason of the damping mechanism that has been described. Thus, a person may obtain the desired amount of exercise through the use of the chair.
In the event that it is desired to lock the chair seat against backward and forward movement, as for shipment, or in the event that no movement is desired, then a rod member 76 (see FIG. 5) is inserted through an aperture 78 in a disk 79 mounted on the right side of the chair assembly, the rod extending through the opening 78 into an aligned opening 80 which i in the side rail 22 of the base assembly.
THE MODIFICATION OF FIGS. 6-8
The modification of FIGS. 6-8 is for the purpose of permitting adjustment of the tension on the damper belt 68. This is accomplished by providing a roller bar 82 which is rotatably carried in the side panels 34, 35 just beneath the seat frame. The bar has a sheave 86 over which a belt 88 is engaged and engages a rear sheave 90 which is mounted on a roller bar 92 which is also rotatably carried in the side panels beneath the frame of the seat at its rearward portion. The roller bar 92 is connected to a handwheel 94 on the outside of the chair for convenient use by a user in order that rotation of the wheel 94 will turn the roller bar 82 on which the end of the belt 68 is mounted, thereby wrapping the belt onto the bar and effectively decreasing its length. The position of the wheel 94 and, hence, of the belt may be secured by a locking wheel 96 which is threaded onto a shaft 97 which extends inside the bar 92 and is fixed at its other end to the panel 35.
Wheel 94 has a friction collar 98 on its inner side for engaging a friction collar 99 on the outer side of the handwheel 94 when the wheel 96 is moved towards the wheel 94. The inside face of the wheel 94 ma also have a friction collar for engaging a friction collar 101 that is fixed to the outside of the panel 34 so that the tightening of the wheel 96 may force the wheel 94 inwardly against the collar and thereby fix its position.
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An exercise glider has its motion resisted by a spring mechanism cooperatively associated with a friction damping mechanism. In one embodiment, the damping mechanism may be varied.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention concerns a sheathing for veins, a method for its manufacture, and its application in surgery.
[0003] 2. Description of the Related Art
[0004] Medicine is frequently confronted with the task of treating cardiovascular diseases, such as arteriosclerosis for instance, caused by changes in blood vessels. Modern surgery employs, in addition to, e.g., deobliteration methods, substitute-vessel implants in the form of bypasses for reconstructing arterial vessels. Known, for example, are vessel implants manufactured from synthetic materials, or synthetic materials combined with natural materials.
[0005] Detrimental interactions with the physiological environment in patients' bodies may occur if full-synthetic materials are employed. Serious complications, such as thrombosis or restenosis of vessel implants, that may require expensive post operations may occur when synthetic materials are substituted for coronary or peripheral vessels with small lumen. It is thus desirable to employ implants formed from natural vessel material, since they beneficially affect natural endothelialization and the anti thrombogenic properties of vessel walls. Such biological substitute-vessel materials are generally obtained from veins. However, implanting veins in the arterial vessel system may cause increases in wall thickness to occur during arterialization. If those increases are accompanied by intimahyperplasy due to the differing compliances of veins and arteries, they may ultimately lead to restenosis of the implants. It will be beneficial to externally encase or reinforce native veins in order that they will be reliably able to perform their intended function as, for example, a coronary or peripheral bypass for arterial blood transport, over the long term. External sheathing or stiffening ribs can adapt the compliance of natural vein material to suit the arterial system and thus both reduce incidences of intimahyperplasy and allow achieving high non closure rates over the long term. Moreover, the aforementioned sheathing will also allow implantation of varicose, ectatic, or thin-walled veins that have not been employed to date due to their unfavorable hemodynamic properties. The latter will be the only means for employing vessel materials from patients' own bodies as substitutes for vessels having small lumen, particularly in the case of patients suffering from multiple vessel imperfections.
[0006] A vessel prosthesis where a woven sheathing is drawn over a natural blood vessel is known from German Patent DE 4340755. A natural blood vessel spirally wrapped in crossed fibers is described in European Patent EP 687164. U.S. Pat. No. 5,645,581 discloses a tube, whose manufacture is described in U.S. Pat. No. 5,755,659, having crossed fibers spirally wrapped around its longitudinal axis.
[0007] According to German Patent DE 19910340, a tube, sheath, or tubing is employed as sheathing for a vein to be used as artery prosthesis. An external reinforcement for vessel prostheses having a duo layer, tubular, polymer-fiber sheathing is known from World Patent WO 00/54703.
[0008] The known reinforcements for vessel material have a number of disadvantages. For example, numerous, complex, procedures are required for preparing them and attaching them to implant vessels. Additional tissue adhesives are required in order to attach the reinforcements. Reinforcements based on metals may adversely impact handling of prostheses and foster incompatibility reactions. Problems, particularly problems in the anastomosis area, may occur due to loose ends of wires.
[0009] The problem addressed by the invention is thus making available a sheathing for veins that will overcome the problems arising from the state of the art, will reinforce veins to be employed as surgical implants for use as durable vessel substitutes, may be simply and inexpensively manufactured following ordinary manufacturing procedures and manufactured on ordinary manufacturing equipment, and will be simply and reliably applicable in surgery.
SUMMARY OF THE INVENTION
[0010] That problem is solved by a sheathing for reinforcing natural veins for use as surgical implants in the form of textile netting that is fabricated by forming a seamless, tubular, essentially pile-less, knit fabric and has loops having large, open apertures having essentially polygonal shapes, in particular, polygonal shapes having rounded corners.
[0011] The invention also comprises a method for manufacturing a sheathing for reinforcing natural veins for use as a surgical implant in the form of textile netting fabricated by forming a seamless, tubular, essentially pile-less, knit fabric that has loops having large, open apertures having essentially polygonal shapes.
[0012] The present invention is particularly suited to use as sheathing for reinforcing native veins in order to provide surgical implants for use as vessel substitutes in human medicine and veterinary medicine.
[0013] The vein sheathing may beneficially be manufactured in the form of open-pored, textile tubing by means of knitting. In the case of one embodiment, the tubing may be manufactured on ordinary circular knitting machines used for manufacturing small-bore tubing. In the case of another embodiment, a dual-bar raschel machine may be used for manufacturing the tubing. Knitting equipment is generally known to specialists in the field, and thus shall not be explained in detail here.
[0014] In the case of one embodiment, vein sheathing according to the invention may be formed by circular knitting employing plain-tricot interlocking. In the case of another, preferred, embodiment, vein sheathing according to the invention may be formed by knitting employing a combination of interlocking techniques. Tricot-Atlas, tricot-strand, strand/weft, and combinations employing fillet needles may be mentioned as examples of such combined knitting techniques. According to the invention, knit fabric knit employing tricot-Atlas interlocking is preferred for sheathing veins. However, various other types of knit fabrics and combination knits, such as open meshes or closed meshes, may be employed.
[0015] The netting's polygonal loops may have various shapes, depending upon the knitting technique chosen. In the case of one embodiment, the netting's loops may be rhombic. Rhombic loops may be formed, particularly in the case of plain-tricot fabrics. In particular, the clear diameter of the rhombs may fall within the range 100 μm to 600 μm, in particular, within the range 100 μm to 400 μm, or, if larger loops are desired, preferably within the range 300 μm to 600 μm. In the case of knit fabrics knit employing tricot-Atlas interlocking, loops having, in particular, honeycomb shapes, may be formed by rounding off corners. The clear diameter of the loops may, preferably, fall within the range 400 μm to 1,600 μm, in particular, within the range 800 μm to 1,200 μm, or, particularly preferred, within the range 600 μm to 1,000 μm.
[0016] It will be particularly beneficial if the tubular knit fabric is essentialy formed from biocompatible polymer fibers. Examples of such biocompatible polymers are synthetic polymers in the form of homopolymers, copolymers, terpolymers or polymer blends, natural polymers, or combinations of synthetic and natural polymers. Employment of resorbable, synthetic polymers is also feasible. In the case of a preferred embodiment of the vein sheathing according to the invention, a high-capillarity polyester yarn fabricated from polyethylene terephthalate (PET) is employed. PET is noted for its good biocompatibility, and is thus particular suited for use as an implant material.
[0017] According to the invention, the sheathing for veins exhibits essentially no pile. The knit fabric may thus have essentially smooth surfaces on its outer and inner walls. In the case of a special embodiment, the sheathing may be essentially free of textured fibers.
[0018] The vein sheathing may be beneficially formed from multifilament yarn. The sheathing according to the invention may be formed from yarn having 2 to 500 filaments, in particular, having 5 to 250 filaments, and preferably having 10 to 100 filaments. The yarn employed according to the invention may have a guage of, preferably, 50f40 dtex. The knit fabric of the sheathing according to the invention may have a mesh width falling within the range 100 μm to 1,000 μm, in particular, 300 μm to 600 μm.
[0019] In the case of plain-tricot interlocking, which is also termed “single-tricot interlocking,” knitting employs a single guide bar only. A suitable choice of the number of strands in the yarn and the course density and wale density of the knit fabric will allow adjusting the inner diameter of the knit tubing for sheathing veins as desired. In the case of tubular sheathing knit employing single interlocking, in particular, plain-tricot interlocking, the number of strands may beneficially fall within the range 5 to 25, the course density may beneficially fall within the range 10 to 20 per centimeter, the wale density may beneficially fall within the range 15 to 25 per centimeter, and the nominal diameter may beneficially fall within the range 2 mm to 10 mm. Knit fabric having low wall thicknesses will be the result, particularly in the case of plain-tricot interlocking. The wall thicknesses of plain-knit tubing and plain-tricot tubing, may preferably fall within the range 0.10 mm to 0.25 mm.
[0020] In the case of the combined knitting technique, in particular, knitting employing tricot-Atlas interlocking, knitting employs a pair of guide bars and special needles. In particular, the knit tubing obtained has a structure similar to that of a honeycomb. Yarn having fewer strands may be employed in order to obtain a mesh having a looser structure. The inner diameter of the knit tubing for encasing veins may be adjusted as desired by suitably choosing the number of strands in the yarn employed and the course density and wale density of the knit fabric. In the case of tubular sheathing knit employing combined interlocking techniques, in particular, tricot-Atlas interlocking, the number of strands may beneficially fall within the range 15 to 90, the course density may beneficially fall within the range 20 to 40 per centimeter, the wale density may beneficially fall within the range 20 to 30 per centimeter, and the nominal diameter may beneficially fall within the range 2 mm to 15 mm. Wall thicknesses may preferably fall within the range 0.10 mm to 0.30 mm, in particular, may fall within the range 0.15 mm to 0.25 mm. According to the invention, a yarn having a gauge of 50f40 dtex may be preferably employed.
[0021] Due to the tighter interlooping of the strands of yarn in the case of the combined knitting technique, the combined knitting technique yields more stable wales and courses than in the case of plain-tricot interlocking. Such a knit fabric may exhibit lower stretchability and greater resistance to distortion. Knit tubing having lower lumen expandability may be obtained in this manner. Knit fabrics according to the invention thus have better abilities to resist stresses due to arterial blood pressure.
[0022] Structural features of knit fabrics for vein sheathings manufactured employing plain-tricot interlocking and tricot-Atlas interlocking according to those knitting techniques described as preferred embodiments will be more clearly evident from the accompanying figures.
[0023] [0023]FIG. 1 depicts a 25×-magnification of a plain-tricot knit fabric. The loop apertures formed in the knit fabric have approximately rhombic to square shapes having clear widths falling within the range 300 μm to 600 μm. The strands of yarn are singly interlooped along the courses and wales, which allows a certain amount of distortion of the loops and stretching of the knit fabric.
[0024] [0024]FIG. 2 depicts a 25×-magnification of a tricot-Atlas knit fabric. The loop apertures formed in the knit fabric have approximately honeycomb to rectangular shapes having clear widths falling within the range 400 μm to 1,200 μm, in particular, falling within the range 600 μm to 800 μm. The strands of yarn are also interlooped along the courses and wales in order to yield greater resistance to distortion of the loops.
[0025] Knit tubing obtained employing the knitting techniques described above may be pretreated in manners that will make it suitable for sheathing veins. In the case of one embodiment of the invention, the untreated knit fabric may be pretreated by cleansing. In the case of another embodiment of the invention, the untreated knit fabric may be pretreated by thermal shrinking and cleansing.
[0026] Cleansing of the untreated knit fabric may be performed in three stages. The material is initially placed in hot water at a temperature of 60° C. and stirred. Residual moisture is then extracted in an extraction apparatus using isopropanol, which will also remove any avivage residues. Finally, the knit fabric is pretreated once again, this time in hot water at a temperature of 40° C. Following cleansing, the knit tubing is dried in a suitable manner, for example, in a laminar-flow box.
[0027] In the case of another embodiment, the untreated knit tubing may also be pretreated by shrinking, in which case, shrinking will be performed prior to the cleansing described above. Shrinking may be performed by dipping the knit tubing in boiling water and allowing to remain therein for a suitable period.
[0028] Cleansed and, if shrinking has been performed, shrunk, knit tubing may be drawn onto a metal mandrel, each end of the tubing clamped to the respective end of the mandrel, and thermoset at 160° C., which will cause the inner diameter of the knit tubing to expand to varying extents relative to the declared inner diameter of the untreated material, a phenomenon that will be described in detail under Examples 4 and 5, below. Thermosetting may be performed in a single stage. Thermosetting may be alternatively performed in two stages, in which case, the knit tubing will be expanded to an even greater extent.
[0029] Knit tubing is preferably thermoset without regard to any pretreatment by shrinking it may have received. In other words, the thermosetting process employed is not determined by the type of pretreatment by shrinking that may have been employed. Since the ends of the knit tubing are clamped to the respective ends of the metal mandrel during thermosetting, it will no longer be able to shrink by much following thermosetting, which, in the case of non preshrunk knit tubing, will lead to larger pores than in the case of shrunk knit tubing. Sheathing according to the invention may beneficially be characterized by the fact that it retains its shape.
[0030] The retaining clamps may be removed and the vein sheathing cut to lengths ranging from about 10 cm to 60 cm, preferably ranging from about 10 cm to 30 cm, and packed once thermosetting has been concluded and the metal mandrel has cooled down to room temperature.
[0031] Determinations of the normalized radial tensile strengths of various samples knit employing plain-tricot interlocking and combined knitting techniques, such as tricot-Atlas interlocking, showed that the tensile strengths of the knit tubing fell within the range 2 N/mm to 10 N/mm, in particular, fell within the range 2 N/mm to 6 N/mm, depending upon the type of knitting involved and the treatment that the knit tubing had received. The radial tensile strength of knit tubing that had not been preshrunk was less than that of knit tubing that had been preshrunk.
[0032] Measurements of the longitudinal tensile strengths of plain-tricot knit tubing yielded values ranging from 70 N to 100 N for samples that had been preshrunk and had not been preshrunk.
[0033] The tensile elasticities of the vein sheathing along the radial direction were determined for forces ranging from 2 N to 12 N. Elastic elongations in the radial direction ranging from 3% to 10%, in particular, ranging from 5% to 8%, for plastic elongations of the same order of magnitude ranging from 5% to 15%, in particular, ranging from 6% to 13%, were determined for samples knit employing plain-tricot interlocking and combined interlocking techniques.
[0034] The sheathing for veins according to the invention may be cut to suitable lengths and suitably packed, ready for use, in order to make it available for use in surgery. In particular, the sheathing material according to the invention may be sterilized in a suitable manner. A suitable sterilization method may be either chosen from the usual physical or chemical methods for deactivating microorganisms or be a combination of such methods. One possible sterilization method includes treatment with ethylene oxide. Sterilization of sheathing according to the invention may preferably be performed employing γ-radiation.
[0035] The vein material to receive sheathing according to the invention involved is a natural vein taken from a mammal. Such veins, or segments of veins, may be taken from deceased donors. Alternatively, such veins, or segments of veins, may be taken from living donors. Vein donors may be animals, for example, pigs. Vein donors may be human beings. It will be particularly preferable if the vein to be sheathed may be taken from the patient who is to receive the sheathed vessel implant. Such an embodiment is particularly preferable, since healing of the patient's bodily tissues without any problems arising is to be expected and incompatibility reactions to the implant may be minimized. No additional attachment of the sheathing using tissue adhesives will be necessary if a natural vein is sheathed according to the invention, which will allow further reducing the technical effort involved in implantation and risks of complications occurring.
[0036] In the following, the present invention will be explained through detailed descriptions of particular embodiments in the form of examples. In the examples, the individual features of the invention may be implemented either alone, or in combination with other features thereof. The examples are for the purpose of explaining the invention and making it more readily comprehensible only, and shall not be construed as representing restrictions of any kind.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
EXAMPLE 1
[0037] Manufacture of Knit Tubing
[0038] A knit fabric knit employing tricot-Atlas interlocking employing a pair of guide rails is manufactured as the raw material for the vein sheathing. Polyethylene-terephthalate-fiber yarn in a gauge of 50f40 dtex is knit at a course density of about 35 per centimeter and a wale density of about 25 per centimeter. Yarn having 20 strands will yield knit tubing having a nominal diameter of 4 mm. Yarn having 80 strands will yield knit tubing having a nominal diameter of 14 mm.
EXAMPLE 2
[0039] Pretreatment by Cleansing
[0040] The untreated knit tubing obtained under Example 1 is cleansed, without shrinking it, by stirring it in hot, demineralized water at a temperature of 60° for 30 min. Under a second step, the material is cleansed and any residues present extracted using isopropanol in a Soxhlet apparatus for a period ranging from 15 min to 3 h, depending upon the quantity of material involved, which will eliminate any avivage residues. In a third cleansing step, the material is, once again, incubated in hot water, this time at a temperature of 40° C., for 10 min, under constant stirring. In a final step, the cleansed material is dried overnight in a laminar-flow box.
EXAMPLE 3
[0041] Pretreatment by Shrinking
[0042] The untreated knit tubing obtained under Example 1 is shrunk in boiling, demineralized water at a temperature falling within the range 97° C. to 100° C. for 5 min. In an initial step, the shrunk material is then cleansed in hot, demineralized water at a temperature of 60° C., under constant stirring. In a second step, the material is cleansed and any residues present extracted using isopropanol in a Soxhlet apparatus for a period ranging from 15 min to 3 h, depending upon the quantity of material involved, which will eliminate any avivage residues. In a third cleansing step, the material is, once again, incubated in hot water, this time at a temperature of 40° C., for 10 min, under constant stirring. In a final step, the shrunk, cleansed material is dried overnight in a laminar-flow box.
EXAMPLE 4
[0043] Thermosetting Plain-Tricot Knit Fabrics
[0044] Knit tubing pretreated according to Example 3 having a declared inner diameter of 3 mm is cut to a length of 40 cm, drawn onto a metal mandrel having an outer diameter of 6 mm, and thermoset in a single step. Knit tubing having declared inner diameters of 4 mm or 5 mm may be drawn onto mandrels having outer diameters of 7 mm or 8 mm, respectively, and thermoset, where the final inner diameter of the vein sheathing will equal the outer diameter of the metal mandrel employed.
[0045] In the case of a two-step thermosetting, tubing having a declared inner diameter of 3 mm is drawn onto a metal mandrel having an outer diameter of 5 mm in an initial step of the thermosetting procedure and drawn onto a mandrel having an outer diameter of 6 mm in a second step of the thermosetting procedure, and thermoset following each step. Tubing having a declared inner diameter of 4 mm is expanded to yield inner diameters of 7 mm and 8 mm and thermoset following these same procedures.
EXAMPLE 5
[0046] Thermosetting Tricot-Atlas Knit Fabrics
[0047] Unlike the plain-tricot knit tubing described under Example 4, tricot-Atlas knit tubing may be only slight expanded. In the case of single-step thermosetting, such tricot-Atlas tubing having a declared inner diameter of 7 mm is drawn onto metal mandrels having outer diameters of 6 mm, 7 mm, or 8 mm and thermoset. Cleansed, shrunk knit tubing may be treated in the same manner. In the case of two-step thermosetting, tricot-Atlas tubing having a declared inner diameter of 7 mm is initially thermoset on a metal mandrel having an outer diameter of 7 mm and thermoset a second time on another metal mandrel having an outer diameter of 8 mm once it has cooled.
EXAMPLE 6
[0048] Properties of Vein Sheathing
[0049] Vein sheathing manufactured according to the examples described above will have well-defined geometric and physical properties.
[0050] The mean wall thickness of sheathing manufactured employing plain-tricot interlocking is 0.17 mm±0.01 mm. The mean wall thickness of sheathing manufactured employing tricot-Atlas interlocking falls within the range 0.22 mm±0.01 mm to 0.23 mm±0.01 mm.
[0051] Measurements of their radial tensile strengths indicate a strong dependence of the values obtained therefore on the type of pretreatment employed. Shrinking in boiling water may significantly increase their tensile strengths in some cases.
[0052] The tensile strengths determined for typical samples appear listed in Table 1, below:
TABLE 1 Normalized Radial Tensile Strength [N/mm] and the Number of Strands in Type of Manufacturing Parameters/ the Yarn Employed Knit Tubing Method (n) Plain tricot Inner diameter expanded 4.5 ± 1.6 from 4 mm to n = 13 8 mm (in two steps, 4 mm → 7 mm, and 7 mm → 8 mm), following preshrinking in boiling water. Inner diameter expanded 4.6 ± 1.6 from 3 mm to n = 26 6 mm (in two steps, 3 mm → 5 mm, and 5 mm → 6 mm), following preshrinking in boiling water. Inner diameter expanded 2.3 ± 0.6 from 5 mm to n = 13 8 mm (in a single step), not preshrunk. Inner diameter expanded 3.5 ± 1.0 from 3 mm to n = 13 6 mm (in two steps, 3 mm → 5 mm, and 5 mm → 6 mm), not preshrunk. Tricot- Inner diameter held 4.9 ± 0.4 Atlas N constant at 6 mm n = 13 (thermoset in a single step), following preshrinking in boiling water. Inner diameter held 4.4 ± 0.4 constant at 6 mm n = 13 (thermoset in a single step), not preshrunk. Tricot- Inner diameter held 5.9 ± 0.4 Atlas N2 constant at 6 mm n = 13 (thermoset in a single step), following preshrinking in boiling water. Inner diameter held 4.6 ± 0.4 constant at 6 mm n = 13 (thermoset in a single step), not preshrunk.
EXAMPLE 7
[0053] Compliances of Sheathed Veins
[0054] In order to test the compliances of veins having sheathing, sheep jugular veins were sheathed in various types of tubular polyester (Dacron) netting at a flow rate of 300 ml/min and a modulating pressure having an amplitude of 50 mm(Hg) and tested for their dynamic compliances and diameters at various pressures. The measured values were compared to those for native sheep carotid arteries and jugular veins and a vein substitute fabricated from polytetrafluoroethylene (PTFE).
[0055] The diameter of the sheep jugular veins employed was 14.7 mm±2.92 mm, and their circumferential compliance was 2.78±1.4%/100 mm(Hg). The diameter of the sheep carotid arteries employed was 6.6 mm±0.27 mm, and their circumferential compliance was 3.3±0.9%/100 mm(Ha). The circumferential compliance of the PTFE vein substitute employed was 0.6±0.05%/100 mm(Hg). The outer diameters of the stents decreased to mean values of 7.4 mm±0.12 mm, and thus virtually equals the artery diameter. The circumferential compliances of veins equipped with stents varied from 1.98%/100 mm(Hg) to 0.74%/mm(Hg), depending upon the structures of the stents involved.
[0056] Veins sheathed in a textile construction, as stipulated by the invention, exhibited a nonlinear compliance, as is observed in the case of natural blood vessels, particularly in the case of arteries. Long-term efficacies and extended service lives of the sheathed, native, vessel prostheses may thus be expected, where incidences of intimahyperplasy will also be reduced.
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Sheathing for reinforcing natural veins for use as surgical implants in the form of textile netting that is configured by forming a seamless, tubular, essentially pile-less, knit fabric and has loops having large, open apertures having essentially polygonal shapes is made available.
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to an image forming apparatus such as a copying machine, a printer and a facsimile machine using an electrophotographic method. In particular, the present invention relates to an image forming apparatus of an intermediate transfer method with which a visible image formed on an image bearing member is first transferred to an intermediate transfer member, and then transferred to a transfer material to obtain image formation.
An image forming apparatus using an intermediate transfer member is an apparatus for obtaining a full color image formation (a copy or a print). This is attained by repeating a process of primarily transferring a toner image (that is, a visible image) formed on a photosensitive member (an image bearing member for toner images of a plurality of colors), and then secondarily transferring the primarily transferred toner images collectively to a recording material such as paper (a transfer material).
A known image forming apparatus of this type is the one employing an intermediate transfer belt. This image forming apparatus is provided with a plurality of image forming portions (stations) of yellow (Y), magenta (M), cyan (C) and black (K) along the intermediate transfer belt. Each image forming portion has a photosensitive drum (a drum-shaped electrophotographic photosensitive member) as an image bearing member.
An image is formed by uniformly charging a surface of a photosensitive drum by a primary charger, forming an electrostatic latent image on the photosensitive drum by exposing an image pattern using an exposure device, and developing the latent image by a developing device to visualize it as a toner image.
Toner images of four colors formed on a plurality of photosensitive drums in this way are primarily transferred onto the intermediate transfer belt while being superimposed over it in a primary transfer portion, in which the photosensitive drums and the intermediate transfer belt contact, by supplying transfer charge from primary transfer means contacting the intermediate transfer belt. Then, a secondary transfer portion is formed by contacting secondary transfer means, which was separated from the intermediate transfer belt, with the intermediate transfer belt, and transfer charge is supplied by the secondary transfer means. The toner images of four colors on the intermediate transfer belt are thereby secondarily transferred collectively onto a recording material such as paper supplied to a secondary transfer portion.
Successively, the recording material on which the toner images of four colors have been transferred is conveyed to a fixing device. A full-color image is formed on the recording material by mixing the toner images of four colors and simultaneously fixing them on the recording material while they are passing through the fixing device.
Toner remains on the intermediate transfer belt by the secondary transfer. A cleaning bias impressing roller, which was separated from the intermediate transfer belt during the image formation on the intermediate transfer belt, contacts the intermediate transfer belt, and is charged in a positive polarity opposite to a normal charging polarity of the toner. This secondary transfer residual toner is thereby transferred to the photosensitive drum in the primary transfer portion when it reaches the primary transfer portion by the movement of the intermediate transfer belt. Then, the secondary transfer residual toner is collected in the same manner as primary transfer residual toner by cleaning means of the photosensitive drum.
Incidentally, in recent years, in order to miniaturize an image forming apparatus and save energy consumed by the same, it has been attempted to devise an image forming apparatus without a cleaner for the photosensitive drum by employing a system of cleaning simultaneous with developing. However, the above mentioned conventional image forming apparatus has the following problems.
If there is no drum cleaner, it is likely that a primary charger will be stained because transfer residual toner or re-transfer toner after passing a primary transfer nip portion may become stuck to the primary charger via the photosensitive drum. In order to prevent such a stain, it is necessary to transfer the transfer residual toner or the like from the photosensitive drum onto the intermediate transfer belt in the primary transfer portion and collect it using cleaning means or the like of the intermediate transfer belt.
However, there is a case in which, when transfer charge is being supplied to the primary transfer means provided in each station, for example, an emergency stop operation for image formation may be taken only in the yellow station, the transfer charge continues to be supplied in the primary transfer portion in the magenta station, the cyan station, and even the primary transfer portion of the black station that follows the yellow station as subsequent image formation processes, as in the yellow station. This becomes a factor for reducing an operating life of the photosensitive drum. In addition, this re-transfers a toner image formed in the yellow station to a photosensitive member in the downstream side, which possibly becomes a factor for mixed colors.
FIG. 7 shows a relationship between a transfer residual rate and a re-transfer rate with respect to a transfer electric current value. Here, the transfer residual rate is a ratio of a transfer residual toner density on the photosensitive drum to a sum of a toner density on the intermediate transfer member and a transfer residual toner density on the photosensitive drum after a solid image formed on the photosensitive drum is primarily transferred onto the intermediate transfer member. In addition, the re-transfer rate is a ratio of a re-transfer toner density on the photosensitive drum of a next primary transfer portion to a sum of a toner density on the intermediate transfer member and a re-transfer toner density on the photosensitive drum of the next primary transfer portion after a solid image transferred to the intermediate transfer member in the primary transfer portion passes the next primary transfer portion. Both of these toner densities are measured by a densitometer (type number 404) manufactured by X-rite Incorporated.
In the case of an image forming apparatus that is not provided with a cleaner in a photosensitive drum, the amount of toner on the photosensitive drum after an image passes a primary transfer portion of each station must be as small as possible. However, there is an optimum primary transfer electric current value (e.g., 22 μA in FIG. 7) for minimizing a transfer residual rate, and transfer electric current must be made small in order to minimize a re-transfer rate. Thus, it is difficult to minimize both the transfer residual rate and the re-transfer rate at a single transfer electric current value.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide an image forming apparatus that, in forming an image on a transfer material via a plurality of image bearing members and an intermediate transfer member, even if an emergency stop operation for image formation is taken due to a failure of transfer material conveyance, an image formation error or the like, prevents a stain of charging means of an image bearing member or that of secondary transfer means due to a toner image existing on the image bearing member, and further is capable of realizing the extension of an operating life of the image bearing member and the prevention of mixed colors between one image forming portion and the other image forming portion.
In order to attain the above-mentioned object, an image forming apparatus comprises:
a plurality of image bearing members;
a plurality of image forming means for forming an image on the plurality of image bearing members;
a plurality of primary transfer means for transferring the images on the plurality of image bearing means onto an intermediate transfer member;
secondary transfer means for transferring the image on the intermediate transfer member onto a transfer material; and
control means for controlling the primary transfer means to operate until an image area on the image bearing member on which an image is being formed at the point when an image formation stop instruction is issued passes at least a transfer region in the primary transfer means opposing to the image bearing member.
In addition, an image forming apparatus in accordance with another aspect of the present invention comprises:
a plurality of image bearing members;
a plurality of image forming means for forming images on the plurality of image bearing members;
a plurality of primary transfer means for transferring the images on the plurality of image bearing members onto an intermediate transfer member;
secondary transfer means for transferring the images on the intermediate transfer member onto a transfer material; and
control means for controlling the plurality of primary transfer means to operate until an image area on an image bearing member on which an image is being formed at the point when an image formation stop instruction is issued at least passes a transfer region in primary transfer means opposing to the image bearing member, and controlling the secondary transfer means not to operate or controlling the secondary transfer means so that an electric field opposite to that which was generated at the time of transfer operation is generated when the image area transferred onto the intermediate transfer member by the operation of the primary transfer means passes at least a transfer region in the secondary transfer means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional view showing an embodiment of an image forming apparatus of the present invention;
FIGS. 2A, 2 B, 2 C and 2 D are sequence illustrations showing a method in the embodiment of FIG. 1;
FIG. 3 is an explanatory view showing behaviors of toner in a secondary transfer portion in the embodiment of FIG. 1;
FIGS. 4A, 4 B, 4 C and 4 D are sequence illustrations showing a method in another embodiment of the present invention;
FIG. 5 is a schematic sectional view showing yet another embodiment of the image forming apparatus of the present invention;
FIGS. 6A, 6 B, 6 C and 6 D are sequence illustrations showing a method in the embodiment of FIG. 5; and
FIG. 7 is a graph showing a relationship between a transfer residual rate and a re-transfer rate with respect to a primary transfer current in a primary transfer portion.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments in accordance with the present invention will be described further in detail with reference to the drawings. In the following description of the embodiments, reference is made to drawing figures. Like reference numerals used throughout the several figures refer to like or corresponding parts.
First Embodiment
FIG. 1 is a schematic sectional view showing an embodiment of an image forming apparatus of the present invention.
An endless intermediate transfer belt 81 that runs in a direction indicated by an arrow X is provided in a main body of the image forming apparatus. This intermediate transfer belt 81 is formed of a film of dielectric resin such as polycarbonate, polyethylene terephthalate, polyvinylidene fluoride, polyimide and ethylene tetrafluoride ethylene polymer. Although a polyimide seamless belt with a volume resistivity of 10 9 Ωcm (measured with impressed voltage of 500 V and impressing time of 60 seconds using a probe conforming to the method of JIS-K6911) and a thickness t=80 μm is employed in this embodiment, a belt of another material, volume resistivity and thickness may be employed.
Four image forming portions (stations) Pa, Pb, Pc and Pd are arranged in series above the intermediate transfer belt 81 . These image forming portions Pa, Pb, Pc and Pd are configured similarly except that they form toner images of magenta, cyan, yellow and black, respectively.
The configurations of the image forming portions will be described referring to the image forming portion Pa as an example. The image forming portion Pa is provided with a drum-shaped electrophotographic photosensitive member, that is, a photosensitive drum 1 a , rotatably arranged therein. Around the photosensitive drum 1 a , there are arranged process devices such as a primary charger (charging roller) 22 a , an exposure device 25 a and a developing device 23 a . Concerning the other image forming portions Pb, Pc and Pd, the suffixes of the reference numerals given to the photosensitive drums and the other devices are replaced with b, c and d, respectively. Magenta toner, cyan toner, yellow toner and black toner are contained in the developing devices 23 a , 23 b , 23 c and 23 d , respectively, which are arranged in the image forming portions Pa, Pb, Pc and Pd.
An image signal according to a magenta component color of an original is irradiated on the photosensitive drum 1 a of the image forming portion Pa via a polygon mirror (not shown) or the like by the exposure device 25 a , and a latent image is formed on the photosensitive drum 1 a . The magenta toner is supplied from the developing device 23 a to the latent image to develope the latent image into a magenta toner image. The magenta toner image reaches a primary transfer portion on which the photosensitive drum 1 a and the intermediate transfer belt 81 abut against each other with the rotation of the photosensitive drum 1 a . Then, the toner image is transferred to the intermediate transfer belt 81 by a primary transfer bias impressed on a primary transfer member (transfer roller) 24 a (a primary transfer).
No later than a time when the intermediate transfer belt 81 bearing the magenta toner image reaches the image forming portion Pb in this way, a cyan image is formed on the photosensitive drum 1 b with a method similar to the above. The cyan image is transferred to the magenta toner image on the intermediate transfer belt 81 in a transfer portion.
Similarly, as the intermediate transfer belt 81 moves to the image forming portion Pc and Pd, a yellow toner image and a black toner image are sequentially superimposed on the magenta toner image and the cyan toner image and transferred onto the intermediate transfer belt 81 in the respective transfer portions of the image forming portions Pc and Pd.
During this process, a recording material P is picked up from a feeding cassette 60 , conveyed to the intermediate transfer belt 81 via a registration roller 31 and a guide 28 , and supplied to a secondary transfer portion in which a secondary transfer roller 29 abuts against the intermediate transfer belt 81 . Simultaneously, a secondary transfer bias is impressed on a secondary transfer opposite roller 40 as a secondary transfer member inside the intermediate transfer belt 81 , and toner images of four colors on the intermediate transfer belt 81 are collectively transferred onto the recording material P (a secondary transfer).
The recording material P onto which the toner images of four colors are transferred is separated from the intermediate transfer belt 81 at a separating portion 33 and conveyed to a fixing device 35 . The fixing device 35 mixes the colors of the toner and fixes the toner by heat and pressure. As a result, a full-color image is formed on the recording material P.
Transfer residual toner remaining on the photosensitive drum 1 initially adheres to the charger 22 a . However, the transfer residual toner is returned onto the photosensitive drum 1 a between a sheet and another sheet, or at the time of pre-rotation or post-rotation of image formation. Then, the transfer residual toner is transferred to the intermediate transfer belt 81 and collected by a belt cleaner 37 .
Each of the above-mentioned operations of the image forming apparatus is controlled by a controller (control means 100 ).
A characteristic of the present invention is that a method has been devised for coping with the case in which image formation is stopped in an emergency, such as due to a conveyance failure of the recording material P, an image formation error or the like in the above-mentioned image forming apparatus.
Sequence illustrations showing a method of this embodiment are shown in FIGS. 2A, 2 B, 2 C and 2 D. FIGS. 2A to 2 D show a part of bias impression or the like relating to this embodiment with image forming operation of two sheets of A 4 size as an example. FIG. 2A shows normal image forming operation, and FIGS. 2B, 2 C and 2 D show operations when emergency stop is instructed during the normal image forming operation.
If an emergency stop signal for stopping image forming operation is generated due to a conveyance failure of a recording material, the chargers 22 a to 22 d , the exposure devices 25 a to 25 d and the developing devices 23 a to 23 d of all the stations Pa to Pd are immediately stopped at that point (however, any one of those which have not yet been activated maintains a stop state without being activated). In this way, an amount of toner adhering to the photosensitive drums 1 a to 1 d can be minimized.
Photosensitive drums 1 a to 1 d , the intermediate transfer belt 81 , the primary transfer rollers 24 a to 24 d , and the secondary transfer roller 29 maintain the rotating state for a while. And, in order to transfer a toner image being formed on a photosensitive drum, when an emergency stop signal for stopping the above-mentioned image forming operation is generated, to the intermediate transfer belt 81 at the primary transfer portion, transfer charge is impressed on a primary transfer roller and supplied to the photosensitive drum (FIGS. 2B, 2 C and 2 D). In addition, at the time when the emergency stop signal is generated, if transfer charge is being impressed on the secondary transfer opposite roller 40 , the impression of transfer charge is immediately stopped (FIG. 2 D).
Here, the primary transfer roller on which transfer charge is impressed is only that in a station in which a toner image exists on the photosensitive drum. It is sufficient that the supplied transfer charge is enough for transferring the toner image formed on the photosensitive drum onto the intermediate transfer belt 81 , and transfer charge need not be supplied to a region other than the toner image.
The surface of the photosensitive drum tends to be abraded when transfer charge is supplied, which may affect the durability of the photosensitive drum or generate an electric memory on the photosensitive drum. Therefore, it is desirable to minimize the required supply of transfer charge to the photosensitive drums 1 a to 1 d.
The toner image transferred onto the intermediate transfer belt 81 thereafter moves to the secondary transfer portion. In this embodiment, it is not necessary to separate the secondary transfer roller 29 from the intermediate transfer belt 81 because a system is employed in which the four photosensitive drums 1 a to 1 d are arranged in tandem and a toner image is transferred to a recording material via the intermediate transfer belt 81 . A separating mechanism is not provided also because shock unevenness is generated in an image due to separation, and a detaching and attaching mechanism is required in the separating mechanism, which may cause degradation or the like.
Therefore, it is particularly effective not to supply transfer charge to the secondary transfer portion of such an image forming apparatus as described above in preventing a toner image generated at the time of emergency stop from adhering to the secondary transfer roller 29 .
Although supply of charge is stopped in the secondary transfer portion in this embodiment, bias having the same polarity as toner's polarity may be impressed on the secondary transfer roller 29 , or bias having the reversed polarity of toner's polarity may be impressed on the secondary transfer opposite roller 40 in order to realize the same effect.
In this embodiment, a toner image transferred onto the intermediate transfer belt 81 hardly adheres to the secondary transfer roller 29 as shown in FIG. 3, and most part of the toner passes through the secondary transfer portion to reach a belt cleaner 37 of the intermediate transfer belt 81 , where the toner is removed. The intermediate transfer belt 81 stops its rotation when the trailing end of the toner image has passed the part of the belt cleaner 37 . In FIG. 3, reference numeral 29 a denotes a spring that presses a core metal of the secondary transfer roller 29 and causes the secondary transfer roller 29 to abut against the intermediate transfer belt 81 .
Further, causes other than the above-mentioned conveyance failure of a recording material may be a condition for taking the emergency stop operation. Outlines of such causes will be described below.
Short-circuit of a circuit board or wiring
Disconnection of an intra-machine heater such as a fixing heater, a drum heater and a cassette heater
Detection of an abnormality by a toner density sensor of a station (in this embodiment, when a ratio of toner and carrier is detected in each of the developing devices 23 a to 23 d and this ratio exceeds a certain range)
Detection of an error by an electrostatic voltmeter of a certain station (when an electrical potential on the photosensitive drum 1 is monitored and the electrical potential significantly deviates from a predetermined electrical potential)
Detection of an error in a driving system (load or the like)
Since this embodiment is configured as described above, a toner image on the photosensitive drum can be efficiently transferred to the intermediate transfer belt, and can be conveyed and processed without being re-transferred to the photosensitive drum when image forming operation is stopped for emergency due to a conveyance failure of a recording material, an image formation error or the like. In addition, a toner stain of the secondary transfer roller can be prevented and toner can be efficiently collected by the cleaner of the intermediate transfer belt. Moreover, an amount of transfer charge supplied to the photosensitive drum can be minimized. As a result, an operating life of the photosensitive drum can be extended and running costs can be reduced.
Second Embodiment
This embodiment is applied to the image forming apparatus of FIG. 1 . FIGS. 4A, 4 B, 4 C and 4 D show sequences of a part of bias impression or the like relating to this embodiment.
The sequences of FIGS. 4A to 4 D are different from the sequences of FIGS. 2A to 2 D of the first embodiment in that rotation of the intermediate transfer stops in the minimum possible time after the emergency stop signal is turned ON.
This embodiment is characterized in that the chargers 22 a to 22 d , the exposure devices 25 a to 25 d and the developing devices 23 a to 23 d of all the stations Pa to Pd are stopped immediately after receiving an emergency stop signal for stopping image forming operation due to a conveyance failure of a recording material, an image formation error or the like, in which case all the operations are stopped upon a trailing end of a toner image formed on the photosensitive drum passing the primary transfer portion.
However, charge is supplied at the primary transfer portion until the trailing end of the toner image passes the primary transfer portion. This is for making it possible to stop the rotational operation as soon as possible to advance to a jam clearance operation or an image formation error releasing operation. When the jam clearance or the image formation error is released, the image forming operation is changed from the emergency stop to a returning operation. At this point, since charge is not supplied at the secondary transfer portion, a toner stain of the secondary transfer roller 29 is restrained to a minimum.
It is needless to say that, in this embodiment, bias having the same polarity as toner's polarity may be impressed on the secondary transfer roller 29 , or bias having the reversed polarity of toner's polarity may be impressed on the secondary transfer opposite roller 40 at this point as in the first embodiment.
According to this embodiment, as in the first embodiment, a toner image on the photosensitive drum can be efficiently transferred to the intermediate transfer belt, and can be conveyed and processed without being re-transferred to the photosensitive drum when image forming operation is stopped for emergency due to a conveyance failure of a recording material, an image formation error or the like. Therefore, a toner stain of the secondary transfer roller can be prevented and toner can be efficiently collected by the cleaner of the intermediate transfer belt. Moreover, an amount of transfer charge supplied to the photosensitive drum can be minimized. As a result, an operating life of the photosensitive drum can be extended and running costs can be reduced.
Third Embodiment
FIG. 5 is a schematic sectional view showing another embodiment of an image forming apparatus of the present invention.
In this embodiment, a cover 52 is installed along the outer surface of the intermediate transfer belt 81 at a predetermined position of the intermediate transfer belt 81 , more specifically, at a position, which is marked with diagonal lines in FIG. 5, between the downstream of the first transfer portion and the upstream of the secondary transfer portion of the image forming portion Pd of the final color in the image forming apparatus shown in FIG. 1 of the first embodiment.
The other mechanical configuration of the image forming apparatus of this embodiment is basically the same as the image forming apparatus of FIG. 1 . In FIG. 5, those components which are identical to the components of the embodiment illustrated in FIG. 1 have been given the same numerical designation as is used in FIG. 1 .
FIGS. 6A, 6 B, 6 C and 6 D show sequences of a part of bias impression or the like relating to this embodiment. In the sequences of FIGS. 6A to 6 D, rotation of the intermediate transfer belt stops in the minimum possible time after the emergency stop signal is turned ON as in the sequences of FIGS. 4A to 4 D of the second embodiment. However, the sequences of the third embodiment take longer than those of the second embodiment until the rotation of the intermediate transfer belt stops. This is because a toner image is conveyed to the above-mentioned predetermined position.
In this embodiment, the chargers 22 a to 22 d , the exposure devices 25 a to 25 d and the developing devices 23 a to 23 d of all the stations Pa to Pd are stopped immediately after receiving an emergency stop signal for stopping image forming operation due to a conveyance failure of a recording material, an image formation error or the like. At this moment, all the operations are stopped upon a trailing end of a toner image formed on the photosensitive drum passing the primary transfer portion and the toner image entering the predetermined position (the hatched part of FIG. 5 ).
However, at the primary transfer portion, charge is supplied only to a station in which a toner image is formed on a photosensitive drum at the time of emergency stop. This is for making it possible to stop the rotational operation as soon as possible to advance to a jam clearance operation and an image formation error releasing operation, and for preventing the toner image from contacting the outside environment when the intermediate transfer belt unit or the like is removed from the image forming apparatus. The cover 52 prevents the toner image from being exposed to the outside environment by temporarily stopping the toner image on the intermediate transfer belt 81 , which was generated at the time of the emergency stop, in the hatched part of FIG. 5 .
When the jam clearance or the image formation error is released, the image forming operation is changed from the emergency stop to a returning operation, and the rotation of the intermediate transfer belt 81 is started. At this point, when the temporarily stopped image moves to the secondary transfer portion, charge is not supplied at the secondary transfer portion. As a result, a toner stain of the secondary transfer roller 29 is restrained to a minimum.
It is needless to say that, in this embodiment, bias having the same polarity as toner's polarity may be impressed on the secondary transfer roller 29 , or bias having the reversed polarity of toner's polarity may be impressed on the secondary transfer opposite roller 40 at this point as in the first and the second embodiments.
A timing for stopping the toner image generated at the time of the emergency stop is fixed in the above-mentioned first through third embodiments. However, the present invention is not limited to this, and the timing for stopping the toner image may be changed according to a condition. For example, the condition is such as the case in which the image forming apparatus has at least two or more modes such as a printer mode, a copy code and the like.
In the printer mode, assuming that a user is not near the image forming apparatus, if the image forming apparatus performs the emergency stop operation, the toner image generated at the time of the emergency stop is stopped after the trailing end of the toner image passes the intermediate transfer belt cleaner as in the first embodiment. In this way, if the surface of the intermediate transfer belt is cleaned to wait for a user to perform the jam clearance and the image formation error release operation, problems such as a stain, sticking or the like by leaving the toner image on the intermediate transfer belt for a long time can be prevented. In addition, in the copy mode, assuming that the image forming apparatus is in the state in which a user can immediately perform the jam clearance or the image formation error release operation, the rotational operation is stopped as soon as possible as in the second and the third embodiments.
In addition, the timing for stopping the toner image may be changed according to a location where a recording material is jammed. For example, in the case of a separation failure at the secondary transfer portion, or in the case that a recording material jam in the fixing device or the like occurs, it is desirable to stop the toner image as soon as possible (the second and the third embodiments). On the other hand, if a paper feeding failure such as a pickup failure of a recording material from a cassette occurs, it is also effective to clean the surface of the intermediate transfer belt (the first embodiment) to wait for a user's processing.
In addition, the timing for stopping the toner image may be changed according to a formed image size or the like. The toner image can be stopped at an optimal position according to a condition. This can be attained by stopping the toner image after cleaning all the toner on the intermediate transfer belt (the first embodiment) if the formed image size is so large that the image cannot be included in the hatched part of FIG. 5, or temporarily stopping the toner image in the hatched part (the third embodiment) if the image can be included in the hatched part.
As described above, a toner image generated at the time of emergency stop can be stopped in an optimal state under each condition by changing the timing for stopping the toner image according to a condition.
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An image forming apparatus includes a plurality of image bearing members, a plurality of image forming portions for forming images on the plurality of images of image bearing members, a plurality of primary transfer portions for transferring the images on the plurality of image bearing members onto an intermediate transfer member, secondary transfer portions for transferring the image on the intermediate transfer member onto a transfer material, and a controller. The controller controls the primary transfer portion to operate until an image area on the image bearing member on which an image is being formed at the point when an image formation stop instruction is issued passes a transfer region in the primary transfer portion opposing the image bearing member.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is a firing device or explosive actuator. In particular, it is an explosive actuator for tail fin launched weapons which rely on gas pressure to eject them safely from aircraft delivering the ordnance.
2. Description of the Prior Art
The concept of using a firing mechanism with locking ball spring and actuating pin is well known and has been used for several decades. Ideally, the use of a spring-loaded actuating pin simply requires that the actuating pin be pulled back until the force of the spring is sufficient that, when released, the actuating pin is propelled forward with sufficient thrust to serve as a detonating pin. Previous patents have used metal balls or other objects connected to a lanyard to avoid jamming of the lanyard while it was being pulled from a non-linear or in-line direction. The goal was to reduce friction rubbing of cable or lanyard to provide a smooth, predictable actuating force to trigger a release mechanism. Traditionally, lanyards were actually pulled by the pilot himself or by the bombardier while flying the plane.
The advent of modern ordnance has led to different criteria for determining the safest and most reliable way of releasing ordnance from aircraft. For non-self-propelled ordnance, it is sometimes desirable to use a tail fin actuator. The tail fins of the ordnance are retracted to facilitate loading problems on the delivery aircraft. After the ordnance is clear of the delivering aircraft, the tail fins are extended and locked in place. Traditional cock and pull fire devices are actuated by a routed cable and spool mechanism which allows a pressure cartridge to have a straight shot at the pusher piston. This type of device has repeated problems with the 90° routing of the lanyard cable and actuation of the cocking spool. Despite the problems of these current devices, they have traditionally been considered superior to the prior generation in-line devices because it was considered the least of the problems. An in-line actuating pin could not be in-line for a straight shot at the pusher piston.
SUMMARY OF THE INVENTION
The present apparatus uses a spring-loaded actuating pin which is kept at a discrete distance from a pressure cartridge by a safety pin and locking balls. The pressure cartridge, in turn, is in a U-shaped tube which terminates in back of a pusher piston for a tail fin device. Upon release of the safety pin, the actuator pin is withdrawn by a lanyard arranged to provide an in-line pull to the actuator pin. This compresses the spring, and when the spring has been compressed a sufficient distance, the locking balls release. Upon release of the locking balls, the actuator pin is propelled forward by the stored energy in the spring and triggers the pressure cartridge. Release of gas in the pressure cartridge builds up in the U-shaped tube, causing sufficient force on the tail fin's pusher piston to open and lock the weapon tail fins.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of the present invention;
FIG. 2 is an end-on view of a section of the present invention;
FIG. 3 is an exploded view of the present invention; and
FIG. 4 is a partial cross-section of the present invention assembled.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, an explosive actuator similar to an explosive actuator such as used in the present invention is shown in cross-sectional detail. A housing 10 is the outer covering of the ordnance to be deployed. An in-line tail fin firing device explosive actuator 12 is mounted in the tail end of housing 10. Actuator 12 has a transfer tube 14 to provide a U-shaped passage 16 which has a pressure cartridge 18 located at one end of U-shaped pressure tube 16. Mounted in the end externally to pressure cartridge 18 is an actuator pin housing 20 which is held in place by a fastener 22, such as a set screw. Within actuator pin housing 20 is an actuator pin 24, also considered a firing pin. Actuator pin 24 is spring-loaded by a compression spring 26 which, in the position shown, is fully relaxed. Actuator pin 24 has a nub 28 which is aligned to rupture pressure cartridge 18 when propelled into it with sufficient preset force. Packing 30 is provided in the form of an O-ring or similar mechanism to assure a snug pressure-tight seal between actuator pin housing 20 and transfer tube 14.
Actuator pin 24 is held in place to prevent it reaching pressure cartridge 18 by locking balls 32. The U-shape expels the tail fin device in the same general direction as the direction of actuator pin 24 needed to release locking balls 32. Locking balls 32 are set in the recessed end of actuator pin 24 as shown and held in place by a ball retainer 34. A cap 36 is mounted around ball retainer 34 and to actuator pin housing 20. In FIG. 1, cap 36 is shown screwed onto actuator pin housing 20 and cushioned by a gasket 37 which holds a snug fit between the two. A lanyard 38 is connected to ball retainer 34 via a sleeve 40. Lanyard 38 can be any suitable high strength cord such as wire rope. Locking sleeve 40 in a fixed position within cap 36 is a safety pin 42 which is fitted within a hole through cap 36 and, for mounting convenience, can also be inserted through a clamp 44 which is mounted externally to cap 36. Sleeve 40 holds lanyard 38 to a pin spring 46 which is part of ball retainer 34. When ball retainer 34 is extracted by lanyard 38, balls 32 are fixed in place until they reach space 48 which permits them to fall free of actuator pin 24.
When locking balls 32 fall free, actuator pin 24 is thrust forward by compression spring 26 and nub 28 ruptures pressure cartridge 18. To prevent movement of ball retainer 34, even after safety pin 42 has been removed, a shear pin 50 can be used to further lock ball retainer 34 in position. An O-ring 52 is used as lubricated packing to prevent binding of ball retainer 34 due to friction. Clamp 44 is held in position by screw 54. Washer 56 can be placed between actuator pin housing 20 and pressure cartridge 18 to assure a snug fit. O-ring 58 is placed around the far end of transfer tube 14 to facilitate ease of movement of a piston pusher assembly 60. Clamp 44 can be held against housing 10 by means of screws 62.
FIG. 2 shows an end-on view of screw clamp 44 with partial cutaways and partial openings of screw locations and firing pin locations. As shown, safety pin 42 is offset within clamp 44 to avoid being directly in the center of the line of motion.
FIG. 3 is an exploded view of the present invention. In addition to numbers referring to portions of previously identified components, fin assemblies 64 are mounted through bearings 66 which permit rotation of fin assembly 64 to housing 10 via pivot bolts 68. Pivot bolts 68 are self-locking screws. Within housing 10 a groove guide 70 is shown which permits fin assemblies 64 to fit within housing 10 while the store is being carried. Within FIG. 3, actuator pin housing 20 is shown screwed to outer housing 10 via screws 72. Fin assemblies 64 are mounted to tail assembly pivot bolts 68 and secured by shear rivets 76 to the piston pusher assembly 60.
Piston pusher assembly 60 has brackets 74 with grips 78. Grips 78 may be made of rubber. The leading edges of fin assemblies 64 are held by grips 78 prior to firing. Shear rivets 76 may also be used as a means to hold fin assemblies 64. When pusher piston 60 is thrust forward, grips 78 rotate fin assemblies 64 to the extended or open position where they lock into position. Shear rivets 76, if present, are sheared by the motion of pusher piston 60. A restraining cable 80 limits the length of stroke of piston pusher assembly 60.
Upon deployment from an aircraft, lanyard 38 has a preselected amount of slack which is extended. When lanyard 38 is pulled, housing 10 has dropped to a safe distance from the aircraft for the tail fins to deploy.
FIG. 4 is a partial cross-section of the present invention. Housing 10 has fin assemblies 64 inside and held to piston pusher assembly 60 via grips 78 and shear rivets 76. Grips 78 and shear rivets 76 are held in place by brackets 74 on piston pusher assembly 60. As piston pusher assembly 60 is driven forward, grips 78 rotate fin assemblies 64 about bearings 66 held by pivot bolts 68. Shear rivets 76 shear and the extensions 61 of piston pusher assembly 60 complete rotation of fin assemblies 64 through groove guides 70 into the extended position. Fin assemblies 64 may have a catch, not shown, to lock them in the extended position. Depending on fin design, air pressure may be adequate to hold them open.
It is obvious to those skilled in the art that numerous modifications to the above can be made.
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A straight pull cock and fire device is used which permits launching of t fin fire devices. The pressure cartridge produces gas which is routed to a pusher piston through a combined ported manifold and firing device pusher assembly mounting unit. In-line pulls avoid rotational jamming. The spring-loaded actuator pin assures that a minimal level of force is required to initiate the device to avoid random jamming from triggering the device.
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BACKGROUND OF INVENTION
This invention relates to a multiple needle tufting machine, and more particularly to a needle bar assembly for a multiple needle tufting machine.
The conventional needle bars for multiple needle tufting machines are long, continuous, solid bars extending transversely of the machine above the base fabric for the entire width of the fabric to be tufted. A conventional needle bar includes a plurality of needle holes extending vertically through the needle bar and desirably parallel to each other, uniformly spaced at the desired needle gauge. Each needle is inserted through the needle hole in the bottom of the needle bar so that each needle extends substantially the full height, if not the full height, of the needle bar. The needles are secured in position in their respective needle holes by transverse set screws.
The conventional needle bar has always been one of the most difficult parts of a tufting machine to manufacture, since the numerous needle holes must be drilled very accurately in the long needle bar. It is extremely difficult to control the path of the drill bit through a needle bar which is usually 7/8" in depth or height. In the drilling operation, the drill bit often "leads off" in one direction or another at an angle to the vertical. Accordingly, such angular drill holes through the needle bar will not be parallel to each other. Therefore, the elongated needles extending through the angular needle holes would be "off gauge" where the needle holes are not drilled in truly vertical paths. The longer the needle, therefore, the greater the gauge error.
The "leadoff" of the drilling paths for each needle hole may be caused by various factors. A drill bit which is not accurately ground, or a drill bit being forced too rapidly into the metal of the needle bar, or a drill bit striking the more dense or harder portion of the metal in the needle bar, can cause the drill bit to deflect from its truly vertical course. Once the "leadoff" begins, the continuing path of the drill bit will diverge further away from the desired vertical course.
Once the drilling of the conventional needle bar has commenced, it is not possible to determine the path of the drill bit unitl it emerges from the opposite side of the needle bar. In a multiple needle tufting machine having several hundred needles, the gauge errors between the needles caused by the inaccurate drilling of the needle holes can create considerable problems.
Not only does the drilling of the needle holes involve maintaining accurate control of the drilling paths of the drill bits, but occasionally a drill bit will break off in the drilled needle hole, and the broken drill bit cannot be removed without damaging the needle bar.
All of the above problems in the drilling of the needle holes can result in a needle bar which cannot be used and which must be discarded or scrapped.
Normally, it takes approximately 40 man-hours to drill all of the required needle holes in a conventional needle bar of a multiple needle tufting machine.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide in a needle tufting machine an improved needle bar assembly incorporating multiple, modular, needle bar parts that will provide a more accurate needle gauge.
The needle bar assembly made in accordance with this invention, includes a long, continuous, mounting bar which is attached directly to the conventional push rods of the needle drive mechanism of the tufting machine, the mounting bar extending the full width of the fabric to be tufted, or in other words, the same length as the conventional needle bar. The plurality of short needle bar segments in the order of 6-12" in length are designed to be secured by appropriate fastener mechanisms such as bolts, in an end-to-end relationship along, beneath, and to the mounting bar. In each of the needle bar segments, is drilled a plurality of holes at the desired needle gauge. These holes may be in a single straight line, or they may be alternately staggered in a well known manner. The length of the needle bar segments are so limited that the needle gauge will be maintained throughout the length of the needle bar assembly when the needle bar segments are fastened end-to-end beneath the mounting bar.
Because of the combined structure of the mounting bar and the needle bar segments, the height or depth of the needle bar segments, in the order of 1/2", is less than the height or depth of a conventional needle bar. Preferably, the needle bar segments are spaced below the bottom surface of the main portion of the mounting bar so that the needles received within their corresponding needle holes will project above the needle bar segments and engage the bottom or abutment surface of the mounting bar. Because of the lesser depth of the needle bar segments than conventional needle bars, any drilling "leadoffs" or divergences from the true vertical course of the drill bit will be minor. Moreover, because of the relatively short lengths of the needle bar segments, the needle holes may be drilled on an ordinary milling machine on which more accurate spacing can be achieved by moving the short needle bar segment within the travel limits of the milling machine table.
Because of the modular construction of the needle bar assembly made in accordance with this invention, small spacing may be provided between the ends of the needle bar segments in order to permit small lateral adjustments to compensate for any gauge errors and permit the needles to accurately align with the tufting hooks below the fabric.
Moreover, if there are any substantial drilling errors in the needle bar segemnts, then only that needle bar segment which includes the unacceptable drilling error can be discarded without sacrificing the remaining needle bar segments.
Furthermore, because of the modular arrangement of the needle bar segments, an entire set of needle bar segments may be replaced by another set of needle bar segments having a different needle gauge, without removing the continuous mounting bar from the push rods.
The mounting bar and the needle bar segments made in accordance with this invention may include overlapping tongue-and-groove structures secured together by detachable bolt-type fasteners in order to assemble and disassemble the various needle bar segments upon the mounting bar. In one form of the invention, the mounting bar may have an inverted U-shaped cross-section to define a pair of depending legs receivable within corresponding longitudinal recesses formed in the upper surfaces of the corresponding needle bar segments. In another form of the invention, the needle bar segments may have U-shaped transverse cross-sections with the legs projecting upward and receivable in longitudinally extending grooves or recesses formed in the bottom surface of the monolithic or solid elongated continuous mounting bar.
The needle bar assembly made in accordance with this invention can also be adapted for use in dual shiftable needle bars, such as those illustrated in U.S. Pat. No. 4,366,761. In such an arrangement, the dual needle mounting bars may be provided with recesses into which extend the upward projecting portions of corresponding sets of substantially shorter needle bar segments, and secured in place by detachable bolt-type fasteners.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a fragmentary sectional elevation taken longitudinally along the line 1--1 of FIG. 3, through a portion of a narrow gauge, staggered-needle tufting machine, incorporating a cutpile looper apparatus, and incorporating the needle bar assembly made in accordance with this invention;
FIG. 2 is a fragmentary front elevation of the needle bar assembly, taken along the line 2--2 of FIG. 1;
FIG. 3 is a fragmentary bottom plan view taken along the line 3--3, of FIG. 1, with portions broken away;
FIG. 4 is a sectional elevation taken along the line 4--4, of FIG. 5, of a modified needle bar assembly;
FIG. 5 is a fragmentary section taken along the line 5--5 of FIG. 4, with portions broken away;
FIG. 6 is a sectional elevation of a modified needle bar assembly for a dual shiftable needle bar type tufting machine, taken along the line 6--6 of FIG. 8;
FIG. 7 is a fragmentary front elevation taken along the line 7--7 of FIG. 6;
FIG. 8 is a fragmentary section taken along the line 8--8 of FIG. 6; and
FIG. 9 is a front perspective view of one of the front needle bar segments.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now, to the drawings in more detail, FIG. 1 discloses a cross-section of a needle bar assembly 10 made in accordance with this invention assembled in a conventional multiple-needle tufting machine. The needle bar assembly 10 supports a first row of uniformly spaced front needles 11 and a second row of uniformly spaced rear needles 12 offset preferably mid-way between the front needles 11, to provide a uniform, narrow gauge, staggered needle tufting machine. The needle bar assembly 10 is vertically reciprocated by conventional needle drive means, including a push rod 13 connected to the needle bar assembly 10 by an attachment collar 14. The push rod 13 vertically reciprocates the needle bar assembly 10 to cause the front and rear needles 11 and 12 to move between an upper position above the base fabric 15 to a lower position (FIG. 1) penetrating the base fabric 15, so that the needles will carry yarns, not shown, through the base fabric 15 to form loops of tufting therein. The base fabric 15 is supported upon a needle plate 16 for movement, by means not shown, in the direction of the arrow 17 of FIG. 1, that is longitudinally from front-to-rear of the machine.
The looper apparatus 18 which cooperates with needles 11 and 12 may include a transverse hook bar 20 of unique, or conventional, construction fixed upon a bracket 22 carried by a rocker arm 23 journalled on a rock shaft, not shown. The rocker arms 23 are driven by conventional means, not shown, for limited reciprocal movement in synchronism with the reciprocal movement of the needles 11 and 12. The hook bar 20 supports a plurality of looper hooks 25 and 26 having bills 27 and 28 of different lengths to cooperate with the respective needles 11 and 12 to seize the corresponding loops of yarn formed by the respective needles 11 and 12 below the base fabric 15.
Where cut pile is formed by the needles 11 and 12 and the corresponding looper hooks 25 and 26, a knife 30 is reciprocably supported to cooperate with each hook for cutting the seized loops, in a well known manner.
In the first embodiment of the invention disclosed in FIGS. 1-3, the needle bar assembly 10 includes a continuous elongated needle mounting bar 32 disclosed as having an inverted U-shaped cross-section. The mounting bar includes an upper main body portion 33 having a bottom needle abutment surface 34 and a pair of depending legs 35 and 36 spaced apart in a front-to-rear direction greater than the front-to-rear spacing of the front needles 11 and the rear needles 12. The top surface 37 of the main body portion 33 is connected to the attachment collar 14 of the push rod 13. The mounting bar 32 extends the entire width of the stitching area, or in other words, has at least as great a span as the width of the base fabric 15 moving through the tufting machine. The mounting bar 32 is substantially the same length as a conventional needle bar.
Detachably mounted upon the mounting bar 32 are a plurality of elongated needle bar segments 40 each of substantially shorter length than the overall length of the mounting bar 32. Each needle bar segment 40 may be approximately 6-12" long. The top surface 41 of each needle bar segment 40 is preferably spaced below the abutment surface 34 of the mounting bar 32, and is provided with a pair of grooves or recesses 43 and 44 parallel to each other and extending longitudinally of each corresponding needle bar segment 40. The recesses 43 and 44 have the same front-to-rear spacing and substantially the same front-to-rear dimensions, as the legs 35 and 36 in order to snugly receive the depending legs 35 and 36 within the corresponding recesses 43 and 44. Formed through the height or depth of each needle bar segment 40 are a plurality of elongated needle holes 45 opening through the top surface 41 and the bottom surface 46, parallel to each other, and arranged at the desired needle gauge and spacing, such as the staggered needle arrangement disclosed in FIGS. 1-3. Each needle hole 45 may be drilled in the same manner as conventional needle bars. However, because of the relatively shallow depth or height of the bar segments 40, substantially less drilling is required, and more accurate drilling is obtained.
Each of the needle holes 45 is of a configuration adapted to snugly receive the shank portion 47 of each of the needles 11 and 12. The shank portions 47 may project above the top surface 41 of each needle bar segment 40, as disclosed in FIG. 1, and engage the needle abutment surface 34 of a mounting bar 32. In this manner, the vertical positions of the needles 11 and 12 may be accurately located, and the shank portions 47 may be gripped by the needle holes 45 below the upper ends of the shank portions 47 over a shorter length, to stabilize the needles 11 and 12 as well as needles are stabilized in a conventional needle bar.
Each of the needles 11 and 12 are secured in their respective needle holes 45 by the front and rear set screws 49 and 50 in substantially the same manner as the needles would be secured in a conventional needle bar.
The legs 35 and 36 are secured in their overlapping, dove-tailed, or tongue-and-groove engagement with their corresponding recesses 43 and 44 by means of the transverse threaded fasteners, such as the bolt members 52.
As disclosed in FIG. 2, each bolt 52 may extend through an oversized, oval, or elongated bolt hole 53 in the side of the corresponding needle bar segment 40 before threadely engaging a corresponding threaded hole within the corresponding leg 35 of the mounting bar 32. The oversized hole 53 permits longitudinal or end-to-end adjustment between adjacent needle bar segments 40. The adjacent, opposing ends of the needle bar segments 40 disclosed in FIG. 2 are shown slightly separated, such as by a spacing in the order of 0.008-0.010 inches. Thus, lateral adjustment is permitted between adjacent needle bar segments 40 to correct for any slight errors in the needle gauge, or to permit localized alignment of the needles 11 and 12 with their corresponding hooks 25 and 26.
It will be apparent from the above description that a needle bar assembly 10 has been developed which substantially reduces the cost and time of manufacture, and also provides more accurate needle gauges, and optionally, a needle bar assembly in which the needle gauge may be subject to slight adjustments.
Moreover, the needle bar assembly 10 made in accordance with this invention, permits the use of a single, long mounting bar 32 which may be permanently connected to the push rods 13, and which supports a plurality of replacable and interchangeable needle bar segments, which can be utilized for readily replacing worn parts without discarding an entire single long needle bar. Furthermore, needle gauges of varying sizes may be utilized with the same mounting bar 32 by mere replacement of the entire set of needle bar segments 40 with another set of needle bar segments of different needle gauge.
In the second embodiment of the needle bar assembly 60 disclosed in FIGS. 4 and 5, the cross-sections of the mounting bar 32 and the needle bar segments 40 have been reversed. The structure of the elongated needle mounting bar 62 is of substantially rectangular cross-section and the needle bar segments 70 are each of U-shaped cross-section.
The mounting bars 62 of the needle bar assembly 60 includes a bottom needle abutment surface 64 in which are formed parallel or elongated grooves or recesses 65 and 66. The recesses 65 and 66 are of a spacing and shape to snugly receive the upward projecting legs 75 and 76 from the main body portion 74 of the needle bar segments 70. The top surface 71 of the main body portion 74 of the needle bar segment 70 is spaced below the needle abutment surface 64 to provide additional room for the upward projection of the shank portions 47 of the needles 11 and 12, which abut the bottom surface 64 of the mounting bar 62.
Needle holes 77 are formed in the main body portion 74 to extend entirely through the main body portion 74. The needle holes 77 open through the bottom surface 72 and the top surface 71 and are arranged in the same configuration and gauge as the needles 11 and 12.
The legs 75 and 76 are secured in the recesses 65 and 66 by the bolt members 79 in the same manner as the corresponding legs 35 and 36 are secured in the recesses 43 and 44 of the needle bar assembly 10 by bolt members 52.
The needles 11 and 12 are secured within the needle holes 77 by the set screws 49 and 50.
Otherwise, the structure and function of the needle bar assembly 60 is essentially the same as that of the needle bar assembly 10.
Because, as best disclosed in FIG. 4, each needle bar segment 70 of the needle bar assembly 60 has a lesser front-to-rear dimension than the corresponding dimension of the mounting bar 62, threads of yarn may be fed to the needles 11 and 12 from the yarn feed rolls, not shown, so that they will extend more nearly parallel to the needles 11 and 12 when they are threaded through the needle eyes.
FIGS. 6-9 disclose a modified form of a needle bar assembly 80 especially adapted to be used with dual shiftable needle bars, such as those disclosed in U.S. Pat. No. 4,366,761 of Roy T. Card, issued Jan. 4, 1983.
The needle bar assembly 80 supports a first row of uniformly spaced front needles 11 and a second row of uniformly spaced rear needles 12 offset preferably mid-way between the front needles 11, to provide a uniform, narrow gauge, staggered needle tufting machine. The needle bar assembly 80 is vertically reciprocated by conventional needle drive means, including the push rods 13 connected to the needle bar assembly 80 by attachment collars 14'. The push rods 13 vertically reciprocate the needle bar assembly 80 to cause the front and rear needles 11 and 12 to move in the same manner as the needles 11 and 12 are moved by the needle bar assembly 10 or 60 in FIGS. 1-5, to penetrate the base fabric 15 to form loops of tufting therein.
The looper apparatus 18 which cooperates with the needles 11 and 12 may be of the same construction as the looper apparatus 18, disclosed in FIG. 1, cooperating with the same knives 30.
The needle bar assembly 80 includes a continuous elongated needle bar holder or slide holder 81 fixedly connected to the push rod collars 14'. The needle bar slide holder 81 includes a pair of parallel slideways 82 and 83 for reciprocably and slideably receiving slides 84 and 85 of substantially T-shaped cross-section. Each slide 84 is fixed to a continuous elongated front needle bar or front needle mounting bar 86, while each slide 85 is fixed to a continuous elongated rear needle bar or needle mounting bar 87.
The needle bar holder 81 and the front and rear needle bars 86 and 87 extend the entire width of the stitching area, and are driven, and operate, in the same manner as the dual shiftable needle bar assembly disclosed in U.S. Pat. No. 4,366,761.
Formed in the inner opposed faces of the needle mounting bars 86 and 87 are a pair of elongated recesses 88 and 89. Each of these recesses 88 and 89 is adapted to receive in assembled end-to-end position, a corresponding set of needle bar inserts or segments 90 and 91. Each of the segments 90 and 91 is substantially shorter than the overall length of either of the needle bars 86 or 87.
Moreover, each of the needle bar segments 90 and 91 preferably has an L-shaped cross-section, as best disclosed in FIGS. 6 and 9, including an upper vertical leg portion 92 and a lower foot flange 93. The upper leg portion 92 of each segment 90 and 91 is adapted to be received substantially flush and in snug engagement within each corresponding recess 88 and 89. Each foot flange 93 is provided to limit the upward movement of each needle bar segment 90 and 91 within its corresponding recess 88 and 89 and to seat against the bottom surface of each of the corresponding needle bars 86 and 87.
A plurality of needle holes 95 are formed vertically through the bottom portion of each of the needle bar segments 90 and 91 and are arranged in transverse longitudinal alignment, yet offset from the needle holes in the opposite needle bar segment so that the needles 11 and 12 are arranged in a conventional staggered pattern for each stitch penetration of the base fabric 15.
Each of the needles 11 and 12 is retained in fixed position within a corresponding needle hole 95 by conventional set screws 96 and 97, respectively.
Each of the needle bar segments 90 and 91 is retained in its respective recess 88 and 89 by the threaded bolts 98, in a manner similar to the retention of the needle bar segments 40 and 70 in the respective needle bar assemblies 10 and 60.
Otherwise, the needle bar segments 90 and 91 in the needle bar assembly 80 have substantially the same function and advantages as the needle bar segments 40 and 70 in the corresponding needle bar assemblies 10 and 60.
The bolts 98 may also be provided with elongated, or over-sized, bolt holes, such as the elongated bolt holes 53 disclosed in FIG. 2, for transverse adjustments of the short needle bar segments 90 and 91.
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A needle bar assembly for a multiple needle tufting machine including an elongated continuous mounting bar connected to the push rod of the needle drive mechanism for reciprocal movement, and a plurality of elongated, but substantially shorter, needle bar segments having needle holes for receiving the needles and secured end-to-end along and to the mounting bar, whereby individual needle bar segments may be independently attached and detached to the mounting bar, and longitudinally adjusted if desired. The needle bar assembly also contemplates a pair of needle mounting bars slideably received in a needle bar holder connected to the needle drive mechanism and two sets of substantially shorter needle bar segments secured end-to-end along each of the corresponding needle mounting bars.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. patent application Ser. No. 13/075,819, filed on Mar. 30, 2011, and allowed on Sep. 17, 2012, the entirety of which is expressly incorporated herein.
FIELD OF THE INVENTION
The present invention relates generally to pumps, and more specifically to pumps utilizing vibration to move the fluid through the pump.
BACKGROUND OF THE INVENTION
A variety of fields of industry and science it is necessary to move a fluid from one location to another. A wide range of pumping devices are available for accomplishing this task. In particular, one type of pump that is especially useful for this task are those pumps disclosed in U.S. Pat. Nos. 6,315,533; 6,364,622; 6,428,289; 6,604,920; 7,354,255B1; and 7,731,105B2, as well as in Published US Patent Application No. US2009/0116979, each of which is expressly incorporated by reference herein.
However, certain design features of these vibratory piston pumps do not allow effective pumping of liquids of higher viscosities, such as, for example, liquid soap, lubricating oils and similar high viscosity liquids. When liquids or fluids of this type are pumped utilizing the piston vibratory pump disclosed in the incorporated references, while the fluid can be pumped, the overall productivity or volume of the fluid pumped/minute decreases and consequent increase in energy consumption the pump drive mechanism occurs.
Therefore, it is desirable to develop a pump capable of utilizing the effective vibratory drive system as described in the cited references with a pump construction that enables fluids having high viscosities to be pumped by the device as effectively as lower viscosity fluids or liquids.
SUMMARY OF THE INVENTION
According to one aspect of the present disclosure, a pump including a vibrating mechanism is provided that is capable of effectively pumping a variety of fluids, including fluids having a high viscosity. In vibratory pump of the present disclosure, this result is achieved by change in the design of the internal working bodies of the pump which effectively causes the various liquids to temporarily decrease the viscosity of the fluid to enable the fluid to be pumped through the device. The vibratory mechanism in the pump includes a piston, an activator, and an apertured disk disposed within a working cylinder, which optionally is included within an external cylinder, a target valve and a drive mechanism connected to a rod extending into the working cylinder on which the piston, activator and disk are mounted. The piston and disk are secured to the rod, while the activator is slidable with regard to the rod, and is held on the rod based on its positioning between the piston and the disk and the sizes of the piston and disk, each of which have a diameter less than external diameter of the activator, but greater than diameter of an internal channel of the activator through which the rod extends.
In operation, as the drive mechanism oscillates or vibrates the rod within the working cylinder, and fluid is drawn upwardly into the working cylinder along an inlet due to the vacuum created within the working cylinder as a result of the movement of the rod, as described in the U.S. patents and applications cited previously. When the fluid reaches the working cylinder, the activator interacts with the fluid as the activator slides between the piston and the disk to create cavitation within the fluid. By creating air bubbles or pockets in the fluid, the cavitation reduces the viscosity of the fluid, enabling it to be efficiently discharged from the pump. In other words, the influence of cavitation on the liquid raises pressure of the liquid in the working cylinder, thereby reducing the kinematic viscosity of the liquid, enabling it to be pumped more effectively.
In certain embodiments or uses, the pump can be utilized to assist in facilitating chemical reactions due to the ability of the pump to break down the material being pumped to increase its chemical activation for use in various chemical reaction processes using the pumped materials as reactants. The energy of the mechanical impact of cavitation on various compounds in liquid solutions happens to be enough for breaking chemical bonds in molecules. Even at comparatively soft conditions, the stress level imparted to the material by the cavitation created in the pump is significantly higher than strengths of chemical bonds (˜4.8-5.5×10 42 erg). Mechanical destruction of the materials due to the cavitation in the pump results in formation of free radicals capable of g chemical reactions. This mechanical destruction of the material result in significant change of physic-chemical properties of materials, formation of new functional groups, change of solubility and viscosity, formation of network systems.
A manageable process of cavitation within the pump to achieve these results on the material being pumped can be realized at certain values of amplitudes and frequency of vibration and, with a suitable geometry or cross-section of the chamber in which the material being pumped is subjected to the cavitation forces, or “reactor”, which may have rectangular or cylinder shapes. In the case of a rectangular reactor, the cavitation interaction happens directly between the liquid material and parts of the device as they interact. Alternatively, in the case of a cylindrical reactor, the cavitation creates vortices and streams of liquid, and inside the streams spinning and oscillation of particles and other interactions occurs between the liquids and/or solid particles which may be present. Vibration and vortex interaction consequently reduces the friction of outer layers of the vortex that interact with walls of the chamber or other structure, and reduces liquid's viscosity, increasing the ease of pumping the fluid.
According to another aspect of the present invention, the working cylinder includes an external cylinder disposed around the working cylinder. The external cylinder is in fluid communication with the working cylinder via apertures in the working cylinder, and includes an integral annular ring disposed about the circumference of the external cylinder. The ring is attached to a pipe that is oriented at a tangent to the ring and is inserted into the reservoir of the fluid being pumped in order to draw the fluid into the ring. Upon entering the ring, the orientation of the ring causes the fluid to move circumferentially around the ring prior to flowing into the external cylinder, where the fluid continues to flow circumferentially around the working cylinder prior to entering the working cylinder. The motion imparted to the fluid by the ring enables the fluid to co-operate with the piston, the activator and the disk in creating the cavitation within the fluid, thereby raising the efficiency of the flow of the liquid into the vibratory cavitation pump. Further, the high frequency of oscillation of the rod with the piston, the activator and the disk allows a high flow rate stream of a liquid (e.g., more than 5 m/sec) to enter and be acted upon by the pump, which creates steady process cavitation within the pump. The influence of cavitation on the liquid raises pressure in the internal cavity of the working cylinder, reduces kinematic viscosity of the liquid and increases the destruction and chemical activation of the liquid.
Additional aspects, features and advantages of the present disclosure will be made apparent from the following detailed description taken together with the drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings illustrate the best way of practicing the present disclosure.
In the drawings:
FIG. 1 is a cross-sectional view of a vibratory cavitation pump constructed according to the present disclosure;
FIG. 2 is a cross-sectional view along line 2 - 2 of FIG. 1 ;
FIG. 3 is a cross-sectional view of a second embodiment of the vibratory cavitation pump of the resent disclosure; and
FIG. 4 is a cross-sectional view of a third embodiment of a vibratory cavitation pump constructed according to the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
With reference now to the drawing figures in which like reference numbers identify like parts throughout the disclosure, in FIG. 1 a first embodiment of the vibratory cavitation pump of the present disclosure is illustrated generally at 100 . The pump 100 includes a case or housing 1 including a securing member 2 , such as a threaded collar or clip, among others, that is used to fasten a container 3 , such as a bottle, to the housing. The container 3 can hold virtually any type of fluid or liquid 4 to be pumped, as will be described.
The liquid 4 in the bottle 3 is in contact with a pump mechanism 5 disposed within the housing 1 that can effectively displace the fluid 4 . In one embodiment shown in FIG. 1 , a frame 6 is fixed to the housing 1 to support an electric motor 7 that is operably connected to a reducer 8 that is in turn connected to an oscillating member 9 that transforms the rotation of a shaft of the motor 7 in longitudinal movement of a rod 10 connected to the mechanism 9 opposite the reducer 8 .
The motor 7 is operably connected to a suitable power source, such as a number of batteries 13 or via a cord and plug (not shown) connectable to a building power grid. The operation of the motor 7 can be controlled through the use of a switch 11 , which is used to turn the motor 7 on and off, and a modulating device 12 , which is utilized to control the speed of operation of the motor 7 , and thus control the frequency of oscillation of the rod 10 .
Also connected to the frame 6 is an arm 14 from which extend a pair of flanges 15 affixed to a securing member 16 disposed on a working cylinder 17 of the pumping mechanism 5 . The working cylinder 17 is formed as a cylindrical member having a sealed aperture 102 at one end through which the rod 10 extends, and an outlet end 22 . The cylinder 17 can also have a number of alternative configurations, such as a rectangular cross-sectional shape. The working cylinder 17 also includes a number of openings 21 extending through the cylinder 17 that are disposed between the aperture 102 and the outlet end 22 .
Within the working cylinder 17 and on the rod 10 are disposed a piston 18 , a disk 19 and an activator 20 . The piston 18 and disk 19 are secured to the rod 10 a specified distance from each other, while the activator 20 include a central passage 36 through which the rod 10 extends, such that the activator 20 is slidably mounted on the rod 10 between the piston 18 and the disk 19 . In one embodiment, the piston 18 and disk 19 have generally circular shapes, with the disk 19 having a number of apertures 34 formed therein, as shown in FIG. 2 . Further, in one embodiment the activator 20 can be formed to be cylindrical in shape, but may also be formed with other alternative shapes, such as a spherical shape.
The exhaust outlet 22 is defined by a narrowing of the working cylinder 17 and includes a valve 23 which restricts the flow of fluid through the outlet 22 and through a nozzle 24 disposed adjacent the valve 23 opposite the outlet 22 .
In the embodiment shown in FIG. 1 , on an external surface of the working cylinder 17 is disposed an external cylinder 25 . The external cylinder 25 is formed similarly to the working cylinder 17 and is secured to the working cylinder 17 over the apertures 21 . As shown in FIGS. 1 and 2 , the external cylinder 25 includes an annular ring 26 that extends outwardly from the external cylinder 25 , forming a ring cavity 27 . An inlet pipe 30 is connected on a tangent to the ring 26 via an aperture 29 , such that fluid 4 entering the ring 26 through the aperture 29 has a rotational motion imparted to it as it is directed around the ring 26 . From the ring cavity 27 , the fluid 4 drawn up from the container 3 through the pipe 30 is then directed into an internal cavity 32 of the external cylinder 25 prior to entering the working cylinder 17 through the apertures 21 .
In operation, when the switch 11 is activated to direct electric current from the battery 13 through the modulator 12 to the motor 7 , the motor 7 operates the mechanism 9 . The mechanism 9 longitudinally moves rod 10 with the piston 18 , a disk 19 and the activator 20 within the internal cavity 31 / 33 of the working cylinder 17 . With the movement of the piston 18 and disk 19 out of the cylinder 17 , the piston 18 moves towards and engages the activator 20 , closing the channel 36 within the activator 20 and urging the activator 20 to move with the piston 18 . This movement of the rod 10 , piston 18 and activator 20 towards the left cavity portion 33 creates a zone of lowered pressure, i.e., vacuum, in the right cavity portion 31 of the working cylinder 17 that functions to draw the liquid 4 out of the container 3 through the pipe 30 , as described one or more of U.S. Pat. Nos. 6,315,533; 6,364,622; 6,428,289; 6,604,920; 7,354,255B1; and 7,731,105B2, as well as in Published US Patent Application No. US2009/0116979, each of which is expressly incorporated by reference herein. As the fluid 4 reaches the pumping mechanism 5 , it enters the ring cavity 27 and is accelerated in a circular path within the cavity 27 , in order to fill the internal cavity 32 of the external cylinder 25 . The accelerated liquid 4 subsequently is directed through the apertures 21 into the right cavity portion 31 defined within the working cylinder 17 .
Subsequently, as the rod 10 begins to move in the opposite direction out of the left cavity portion 33 towards the right cavity portion 31 due to the oscillating movement of the mechanism 9 , the disk 19 contacts the activator 20 , closes the channel 36 in the activator 20 and together with the activator 20 urges the liquid 4 out of the right cavity portion 31 through the outlet 22 . In passing through the outlet 22 , the pressure of the fluid 4 is sufficient to open the valve 23 such that the fluid 4 can be discharged in a pressurized manner through the nozzle 24 .
As the rod 10 moves towards the right cavity portion 31 , the liquid 4 is drawn into the left cavity portion 33 of the working cylinder 17 in order to replacement the liquid 4 expelled from the right cavity portion 31 through the valve 23 and nozzle 24 . This process of operation of the pump mechanism 9 is repeated at a frequency which is defined by speed of operation the motor 7 .
Further, as a result of the oscillating movement of the rod 10 in the cylinder 17 , the activator 20 , the piston 18 and the disk 19 regularly and alternately collide with the lateral surfaces of the activator 20 . In the course of these collisions, kinetic energy is created which affects the liquid 4 in the working cylinder 17 by promoting cavitation of the liquid 4 in the working cylinder 17 , which results in actively mixing the liquid 4 , consequently reducing forces of intermolecular coupling in the liquid 4 , thereby reducing the viscosity of the liquid 4 and increasing the pumpability of the fluid 4 .
In addition, in conjunction with the oscillatory movement of the rod 10 , piston 18 , disk 19 and activator 20 , cavitation of the fluid 4 in the working cavity 17 is created by the shape of the ring cavity 27 . As the fluid 4 is drawn into the ring cavity 27 via the pipe 30 , the cavity 27 causes an accelerated rotary movement of the stream of fluid 4 in the cavity 27 around the working cylinder 17 . As more fluid 4 is drawn into the ring cavity 27 , the accelerated fluid 4 is displaced into the working cylinder 17 through the apertures 21 and distributed into the left and right portions 31 and 33 of the cavity 32 of the working cylinder 17 . The entrance of the accelerated fluid 4 creates zones of active compression and variable pressure in the working cylinder 17 , thus providing an alternative and steady source of cavitation of the fluid 4 . This cavitation of the fluid 4 is accompanied by a sharp increase of pressure in the working cylinder 17 and as a consequence the fluid being pumped is altered in into a microdrop form, comparable in quality to fog, that provides the best molecular interaction potential.
The pump mechanism 9 can be operated over a wide frequency range to create the cavitation of the fluid 4 within the working cylinder 17 , with a minimum oscillation frequency being about 1-5 Hz. This minimum operating mode of the pump mechanism 9 corresponds to the best conditions for pumping highly viscous liquids which produces an effective discharge fluid stream in absence cavitation.
Referring now to FIG. 3 , a second embodiment of the vibratory cavitation pump 300 is illustrated. This pump 300 is developed for use with liquids of various viscosity, including liquid soap, lotions, a cream, lubricating oils and other dense lubricant products while considerably reducing the losses of electric energy during the operation of the pump 300 .
The pump 300 is formed similarly to the pump 100 , with the main differences being the orientation of the working cylinder 17 in a vertical direction on the frame 6 , the removal of the external cylinder 25 and apertures 21 in the working cylinder 17 , and the switching of the placement of the pipe 30 and outlet 22 relative to the working cylinder 17 .
In operation, the movement of the rod in the working cylinder 17 draws the fluid 4 up the pipe 30 into the cavity 32 , where it is acted upon by piston 18 , disk 19 and activator 20 in the manner described previously, prior to the fluid being discharged through the outlet 22 .
Looking now at FIG. 4 , a third embodiment of the pump 400 is illustrated. In this embodiment, pump 400 is formed similarly to the pump 300 , without the external cylinder 25 and apertures 21 in the working cylinder 17 , but the cylinder 17 is again oriented horizontally with the inlet pipe 30 and outlet 22 reverting back to locations similar to the first embodiment for the pump 100 . The pump mechanism 9 for the pump 400 is formed as a conventional reciprocating tool having a motor 7 disposed therein which is connected to the mechanism 9 in order to selectively oscillate the rod 10 and operate the pump 400 in a manner similar to that described previously regarding pump 100 .
In addition to the above description, the following are some of the advantages of the pump of this present disclosure:
Technical and Economical Advantages of Pump
1. Simple and reliable production of vibratory-cavitation pumps and other devices.
2. Easy to manufacture them from various materials including plastics.
3. There are no valves, springs and other fast wearing parts.
4. In working reservoirs with a fluid pressure corresponds to the atmospheric.
5. Reduction up to 20-25% of energy consumption during elevation, transportation and spraying of liquids.
6. Safely pumping aggressive liquids (concentrated acids, alkali, and etc.) and taking probes of those.
7. Pumps can be produced with different productivities (or flow rates) from 3 ml/sec to 200 ml/sec and more; pressures from 10 PSI up to 350 PSI.
8. Electric motors can be used having power from 3 watt to 1 kilowatt and more; also various electro vibrators of different productivity can be used with alternating current or with converters.
9. In households the pumps for spraying liquids can be used with batteries of AA 1.5 V or rechargeable batteries of 7-18 V.
The Potential Use of the Vibratory Cavitation Pumps
1. Chemical industry and laboratories.
2. Transportation of viscous oils, liquid soap, lotions.
3. In scientific laboratories.
4. Micro- and mini pumps for cooling electronic chips.
5. Medicine: in metering devices, in devices for disinfection of premises, in devices for preparation of medical cocktails, in mechanisms for artificial blood circulation, in devices for flushing out of blood vessels and in other applications.
6. Perfumes development and production: In devices for manufacturing emulsion on the basis of essential oil and water with concentration of water to 60%, in devices for manufacturing of medical flints.
7. Agriculture: In devices for spraying plants, in devices for sanitary machining of plants and a premise of poultry plants, the cattle and equipment maintenance.
8. In devices for sanitary, chemical and radiation clearing and protection of people and buildings, cars and other civil and military objects.
9. In devices for more efficient combustion of fuels.
10. In devices for development and production of alternative aspects fuels.
11. Vibratory-cavitation technology can be efficiently used for creation and production of new materials of custom-made, new combination of properties, for handling and storage of nuclear wastes.
Numerous alternative embodiments of the present disclosure are contemplated as being within the scope of the following claims which particularly point out and distinctly claims the subject matter regarded as the present invention.
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A vibratory cavitation pump is provided that includes a working cylinder having an fluid inlet and a fluid outlet, a rod extending into the cylinder, a piston fixed to the rod, a plate fixed to the rod and spaced from the piston, an activator slidably mounted to the rod between the piston and the plate and an oscillating pumping mechanism operably connected to the rod to move the rod with respect to the working cylinder. The sliding activator creates cavitation in the fluid being pumped to increase the ease of pumping the fluid, such as high viscosity fluids. The pump can also include an external cylinder disposed around the working cylinder to impart rotational motion to the incoming fluid, thereby enhancing the cavitation created in the fluid by the pump, rendering the fluid easy to displace.
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FIELD OF THE INVENTION
[0001] This invention relates to improved phosphine ligands and catalysts derived therefrom that are useful for asymmetric hydrogenation processes and for other asymmetric reactions.
BACKGROUND TO THE INVENTION
[0002] Homogeneous catalytic asymmetric hydrogenation is an important reaction for providing chiral intermediates for pharmaceutical agents and other products useful in the life sciences, required in the necessary single stereoisomeric form. In the ongoing quest to design more selective and more efficacious pharmaceutical agents, added structural complexity means that when an asymmetric hydrogenation approach to such agents is contemplated, the existing catalysts may not provide manufacturing solutions in every case and hence design of novel catalysts continues to be an important endeavour.
[0003] The majority of known catalysts for asymmetric hydrogenation take the form of transition metal complexes of chiral phosphorus-containing ligands, which are either monodentate or more commonly bidentate. Diphosphines represent the most widely investigated and industrially significant class of such bidentate ligands and a very large number of these ligands are reported in the literature [W. Tang and X. Zhang, Chem. Rev. 2003, 103, 3029-3069; I. C. Lennon and P. H. Moran, Curr. Opin. Drug Discovery Dev. 2003, 6, 855-875]. Bisphospholanes represent a subclass of diphosphines that has proved especially useful in pharmaceutical applications [I. C. Lennon and C. J. Pilkington, Synthesis, 2003, 1639-1642; M. J. Burk, Acc. Chem. Res. 2000, 33, 363-372]. Since the introduction of the pioneering DuPhos family of bisphospholanes, as represented by general formula (A),
[0000]
[0000] numerous alternative bisphospholanes have been reported, based on the following structural variations:
(a) Different backbone structures to 1,2-diphenylene linking the phosphine groups. Ligands of formulae (B) to (D) are representative examples [M. J. Burk, J. E. Feaster, W. A. Nugent and R. L. Harlow, J. Am. Chem. Soc. 1993, 115, 10125-10138; M. J. Burk and M. F. Gross, Tetrahedron Letters, 1994, 35, 9363-9366; J. Holz, A. Monsees, H. Jiao, J. You, I. V. Komarov, C. Fischer, K. Drauz and A. Borner, J. Org. Chem. 2003, 68, 1701-1707].
[0000]
(b) Introduction of extra substituents at the 3-position and/or 4-position of each phospholane ring. The ligand of formula (E) is a representative example [W. Li, Z. Zhang, D. Xiao, X. Zhang J. Org. Chem. 2000, 65, 3489-3496; J. Holz, M. Quirmbach, U. Schmidt, D. Heller, R. Stümer and A. Borner, J. Org. Chem. 1998, 63, 8031-8034; Q. Dai; C-J. Wang, X. Zhang, Tetrahedron 2006, 62, 868-871].
[0000]
(c) The 2-position of each phospholane ring has an alkyl substituent but the 5-position is unsubstituted. This renders such ligands chiral by virtue of the phosphorus atom becoming a chiral centre and accordingly such ligands have been described as “P-chirogenic”. The ligand of formula (F) is a representative example [G. Hoge, J. Am. Chem. Soc. 2004, 126, 9920-9921].
[0000]
(d) The alkyl substituents at the 2- and 5-positions of each phospholane rings are replaced by aryl substituents. To date, the only ligand reported with this structural variation and characterised for catalysis of asymmetric hydrogenation is Ph-BPE (G) (C. J. Pilkington and A. Zanotti-Gerosa, Org. Lett. 2003, 5, 1273-1275).
[0000]
[0008] General synthetic methods first introduced for the DuPhos family of ligands and applicable to make ligands of types (a)-(c) are not applicable to ligands of type (d) so access to the latter presents technical challenges. For the first time, the present invention serves to significantly broaden the structural diversity of ligands of type (d), leading to enhanced diversity in the catalyst performance (as characterised by substrate scope, enantioselectivity and activity) of the corresponding transition metal complexes.
SUMMARY OF THE INVENTION
[0009] The present invention is based around the design and discovery of novel bisphospholane ligands having utility as components of catalysts for selective and efficient asymmetric hydrogenation processes and for other asymmetric reactions. One aspect of this invention relates to an enantiomerically enriched compound of formula (1) or the opposite enantiomer thereof
[0000]
[0000] wherein each of Ar 1 —Ar 4 represent the same or different aromatic groups of up to 20 carbon atoms and the bridging group X is selected from the group consisting of CH 2 and structural fragments according to formulae (2) to (5) in which * denotes points of attachment to phosphorus atoms, Y in (2) is O or N-alkyl and R in (4) is H or alkyl.
[0000]
[0010] The invention further relates to metal-ligand complex catalysts comprising a transition metal complexed with a compound of formula (1) and application of these catalysts in asymmetric hydrogenation processes and for other asymmetric reactions. The invention yet further relates to novel intermediates required in the preparation of a compound of formula (1) containing, as bridging group, CH 2 or the structural fragment of formula (5).
DETAILED DESCRIPTION OF THE INVENTION
[0011] In the novel bisphospholanes (1) of the present invention, preferably each of Ar 1 —Ar 4 is the same, more preferably each of Ar 1 —Ar 4 is phenyl or substituted phenyl and most preferably each of Ar 1 —Ar 4 is phenyl. A specific embodiment of the latter sub-class of ligands consists of compounds of formulae (6) to (10), either as the (R,R)-enantiomers depicted or as the opposite (S,S)-enantiomers.
[0000]
[0012] Synthetic routes to compounds of formulae (6) to (10), as described in the examples below, proceed by way of reactants containing a pre-formed trans-2,5-diphenylphospholane unit that is suitably activated for coupling reactions. This represents another aspect of the invention. In the case of the compound of formula (6), the synthetic method comprises the following steps for the (R,R)-enantiomer or equivalent steps for the (S,S)-enantiomer, and proceeds by way of novel reactants (12) and (13):
[0000] (a) conversion of the (R,R)-2,5-trans-diphenylphospholane-borane adduct (11) to (R,R)-(2,5-diphenylphospholan-1-yl)methanol borane adduct (12) preferably by treatment with formaldehyde or a formaldehyde equivalent, preferably paraformaldehyde, in the presence of a base. Preferred bases may be selected from alkali metal hydroxides, alkali metal alkoxides and organolithium compounds. More preferred bases are potassium hydroxide and sodium hydroxide, with potassium hydroxide being most preferred. Reaction solvents are selected to be compatible with the particular base used, for example organolithium compounds typically require an ethereal solvent, preferably tetrahydrofuran. Alkali metal hydroxides require a protic solvent selected from C 1-4 alcohols, water and mixtures thereof, optionally in the presence of a miscible ethereal cosolvent selected from tetrahydrofuran, 1,4-dioxane, 1,2-dimethoxyethane and bis(2-methoxyethyl)ether. Preferably, the protic solvent is a C 1-4 alcohol and more preferably it is methanol. The operating temperature is in the range of −78 to +40° C., preferably in the range of −10 to +30° C., and more preferably in the range of 20 to 30° C.
(b) conversion of (R,R)-(2,5-diphenylphospholan-1-yl)methanol borane adduct (12) to an activated O-sulfonyl derivative (13) wherein R 1 is alkyl, fluoroalkyl or aryl and preferably is trifluoromethyl, preferably by treatment with the corresponding sulfonic acid anhydride or sulfonic acid chloride. For the preferred embodiment of R 1 is trifluoromethyl, triflic anhydride is the preferred reagent. The base is preferably an amine, pyridine or a substituted pyridine, more preferably triethylamine or diisopropylethylamine and most preferably triethylamine. The reaction solvent is an aprotic solvent, preferably dichloromethane, toluene, diethyl ether, tert-butyl methyl ether, tetrahydrofuran, 1,4-dioxane, 1,2-dimethoxyethane and bis(2-methoxyethyl)ether, or mixtures thereof. More preferably, the reaction solvent is dichloromethane. The operating temperature is in the range of −78 to +30° C., or, for the preferred embodiment of R 1 is trifluoromethyl, in the range of range of −78 to 0° C., preferably −30 to 0° C.
(c) coupling of the O-sulfonyl derivative (13) with (R,R)-2,5-trans-diphenylphospholane-borane adduct (11) in the presence of an organolithium base to give the borane adduct of (R,R)-(6). The organolithium base may be selected from C 1-6 alkyl lithium compounds, phenyl lithium, lithium diisopropylamide and lithium hexamethyldisilazide. Preferably, the organolithium base is n-butyl lithium, sec-butyl lithium, tert-butyl lithium, methyl lithium or n-hexyl lithium and more preferably it is n-butyl lithium. The reaction solvent is an preferably an ethereal solvent selected from diethyl ether, tert-butyl methyl ether, tetrahydrofuran, 1,4-dioxane, 1,2-dimethoxyethane and bis(2-methoxyethyl)ether, and mixtures thereof. More preferably, the reaction solvent is tetrahydrofuran. A hydrocarbon solvent such as hexane may also present, typically as solvent for an alkyl lithium base added to the reaction mixture. The operating temperature will vary, dependent on the scale of operation, and is preferably in the range of −78 to 0° C. during the addition of reagents.
(d) removal of the borane component to give (R,R)-(6) as free ligand, preferably by treatment with an amine or diamine reagent. More preferably, the reagent is selected from 1,4-diazabicyclo[2.2.2]octane (DABCO), 1,5-diazabicyclo[4.3.0]non-5-ene, 1,8-diazabicyclo[4.4.0]undec-7-ene, N,N,N,N-tetramethylethylenediamine (TMEDA), morpholine, pyrrolidine and diethylamine. Most preferably, the reagent is DABCO. Toluene and tetrahydrofuran are preferred solvents and toluene is more preferred. The operating temperature is in the range of 10 to 110° C., preferably in the range of −10 to +30° C., and more preferably in the range of 20 to 30° C.
[0000]
[0013] In the case of the compound of formula (10), the synthetic method comprises the following steps for the (R,R)-enantiomer or equivalent steps for the (S,S)-enantiomer, and proceeds by way of novel reactant (15):
[0000] (a) conversion of (R,R)-1-oxo-2,5-diphenylphospholane (14) to (R,R)-1-halogeno-2,5-diphenylphospholane (15), wherein halogeno (Z) is chloro or bromo. PZ 3 is the preferred reagent for this transformation. Preferred solvents may be selected from aromatic hydrocarbons, chlorinated aromatic hydrocarbons or ethers. From these general solvent classes, more preferred solvents are benzene, toluene, xylene, cumene, mesitylene, ethyl benzene, chlorobenzene, 1,2-dichlorobenzene, tetrahydrofuran, 1,4-dioxane, 1,2-dimethoxyethane and bis(2-methoxyethyl)ether. Toluene is the most preferred solvent. The operating temperature is in the range of −78 to +50° C., preferably in the range of −20 to +40° C., and more preferably in the range of 15 to 25° C.
(b) coupling of (R,R)—-chloro-2,5-diphenylphospholane (15) with 1,1′-dilithioferrocene, preferably as its N,N,N,N-tetramethylethylenediamine (TMEDA) complex. Preferred solvents may be selected from aromatic hydrocarbons or ethers. From these general solvent classes, more preferred solvents are benzene, toluene, xylene, cumene, mesitylene, ethyl benzene, diethyl ether, tert-butyl methyl ether, tetrahydrofuran, 1,4-dioxane, 1,2-dimethoxyethane and bis(2-methoxyethyl)ether. Toluene is the most preferred solvent. The operating temperature is in the range of −78 to +30° C., preferably in the range of −20 to +30° C., and more preferably in the range of 10 to 25° C.
[0000]
[0014] Another aspect of the present invention concerns novel transition metal complexes based on ligands according to formula (1) and utility of these complexes as catalysts for asymmetric hydrogenation processes and for other asymmetric reactions, including but not limited to hydroformylation, hydrocyanation, hydroesterification and hydrocarboxylation. In aforementioned transition metal complexes, preferred transition metals are rhodium, ruthenium, iridium, nickel and palladium. In application of such transition metal complexes to the catalysis asymmetric hydrogenation processes, the substrate undergoing stereoselective hydrogenation is preferably an olefin, a ketone or an imine. In such processes the transition metal is preferably rhodium, ruthenium or iridium and more preferably the transition metal is either rhodium or ruthenium. Thus, another preferred embodiment of this invention comprises providing a substrate selected from an olefin, a ketone or an imine and a catalyst complex comprising the ligands of formula 1 and a transition metal in a solvent for the substrate and the complex in the presence of hydrogen gas. Preferably, this reaction would occur at pressures above ambient pressure. The preferred temperature for the reaction is from 0 to 100° C., more preferably ambient to 70° C. The mole ratio of substrate to catalyst complex is preferably greater than 200:1, more preferably greater than 500:1, most preferably at least 1000:1. The maximum mole ratio will be limited by effectiveness of the reaction and is desired to be as high as possible but is generally not more than 100,000:1.
[0015] The invention is further illustrated by the following examples.
EXAMPLE 1
Synthesis of 1,2-bis[(R,R)-2,5-diphenylphospholano]methane
(i) (R,R)-2,5-trans-diphenylphospholane-borane Adduct
[0016]
[0017] (R,R)-1-Hydroxy-1-oxo-2,5-trans-diphenylphospholane (40.1 g, 147.3 mmol; prepared according the method of Guillen, F et al. Tetrahedron 2002, 58, 5895) was suspended in toluene (450 ml). The mixture was degassed by evacuation and filling with nitrogen (×5) and then heated in an oil bath at 120° C. (internal temperature 100° C.). Phenylsilane (36.3 ml, 294.5 mmol) was added in portions over 2 h. The solution was heated for a further 2 h and then cooled to 5° C. Borane dimethyl sulfide complex (94%, 15 ml, 147.3 mmol) was added over 5 minutes. The mixture was allowed to warm to room temperature and stirred overnight. The solution was filtered through a pad of silica (100 g), eluting with toluene (600 ml). Concentrated under reduced pressure and crystallized from toluene/heptane (1:4, 150 ml). The solid was filtered and washed with toluene/heptane (1:4, 50 ml). Dried under vacuum to give the title compound (31.22 g, 83%).
[0018] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 7.2-7.4 (10H, m), 4.82 (1H, dq, J HP 361 Hz, J HH 11 Hz), 3.95 (1H, m), 3.52 (1H, m), 2.55-2.65 (2H, m), 2.15-2.25 (2H, m) and 0.1-0.9 (3H, br q, BH 3 ).
[0019] 13 C NMR (100 MHz, CDCl 3 ) δ ppm 138.1 (d, J 5 Hz), 136.9, 129.4, 129.1, 129.0, 128.9, 128.2, 127.7, 44.9 (d, J 33 Hz), 41.0 (d, J 29 Hz), 35.0 (d, J 4 Hz) and 34.3.
[0020] 31 P NMR (162 MHz, CDCl 3 ) δ ppm 30.1.
(ii) (R,R)-(2,5-Diphenylphospholan-1-yl)methanol Borane Adduct
[0021]
[0022] (R,R)-2,5-trans-diphenylphospholane-borane adduct (9.24 g, 36.4 mmol) and paraformaldehyde (9.2 g) were suspended in methanol (40 ml) at 20° C. under nitrogen. A solution of potassium hydroxide (4.64 g, 72.7 mmol) in methanol (50 ml) was added over 10 minutes (a clear solution soon forms). The mixture was stirred overnight and then acidified with 1M aqueous hydrochloric acid (80 ml). The product was extracted with ethyl acetate (2×100 ml) and washed with saturated sodium hydrogen carbonate solution (50 ml) and brine (50 ml). The organic phase was dried (MgSO 4 ), filtered and concentrated under reduced pressure. Heptane (30 ml) was added and the solid was filtered. Washed with ethyl acetate/heptane (1:4, 3×20 ml). Dried under vacuum to give the title compound (8.89 g, 86%).
[0023] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 7.45-7.25 (1H, m), 3.93-3.84 (1H, m), 3.73-3.65 (1H, m), 3.68 (2H, s), 2.65-2.17 (4H, m), 1.45 (1H, br) and 0.75 to −0.1 (3H, br q, BH 3 ).
[0024] 13 C NMR (100 MHz, CDCl 3 ) δ ppm 137.2, 136.0 (d, J 5 Hz), 129.5, 129.0 (d, J 5 Hz), 128.9, 127.8 (d, J 2 Hz), 127.7 (d, J 3.5 Hz), 127.5 (d, J 3 Hz), 57.6 (d, J 30 Hz), 44.8 (d, J 30 Hz), 40.9 (d, J 28 Hz), 33.2 (d, J 5 Hz) and 31.0.
[0025] 31 P NMR (162 MHz, CDCl 3 ) δ ppm 47.1 (br).
(iii) Trifluoromethanesulfonic acid (R,R)-2,5-diphenyl-phospholan-1-ylmethyl Ester Borane Adduct
[0026]
[0027] (R,R)-(2,5-Diphenylphospholan-1-yl)methanol borane adduct (4.70 g, 16.5 mmol) was dissolved in DCM (40 ml) under nitrogen and cooled to −30° C. Triethylamine (2.5 ml, 18.2 mmol) was added followed by triflic anhydride (3.10 ml, 18.2 mmol) dropwise over 5 minutes (temperature −30 to −27° C.). The reaction was stirred for 45 minutes and then quenched with water (20 ml). The organic phase was separated and washed with water (2×20 ml). Dried (MgSO 4 ) and filtered through a pad of silica eluting with DCM (50 ml). Evaporated under reduced pressure to give the title compound as a colourless oil (6.23 g, 90%).
[0028] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 7.40-7.25 (10H, m), 4.53 (1H, d, J 12 Hz), 4.20 (1H, dd, J 13, 3, Hz), 3.88-3.74 (2H, m), 2.76-2.48 (2H, m), 2.44-2.20 (2H, m) and 0.8 to −0.2 (3H, br q, BH 3 ).
[0029] 13 C NMR (100 MHz, CDCl 3 ) δ ppm 135.4, 133.9 (d, J 6 Hz), 129.6, 129.2, 128.9 (d, J 5 Hz), 128.3, 128.1, 127.8 (d, J 4 Hz), 122.0 (d, J 320 Hz), 67.7 (d, J=16 Hz), 45.2 (d, J 30 Hz), 41.1 (d, J 26 Hz), 33.3 (d, J 6 Hz) and 30.8.
[0030] 31 P NMR (162 MHz, CDCl 3 ) δ ppm 49.7.
(iv) 1,2-Bis[(R,R)-2,5-diphenylphospholano]methane-borane Adduct
[0031]
[0032] (R,R)-2,5-trans-diphenylphospholane-borane adduct (3.44 g, 13.54 mmol) was dissolved in dry THF (30 ml) under nitrogen. The solution was cooled to −65° C. Added a solution of n-BuLi (2.5 M in hexanes, 0.34 ml, 0.86 mmol) dropwise (temperature −60 to −65° C., initially there is insoluble substrate which dissolves as the BuLi is added to give a yellow solution). Stirred for 1 h and then added a solution of trifluoromethanesulfonic acid (R,R)-2,5-diphenyl-phospholan-1-ylmethyl ester borane adduct (6.20 g, 14.90 mmol) in dry THF (15 ml). Allowed to warm to room temperature and stirred overnight. Quenched with 1M aqueous HCl (30 ml). Separated the THF phase and concentrated under reduced pressure. The aqueous phase was extracted with DCM (2×30 ml). The DCM extracts were combined with the THF concentrate and washed with water (20 ml), dried (MgSO 4 ), and filtered through silica (25 g) eluting with DCM (50 ml). The solution was concentrated under reduced pressure and the residue crystallised from ethyl acetate/heptane (1:3, 16 ml). Filtered and washed with ethyl acetate/heptane (1:2, 2×6 ml) followed by ethyl acetate/heptane (1:1, 2 ml) Dried under vacuum to give the title compound (4.33 g, 610%).
[0033] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 7.35-7.0 (2H, m), 4.0-3.90 (2H, m), 2.58-2.42 (2H, m), 2.34-2.22 (2H, m), 2.0-1.86 (4H, m), 0.94 (2H, t, J 14 Hz) and 1.1-0.3 (6H, br).
[0034] 13 C NMR (100 MHz, CDCl 3 ) δ ppm 138.2, 134.8 (d, J 5 Hz), 129.8 (d, J 5 Hz), 129.3, 128.5, 128.0, 127.7, 127.1, 49.1 (dd, J 30, 5 Hz), 43.1 (d, J 26 Hz), 36.3, 29.6 and 19.1 (t, J 16 Hz).
[0035] 31 P NMR (162 MHz, CDCl 3 ) 3 ppm 43.9.
(v) 1,2-Bis[(R,R)-2,5-diphenylphospholano]methane
[0036]
[0000] (All Solvents were Degassed Prior to Use)
[0037] 1,2-Bis[(R,R)-2,5-diphenylphospholano]methane-borane adduct (986 mg, 1.90 mmol) and DABCO (639 mg, 5.69 mmol) were charged to a 50 ml Schlenk flask. Deoxygenated by evacuation and filling with nitrogen (×5). Added toluene (10 ml). Heated in an oil bath at 60° C. (external temperature) for 2 h. Allowed to cool to room temperature with stirring overnight. Filtered through a pad of silica (6 g) under nitrogen, eluting with toluene (20 ml). Evaporated under reduced pressure to give a cloudy oil. Solidified by trituration with isopropanol (3 ml) and evaporated under reduced pressure to give the title compound (929 mg, 99%).
[0038] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 7.25-6.90 (20H, m), 3.60-3.50 (2H, m), 3.27-3.18 (2H, m), 2.36-2.24 (2H, m), 2.16-2.06 (2H, m), 1.94-1.70 (4H, m) and 0.68 (2H, m).
[0039] 13 C NMR (100 MHz, CDCl 3 ) δ ppm 144.4 (t, J 8 Hz), 139.1, 128.7, 128.6, 128.3 (t, J 5 Hz), 128.1, 126.2, 125.8, 49.3 (t, J 5 Hz), 47.3 (t, J 5 Hz), 36.9, 31.8 and 22.0 (t, J 34 Hz).
[0040] 31 P NMR (162 MHz, CDCl 3 ) δ ppm 4.5.
EXAMPLE 2
Preparation of Transition Metal Catalyst Complexes of 1,2-bis[(R,R)-2,5-diphenylphospholano]methane
(i) 1,2-Bis[(R,R)-2,5-diphenylphospholano]methane-(1,5-cyclooctadiene) rhodium(I) tetrafluoroborate
[0041]
[0042] Bis[(R,R)-2,5-diphenylphospholano]methane (150 mg, 0.30 mmol) and bis(1,5-cyclooctadiene) rhodium(I) tetrafluoroborate (124 mg, 0.30 mmol) were added to a Schlenk flask. Evacuated and filled with nitrogen (×5). Added DCM (degassed; 3 ml) and stirred at room temperature overnight. The solution was evaporated under reduced pressure and the residue was triturated with ether (degassed; 2 ml) to give an orange solid. The supernatant liquid was removed by syringe and the solid was washed with ether (degassed; 3×2 ml) and pentane (degassed; 2×3 ml). Dried under vacuum to give the title compound (205 mg, 86%).
[0043] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 7.62-7.55 (8H, m), 7.47-7.40 (2H, m), 7.20-7.15 (6H, m), 6.81 (4H, d, J 8 Hz), 5.30 (2H, m), 3.70-3.60 (4H, m), 3.32-3.26 (2H, m), 3.15-2.98 (2H, m), 2.52-2.38 (6H, m), 2.25-2.15 (2H, m), 2.08-1.96 (4H, m), 1.70-1.60 (2H, m) and 1.38-1.28 (2H, m).
[0044] 13 C NMR (100 MHz, CDCl 3 ) δ ppm 140.4, 135.3, 129.9, 129.4, 129.1, 128.3, 127.8, 127.4, 100.2, 99.7, 49.5, 47.3, 39.8 (t, J 20 Hz), 31.2, 30.6, 30.1 and 28.4.
[0045] 31 P NMR (162 MHz, CDCl 3 ) δ ppm −6.9 (d, J 136 Hz).
[0046] m/z (ESI) 703 (M-BF 4 ).
(ii) Chloro-{1,2-Bis[(R,R)-2,5-diphenylphospholano]methane}-cymene)ruthenium (II) Chloride
[0047]
[0048] Bis[(R,R)-2,5-diphenylphospholano]methane (214 mg, 0.43 mmol) and dichloro(p-cymene) ruthenium (II) dimer (133 mg, 0.22 mmol) were added to a Schlenk flask. Evacuated and filled with nitrogen (×5). Added DCM (2 ml) and ethanol (4 ml) and heated in an oil bath at 70° C. for 2 h. The solution was evaporated under reduced pressure and the residue was triturated with pentane (5 ml). The mixture was filtered and dried under vacuum to give a yellow-brown solid (343 mg, 100%).
[0049] 31 P NMR (162 MHz, CDCl 3 ) δ ppm 43.2 (d, J 83 Hz) and 29.9 (d, J 83 Hz). m/z (ESI) 763 (M-Cl, 100%), 593 (M-2Cl-cym, 93).
(iii) Dichloro-{1,2-Bis[(2R,5R)-2,5-diphenylphospholano]methane}[(1S,2S)-1,2-diphenylethylenediamine)] ruthenium (II)
[0050]
[0051] Chloro-{1,2-Bis[(2R,5R)-2,5-diphenylphospholano]methane} (p-cymene)ruthenium (II) chloride (320 mg, 0.40 mmol) and (1S,2S)-1,2-diphenylethylenediamine (85 mg, 0.40 mmol) were added to a Schlenk flask. Evacuated and filled with nitrogen (×5). Added THF (2 ml) and heated in an oil bath at 70° C. overnight. The solution was evaporated under reduced pressure to give a brown oil. Triturated with isopropanol (2 ml) and filtered. Washed with isopropanol (2×1 ml) and dried under vacuum to give the title compound as a yellow solid (265 mg, 75%).
[0052] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 7.53-7.47 (4H, m), 7.39 (4H, t, J 7 Hz), 7.31 (2H, t, J 7 Hz), 7.15-6.95 (16H, m), 6.85 (4H, m), 4.15-4.00 (4H, m), 3.45-3.35 (2H, m), 3.22 (2H, t, J 10 Hz), 2.85-2.73 (4H, m), 2.50-2.35 (2H, m), 2.28-2.10 (4H, m) and 1.95-1.80 (2H, m).
[0053] 13 C NMR (100 MHz, CDCl 3 ) δ ppm 143.6, 141.9, 140.4, 130.1, 129.0, 128.5, 128.1, 127.7, 127.1, 126.0, 125.9, 64.4, 62.7, 48.2, 44.4, 34.8, 33.8 and 25.4.
[0054] 31 P NMR (162 MHz, CDCl 3 ) δ ppm 50.2.
EXAMPLE 3
Asymmetric Hydrogenation Processes Using Transition Metal Catalyst Complexes of 1,2-bis[(R,R)-2,5-diphenylphospholano]methane
(i) Hydrogenation of Dimethyl Itaconate
[0055]
[0056] The reaction was carried out in an Argonaut Endeavor hydrogenation vessel. The glass liner was charged with dimethyl itaconate (1.58 g, 10.0 mmol) and 1,2-bis[(R,R)-2,5-diphenylphospholano]methane-(1,5-cyclooctadiene) rhodium(I) tetrafluoroborate (0.8 mg, 0.001 mmol, S/C 10000). Charged to 10 bar nitrogen and vented (×5). Added degassed methanol (4 ml). Charged to 10 bar nitrogen and vented (×2). Commenced stirring at 1000 rpm and heated to 30° C. Charged to 10 bar H 2 and monitored hydrogen uptake (reaction complete after 15 minutes). Cooled to room temperature, vented and evaporated to give (S)-2-methylsuccinic acid dimethyl ester, conversion 100%, ee 99.5% (Cbiraldex GTA, 15 m×0.25 mm, injector/detector 180° C., helium 14 psi, 90° C. for 6 min then ramp at 1° C./min to 105° C., retention times R 9.81 minutes, S 10.03 minutes).
(ii) Hydrogenation of methyl 2-acetamidoacrylate
[0057]
[0058] (S)-2-Acetylaminopropionic acid methyl ester, conversion >99%, ee >99% (Chirasil Dex CB, 25 m×0.25 mm, injector/detector 200° C., helium 20 psi, 130° C. for 10 minutes then ramp at 10° C./min to 200° C., retention times S 3.10 minutes, R 3.21 minutes).
(iii) Hydrogenation of 2-acetamidoacrylic Acid
[0059]
[0060] (S)-2-Acetylaminopropionic acid methyl ester, conversion >99%, ee >99% (derivatised using TMS-diazomethane and then analysed using the same method developed for the methyl ester).
(iv) Hydrogenation of Methyl Acetamidocinnamate
[0061]
[0062] (S)-2-Acetylamino-3-phenyl-propionic acid methyl ester, conversion 100%, ee 99% (Chirasil Dex CB, 25 m×0.25 mm, injector/detector 200° C., helium 20 psi, 150° C. for 25 minutes then ramp at 10° C./min to 200° C., retention times R 19.10 minutes, S 19.64 minutes).
(v) Hydrogenation of 2-(tert-Butoxycarbonyl-methyl-amino)-3-(3,4-dichloro-phenyl)acrylic Acid
[0063]
[0064] 2-(tert-Butoxycarbonyl-methyl-amino)-3-(3,4-dichloro-phenyl)-propionic acid, conversion 96%, ee 95% (HPLC, Chirobiotic R, 250 mm×4.6 mm, MeOH/0.1% TEA acetate pH 4.75 (40:60), 0.5 ml/min, ambient temperature, detection UV 230 nm, retention times 16.79 minutes and 21.53 minutes).
(vi) Hydrogenation of 2-Cyclohexylmethylene-succinic Acid 1-methyl Ester
[0065]
[0066] 2-Cyclohexylmethyl-succinic acid 1-methyl ester, conversion 100%, ee 91% (Chirasil Dex CB, 25 m×0.25 mm, injector/detector 200° C., helium 20 psi, 50° C. for 2 minutes then ramp at 10° C./min to 200° C., hold for 5 minutes, retention times 16.00 minutes and 16.06 minutes).
(vii) Hydrogenation of N-(1-phenylethylidene)aniline
[0067]
[0068] The reaction was carried out in a multiwell hydrogenation vessel. Dichloro-{1,2-Bis[(2R,5R)-2,5-diphenylphospholano]methane}[(1S,2S)-1,2-diphenylethylenediamine)] ruthenium (II) (2.2 mg, 0.0025 mmol) was suspended in degassed isopropanol (2 ml) in a Schlenk flask under nitrogen. Added potassium tert-butoxide (1M in tert-butanol, 0.025 ml) and heated until a yellow solution was obtained. The glass liner was charged with N-(1-phenylethylidene)aniline (98 mg, 0.50 mmol). Charged to 10 bar nitrogen and vented (×5). Added the precatalyst solution and charged to 10 bar nitrogen and vented (×2). Commenced stirring at 1000 rpm and heated to 60° C. Charged to 10 bar H 2 and stirred for 18 h. Cooled to room temperature, vented and evaporated to give phenyl-(1-phenylethyl)amine, conversion >99%, ee 71% (GC, sample derivatised by treatment with acetic anhydride pyridine, Chirasil DEX CB, 25 m×0.25 mm, injector/detector 200° C., helium 20 psi, 140° C. for 20 minutes then ramp at 5° C./min to 200° C., hold for 5 minutes, retention times 23.21 minutes and 23.45 minutes).
(viii) Hydrogenation of N-(1-phenylethylidene)benzylamine
[0069]
[0070] Benzyl-(1-phenylethyl)amine, conversion >99%, ee 82% (GC, sample derivatised by treatment with acetic anhydride pyridine, Chirasil DEX CB, 25 m×0.25 mm, injector/detector 200° C., helium 20 psi, 170° C. for 40 minutes then ramp at 15° C./min to 200° C., retention times 29.71 minutes and 30.73 minutes).
(iv) Hydrogenation of 1-methyl-6,7-dimethoxy-3,4-dihydroisoquinoline
[0071]
[0072] 6,7-Dimethoxy-1-methyl-1,2,3,4-tetrahydroisoquinoline, conversion >99%, ee 82% (GC, sample derivatised by treatment with acetic anhydride pyridine, Chirasil DEX CB, 25 m×0.25 mm, injector/detector 200° C., helium 20 psi, 170° C. for 20 minutes then ramp at 5° C./min to 200° C., hold for 10 minutes, retention times 30.18 minutes and 30.45 minutes).
EXAMPLE 4
Synthesis of 3,4-Bis[(S,S)-2,5-diphenyl-phospholan-1-yl]furan-2,5-dione
[0073]
[0074] (S,S)-1-hydroxy-1-oxo-2,5-trans-diphenylphospholane (600 mg, 2.20 mmol) was suspended in toluene (6 ml). The mixture was degassed by evacuation and filling with nitrogen (×5) and then heated in an oil bath at 110° C. (external temperature). Phenylsilane (0.54 ml, 4.41 mmol) was added in one portion and the mixture was heated for 2 h (during this time vigorous effervescence is observed and a clear solution forms). The solution was cooled to room temperature and the solvent was evaporated under reduced pressure. The crude phosphine was further dried under high vacuum (2.9 mbar, 60° C.). The residue was cooled to room temperature and dissolved in THF (3 ml) under nitrogen. Triethylamine (0.31 ml, 2.20 mmol) was added, followed by a solution of 2,3-dichloromaleic anhydride (167 mg, 1.00 mmol) in THF (2 ml). The mixture was heated in an oil bath at 60° C. (external temperature) and stirred for 18 h (dark purple solution forms). The solution was cooled to room temperature and solvent was evaporated under reduced pressure. The residue was chromatographed on silica, eluting with DCM/heptane (2:3) to give a deep red oil which solidified on standing (180 mg, 0.31 mmol, 31%).
[0075] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 7.51-7.34 (10H, m), 6.90 (4H, d, J 8 Hz), 6.80 (2H, t, J 7 Hz), 6.56 (4H, t, J 8 Hz), 4.60-4.53 (2H, m), 4.05-3.93 (2H, m), 2.73-2.61 (2H, m), 2.58-2.45 (2H, m), 2.44-2.35 (2H, m) and 1.97-1.85 (2H, m).
[0076] 13 C NMR (100 MHz, CDCl 3 ) δ ppm 161.7, 156.2 (m), 141.1 (t, J 11 Hz), 136.6, 127.1, 127.0, 126.9, 126.8, 125.0, 124.9, 124.7, 48.2 (d, J 7 Hz), 41.1 (d, J 5 Hz), 38.0 and 31.6.
[0077] 31 P NMR (162 MHz, CDCl 3 ) δ ppm 3.5.
EXAMPLE 5
Synthesis of 3,4-Bis[(S,S)-2,5-diphenyl-phospholan-1-yl]-furan-2,5-dione-(1,5-cyclooctadiene) rhodium(I) tetrafluoroborate
[0078]
[0079] (S,S)-Ph-Malphos (102 mg, 0.178 mmol) and [Rh(COD) 2 ]BF 4 (72 mg, 0.178 mg) were charged to a 25 ml Schlenk flask. The flask was evacuated and filled with nitrogen (×5). Degassed DCM (2 ml) was added (a dark brown solution forms) and the mixture was stirred overnight. The solvent was evaporated and the residue was triturated with degassed ether (3 ml). The solid was filtered under nitrogen, washed with degassed ether (2×2 ml) and dried to give the title compound as a brown solid (133 mg, 0.15 mmol, 86%).
[0080] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 7.41-7.36 (4H, m), 7.30-7.26 (6H, m), 7.22-7.18 (6H, m), 7.11-7.07 (4H, m), 5.68-5.62 (2H, m), 4.51-4.36 (4H, m), 4.00 (2H, dd, J 13, 6 Hz), 3.08-2.94 (2H, m), 2.66-2.43 (6H, m), 2.05-1.96 (2H, m), 1.82-1.71 (2H, m), 1.31 1.13 (4H, m).
[0081] 31 P NMR (162 MHz, CDCl 3 ) δ ppm 62.8 (d, J 154 Hz).
EXAMPLE 6
Synthesis of (S,S)-2,3-Bis(2,5-diphenyl-phospholan-1-yl)-quinoxaline
[0082]
[0083] (S,S)-2,5-trans-Diphenylphospholane-borane adduct (381 mg, 1.50 mmol) was dissolved in dry THF (3 ml) under nitrogen. The solution was cooled to −20° C. A solution of n-BuLi (2.5 M in hexanes, 0.6 ml, 1.50 mmol) was added dropwise and the mixture was stirred for 30 minutes (a yellow solution is formed). 2,3-Dichloroquinoxaline (136 mg, 0.68 mmol) was added in one portion and the residues were washed in with dry THF (1 ml) (the quinoxaline is only sparingly soluble in THF). The mixture was allowed to warm to room temperature (red/orange solution is observed). The reaction mixture was stirred overnight and then quenched with 1M aqueous HCl (5 ml) (effervescence was observed) and extracted with ethyl acetate (10 ml). The organic solution was washed with water (5 ml) and brine (5 ml), dried (MgSO 4 ), filtered and concentrated under reduced pressure. The residue was chromatographed on silica, eluting with DCM/heptane (2:3) to give a yellow solid (200 mg, 0.33 mmol, 48%).
[0084] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 8.11-8.06 (2H, m), 7.77-7.73 (2H, m), 7.36-7.21 (10H, m), 6.37 (2H, t, J 8 Hz), 6.29 (4H, d, J 8 Hz), 6.07 (4H, t, J 8 Hz), 4.53-4.46 (2H, m), 3.83-3.73 (2H, m), 2.58-2.45 (2H, m), 2.09-1.99 (4H, m) and 1.87-1.75 (2H, m).
[0085] 13 C NMR (100 MHz, CDCl 3 ) δ ppm 163.2 (br d), 144.2 (t, J 10 Hz), 141.2, 139.8, 129.4, 129.2, 129.1 (t, J 5 Hz), 128.1, 127.4, 126.9, 125.7, 125.4, 49.6 (t, J 10 Hz), 43.3, 37.9 and 33.7.
[0086] 31 P NMR (162 MHz, CDCl 3 ) δ ppm 9.1.
EXAMPLE 7
Synthesis of (S,S)-2,3-Bis(2,5-diphenyl-phospholan-1-yl)-(1,5-cyclooctadiene) rhodium(I) tetrafluoroborate
[0087]
[0088] 2,3-Bis[(S,S)-2,5-diphenyl-phospholan-1-yl]-quinoxaline (104 mg, 0.171 mmol) and [Rh(COD) 2 ]BF 4 (70 mg, 0.171 mg) were charged to a 25 ml Schlenk flask. The flask was evacuated and filled with nitrogen (×5). Degassed DCM (2 ml) was added (a deep red solution forms) and the mixture was stirred for 3 h. The solvent was evaporated and the residue was triturated with degassed ether (3 ml). The solid was filtered under nitrogen, washed with degassed ether (2×2 ml) and dried to give the title compound as an orange solid (119 mg, 0.13 mmol, 77%).
[0089] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 8.38 (2H, dd, J 6, 4 Hz), 8.15 (2H, dd, J 7, 4 Hz), 7.30-7.23 (6H, m), 7.02-6.93 (6H, m), 6.83-6.75 (8H, m), 5.75-5.69 (2H, m), 4.77-4.67 (2H, m), 4.33-4.26 (2H, m), 3.98-3.90 (2H, m), 3.09-2.97 (2H, m), 2.88-2.75 (2H, m), 2.61-2.47 (4H, m), 2.27-2.18 (2H, m), 1.93-1.81 (2H, m), 1.76-1.65 (2H, m) and 1.35-1.25 (2H, m).
[0090] 13 C NMR (100 MHz, CDCl 3 ) δ ppm 156.4 (t, J 49 Hz), 142.6, 138.6, 135.3, 134.1, 130.4, 129.3, 128.8, 128.3, 127.8 (d, J 11 Hz), 105.1 (m), 98.9 (m), 53.0 (t, J 8 Hz), 49.8 (t, J 10 Hz), 33.8, 31.9, 31.8 and 28.2.
[0091] 31 P NMR (162 MHz, CDCl 3 ) δ ppm 58.6 (d, J 151 Hz).
EXAMPLE 8
Synthesis of (R,R)-2,3-Bis(2,5-diphenyl-phospholan-1-yl)-pyrazine
[0092]
[0093] (R,R)-2,5-trans-diphenylphospholane-borane adduct (518 mg, 2.04 mmol) was dissolved in dry THF (3 ml) under nitrogen. The solution was cooled to −20° C. A solution of n-BuLi (2.5 M in hexanes, 0.82 ml, 2.04 mmol) was added dropwise and the mixture was stirred for 30 minutes (a yellow solution is formed) A solution of 2,3-dichloropyrazine (137 mg, 0.92 mmol) in THF (2 ml) was added and the solution was allowed to warm to room temperature (red/brown colour is observed instantly when the pyrazine is added). After 5 h, TMEDA (0.45 ml, 3.0 mmol, 1.5 eq.) was added and the mixture was stirred overnight. The reaction was quenched with 1M aqueous HCl (5 ml) and extracted with ethyl acetate (10 ml). The organic solution was washed with half saturated brine (10 ml), dried (MgSO 4 ), filtered and concentrated under reduced pressure. The residue was chromatographed on silica, eluting with ethyl acetate/heptane (1:8) to give the title compound as a yellow solid (105 mg, 0.19 mmol, 21%).
[0094] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 8.36 (2H, s), 7.35-7.21 (10H, m), 6.48 (2H, t, J 7 Hz), 6.40 (4H, d, J 8 Hz), 6.24 (4H, t, J 8 Hz), 4.27-4.20 (2H, m), 3.80-3.69 (2H, m), 2.54-2.43 (2H, m), 2.07-1.99 (4H, m) and 1.80-1.66 (2H, m).
[0095] 13 C NMR (100 MHz, CDCl 3 ) δ ppm 163.9 (br d), 144.6 (t, J 10 Hz), 142.4, 139.9, 129.4 (t, J 5 Hz), 128.5, 127.5 (m), 126.1, 125.9, 50.0 (t, J 10 Hz), 43.8, 38.9 and 33.5.
[0096] 31 P NMR (162 MHz, CDCl 3 ) δ ppm 7.2.
EXAMPLE 9
Synthesis of 2,3-Bis[(R,R)-2,5-diphenyl-phospholan-1-yl]-pyrazine-(1,5-cyclooctadiene) rhodium(I) tetrafluoroborate
[0097]
[0098] 2,3-Bis[(R,R)-2,5-diphenyl-phospholan-1-yl]-pyrazine (50 mg, 0.09 mmol) and [Rh(COD) 2 ]BF 4 (36 mg, 0.09 mmol) were charged to a Schlenk flask. The flask was evacuated and filled with nitrogen (×5). Degassed DCM (1 ml) was added (a deep red solution forms) and the mixture was stirred for 3 h. The solvent was evaporated and the residue was washed with degassed ether (4×2 ml) and dried to give the title compound as an orange solid (76 mg, 0.088 mmol, 98%).
[0099] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 9.10 (2H, br d), 7.26-7.12 (12H, m), 6.83 (4H, d, J 8 Hz), 6.76-6.73 (4H, m), 5.67-5.60 (2H, m), 4.56-4.46 (2H, m), 4.26-4.19 (2H, m), 3.85-3.78 (2H, m), 2.97-2.84 (2H, m), 2.79-2.65 (2H, m), 2.56-2.41 (4H, m), 2.24-2.14 (2H, m), 1.89-1.78 (2H, m), 1.73-1.62 (2H, m) and 1.30-1.20 (2H, m).
[0100] 13 C NMR (100 MHz, CDCl 3 ) δ ppm 158.3 (t, J 49 Hz), 147.5, 138.5, 135.2, 129.3, 129.1, 128.7, 128.1, 128.0, 127.7, 104.9 (m), 98.5 (m), 52.6 (t, J 8 Hz), 49.2 (t, J 11 Hz), 33.7, 31.8, 31.7 and 28.1.
[0101] 31 P NMR (162 MHz, CDCl 3 ) δ ppm 60.2 (d, J 151 Hz).
EXAMPLE 10
Synthesis of 1,1′-Bis[(R,R)-2,5-diphenyl-phospholan-1-yl]-ferrocene
(i) (2S,5S)-2,5-Diphenylphospholanoyl Chloride
[0102]
[0103] (2S,5S)-1-Hydroxy-1-oxo-2,5-trans-diphenylphospholane (5.0 g, 18.36 mmol) was placed in a flask. This was purged with nitrogen, then anhydrous dichloromethane (50 ml) was added. The suspension was cooled to 0-5° C., then oxalyl chloride (3.2 ml, 36.7 mmol) was added over 20 minutes. The suspension was stirred at 0-5° C. for 1 h, then allowed to warm to room temperature and stirred for 22 h. Anhydrous toluene (20 ml) was added to the solution, then the solvent was evaporated to give (2S,5S)-Diphenylphospholanoyl chloride as a white solid (5.38 g, quant.)
[0104] mp 133-136° C.
[0105] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 3.85-3.75 (1H, m), 3.73-3.63 (1H, m), 2.78-2.61 (1H, m), 2.59-2.42 (1H, m) and 2.37-2.19 (2H, m).
[0106] 13 C NMR (100 MHz, CDCl 3 ) 135.1 (d, J C-P =5.9 Hz), 134.2 (d, J C-P =6.4 Hz), 129.3 (d, J C-P =2.2 Hz), 129.2, 129.2 (d, J C-P =3.5 Hz), 128.3 (d, J C-P =4.6 Hz), 128.1 (d, J C-P =4.2 Hz), 128.0 (d, J C-P =3.9 Hz), 52.5 (d, J C-P =53.7 Hz), 51.7 (d, J C-P =68.1 Hz), 30.9 (d, J C-P =14.1 Hz) and 25.7 (d, J C-P =14.8 Hz).
[0107] 31 P NMR (162 MHz, CDCl 3 ) δ ppm+80.9.
[0108] Anal. Calcd for C 16 H 16 ClPO (290.73): C, 66.10; H, 5.55; Cl, 12.19. Found: C, 66.21; H, 5.53; Cl, 11.93.
(ii) (2S,5S)-2,5-Diphenylphospholane-1-oxide
[0109]
[0110] (2S,5S)-2,5-Diphenylphospholanoyl chloride (4.80 g, 16.5 mmol) was placed in a dry flask. This was purged with nitrogen, then anhydrous dichloromethane (38 ml) was added. The solution was cooled to −70° C., then DIBAL-H (1.0 M solution in dichloromethane, 17.3 ml) was added over 40 minutes. The solution was stirred at −70° C. for 1 h, then quenched with methanol (3.8 ml) over 15 minutes, after which the solution was allowed to warm to room temperature. 1 M citric acid (50 ml) was added, then the mixture was extracted with dichloromethane (2×20 ml). The combined organic layers were washed with brine (50 ml), which was back-extracted with dichloromethane (2×20 ml). The combined organic layers were dried (Na 2 SO 4 ), filtered, and the solvent was evaporated. The solid was dissolved in dichloromethane (15 ml) and heptane (60 ml) was added while stirring. The solid was collected by filtration and dried to give (2S,5S)-diphenylphospholane-1-oxide as a white solid (3.07 g, 73%).
[0111] mp 141-143° C.
[0112] [α] D 25 -61.4, c=1.02, CHCl 3 .
[0113] 1 H NMR (400 MHz, CDCl 3 ) δ ppm 7.41-7.26 (110H, m), 7.18 (1H, dq, J 470, 2.8 Hz), 3.63-3.52 (1H, m), 3.32-3.25 (1H, m), 2.70-2.49 (2H, m), 2.44-2.32 (1H, m) and 2.07-1.95 (1H, m).
[0114] 13 C NMR (100 MHz, CDCl 3 ) 136.8 (d, J C-P 2.8 Hz), 135.6 (d, J C-P 5.7 Hz), 129.6, 129.5, 129.2, 127.9 (d, J C-P 5.6 Hz), 127.7 (d, J C-P 2.1 Hz), 127.6 (d, J C-P 2.1 Hz), 48.9 (d, J C-P 60.0 Hz), 45.9 (d, J C-P 59.4 Hz), 33.4 (d, J C-P 7.2 Hz) and 33.4 (d, J C-P 10.9 Hz).
[0115] 31 P NMR (162 MHz, CDCl 3 ) δ ppm+55.2.
[0116] HRMS (ESI, M+Na) + : (m/z) calcd for C 16 H 17 PO: 279.091. Found 279.087.
(i) (2S,5S)-1-Chloro-2,5-Diphenylphospholane
[0117]
[0118] (2S,5S)-Diphenylphospholane-1-oxide (1.83 g, 1.95 mmol) was suspended in 40 mL of toluene and solution was cooled −40° C. To this suspension was added 3.92 g (28.6 mmol) of PCl 3 dissolved in 4 mL of toluene within 1 min. Solution was warmed to r.t. and stirred overnight resulting in formation of white sticky solid and colorless solution. Solution was transferred into another vessel and solvent was removed under reduced pressure leaving oily residue. Toluene was added (30 mL) and solvent was removed again under reduced pressure leaving 1.918 g of product as a colorless oil. Yield 97.8%.
[0119] 1 H NMR (C 6 D 6 , 23° C., 300 MHz): δ 6.97-715 (10H, m), 3.75 (1H, td, 3 J H-H 8.7 Hz, 2 J H-P 2.1 Hz), 3.11 (1H, ddd, 2 J H-P 33.6 Hz, 3 J H-H 12.6 Hz, 3 J H-H 6.0 Hz), 2.24-2.49 (2H, m), 1.97-2.08 (1H, m), 1.50-1.65 (1H, m).
[0120] 13 C NMR (C 6 D 6 , 23° C., 75 MHz): δ 141.92 (d, 2 J C-P =19.8 Hz, quat.), 137.09 (quat.), 129.05, 128.54, 128.51 (d, 3 J C-P 3.8 Hz), 128.01 (d, 3 J C-P 8.4 Hz), 126.82, 126.79, 58.16 (d, 2 J C-P 32.8 Hz), 53.64 (d, 2 J C-P 32.8 Hz), 34.68 (d, 3 J C-P 2.3 Hz), 31.91 (d, 3 J C-P 2.3 Hz).
[0121] 31 P NMR (C 6 D 6 , 23° C., 121, MHz): δ 137.687/137.656 in 2:1 ratio ( 35 Cl/ 37 Cl isotopic shift).
(iv) 1,1′-Bis[(2S,5S)-Diphenylphospholano]ferrocene
[0122]
[0123] To a 40 ml chilled (−40° C.) solution of (2S,5S)-1-chloro-2,5-diphenylphospholane (0.900 g, 3.28 mmol) in toluene was added 0.5145 g (1.64 mmol) of ferrocene dilithium TMEDA complex (J. J. Bishop, A. Davison, M. L. Katcher, D. W. Lichtenberg, R. E. Merrill and J. C. Smart, J. Organomet. Chem. 1971, 27, 241-249) as a solid. Reaction mixture was stirred at room temperature for 24 hr. Methylene chloride (10 ml) was added to the mixture to dissolve some of the product that crystallized. The 31 P{ 1 H} of this reaction mixture showed formation of the desired product in about 90% together with about 10% of mono-phosphine, (2S,5S)-diphenylphospholano]ferrocene). Solvent was removed under reduced pressure to give yellow-orange solid. Toluene was added (12 ml) and suspension was stirred for 1 hr. Yellow solid was collected on the frit, washed with 10 ml of hexane and dried under reduced pressure to give 0.76 g of clean product 8. Yield 70%.
[0124] 1 H NMR (C 6 D 6 , 23° C., 300 MHz): δ 7.47 (4H, dm, 3 J H-H 8.4 Hz, ortho 1 —H), 7.24 (4H, tm, 3 J H-H 7.8 Hz, meta 1 —H), 7.10 (2H, tm, 3 J H-H 7.7 Hz, para 1 —H), 6.92-6.99 (4H, m), 6.84-6.92 (6H, m), 4.08 (2H, m, Cp), 4.06 (2H, m, Cp), 3.75 (2H, m, Cp), 3.72 (2H, m, CH), 3.47 (2H, m, Cp), 3.30 (2H, m, CH), 2.47 (2H, m, CH 2 ), 1.95-2.18 (4H, m, CH 2 ), 1.64 (2H m, CH 2 ).
[0125] 13 C NMR (C 6 D 6 , 23° C., 75 MHz): δ 146.24 (d, 2 J C-P =18.9 Hz, quat.), 139.16 (quat.), 128.95 (meta-C), 128.46 (d, 3 J C-P 10.4 Hz, ortho-C), 128.09 (d, 3 J C-P 3.6 Hz, ortho-C), 127.96, 126.27 (para-C), 125.69 (para-C), 77.33 (d, J C-P 31.1 Hz, Cp), 76.02 (d, 1 J C-P 27.5 Hz, Cp, quat.), 72.67 (d, J C-P 7.9 Hz, Cp). 71.63 (s, Cp), 69.86 (d, J C-P 4.2 Hz, Cp), 50.07 (d, 2 J C-P 15.9 Hz, CH), 48.85 (d, 2 J C-P 14.6 Hz, CH), 39.20 (s, CH 2 ), 33.73 (d, 3 J C-P 3.6 Hz, CH 2 ).
[0126] 31 P NMR (C 6 D 6 , 23° C., 121 MHz): δ 12.19.
[0127] HSQC (C 6 D 6 , 23° C.): δ 128.95/7.24, 128.46/7.47, 128.09/(6.92-6.99), 127.96/(6.84-6.92), 126.27/7.10, 125.69/(6.92-6.99), 77.33/3.47, 72.67/3.75, 71.63/4.08, 69.86/4.06, 50.07/3.30, 48.85/3.72, 39.20/(2.47, 1.64), 33.73/(1.95-2.18).
[0128] HRMS (ESI, M+H) + :(m/z) calcd for C 42 H 41 FeP 2 : 663.203. Found 663.200. Anal. Calcd for C 42 H 40 FeP 2 (662.58): C, 76.14; H, 6.09. Found: C, 76.02; H, 5.88.
EXAMPLE 11
Synthesis of 1,1′-Bis[(2S,5S)-Diphenylphospholano]ferrocene(1,5-cyclooctadiene)rhodium(I) tetrafluoroborate
[0129]
[0130] 1,1′-Bis[(2S,5S)-2,5-diphenylphospholano]ferrocene 8 (0.354 g, 0.53 mmol) and Rh(COD) 2 BF 4 (0.2171 g, 0.53) were dissolved in 10 ml of CH 2 Cl 2 giving rise to red-orange solution. After stirring for 30 min. the 31 P{ 1 H} NMR showed clean formation of the desired complex. Solvent was reduced to about 1 ml and 0.5 ml of ether was added causing formation of orange-red crystals. After 30 min. more ether was added (1 ml) and solution was left standing for 2 hr. Solvent was decanted and the remaining crystals were washed with ether (2 ml) and then dried under reduced pressure to give 0.446 g of product as red-orange crystals. Crystals contain one molecule of methylene chloride Yield 79.8%.
[0131] 1 H NMR (CD 2 Cl 2 , 23° C., 300 MHz): δ ppm 7.81 (4H, m, ortho 1 —H), 7.40 (6H, m, meta 1 /para 1 ), 7.13 (6H, m, meta 2 /para 2 ), 6.68 (4H, d, 3 J H-H 7.5 Hz, ortho 2 —H), 5.59 (2H, br. t., 3 J H-H 6.9 Hz, COD), 4.50 (2H, br. COD), 4.42 (6H, m, Cp), 4.14 (2H, qm, J H-P 9.6 Hz, PCH), 3.60 (2H, m, Cp), 3.36 (2H, dd, J H-P 11.7 Hz, 3 J H-H 6.3 Hz, PCH), 2.61-2.80 (2H, m, PCHCH 2 ), 2.24-2.46 (4H, m, PCHCH 2 ), 1.70-2.50 (10H, m, PCHCH 2 /COD).
[0132] 13 C NMR (CD 2 Cl 2 , 23° C., 75 MHz): δ ppm 140.21 (t, J C-P 2.4 Hz, quat.), 136.29 (quat.), 129.17 (meta 1 ), 128.89 (t, J C-P 1.8 Hz, ortho 2 ), 128.76 (t, J C-P 3.7 Hz, ortho 1 ), 128.38 (meta 2 ), 128.13 (para 1 ), 127.28 (para 2 ), 98.41 (dt, J C-Rh =9.3 Hz, J C-P =2.4 Hz, COD), 89.57 (q, J 7.2 Hz, COD), 76.54 (dt, J 18.3 Hz, J=7.9 Hz, Cp), 75.38 (t, J C-P 4.3 Hz, Cp), 73.11 (Cp), 72.65 (t, J C-P 1.8 Hz, Cp), 70.92 (d, 1 J C-P 42.7 Hz, Cp, quat.), 49.72 (dt, J 20.7 Hz, J 8.5 Hz, PCH), 46.47 (dt, J 14.6 Hz, J 10.3 Hz, PCH), 35.35 (PCHCH 2 ), 33.23 (PCHCH 2 ), 33.13 (COD), 28.12 (COD).
[0133] HSQC (CD 2 Cl 2 , 23° C.): δ ppm 129.17/7.40, 128.89/6.68, 128.76/7.81, 128.38/7.13, 128.13/7.40, 127.28/7.13, 98.41/5.59, 89.57/4.50, 76.54/3.60, 75.38/4.42, 73.11/4.42, 72.65/4.42, 49.72/4.14, 46.47/3.30, 35.35/(2.70, 2.31), 33.23/(2.38, 2.18), 33.13/1.99, 28.12/1.85.
[0134] 31 P NMR (CD 2 Cl 2 , 23° C., 121 MHz): δ ppm 36.79 (d, 1 J P-Rh =146.5 Hz).
[0135] 19 F NMR (CD 2 Cl 2 , 23° C., 282 MHz): δ ppm −153.43.
[0136] HRMS (ESI, M + ): (m/z) calcd for C 50 H 52 FeP 2 Rh: 873.195. Found 873.194.
[0137] Anal. Calcd for C 51 H 54 FeCl 2 P 2 RhBF 4 : C, 58.60; H, 5.21. Found: C, 58.76; H, 5.17.
EXAMPLE 12
Asymmetric Hydrogenation Processes Using Transition Metal Catalyst Complexes of Examples 5, 7, 9 & 11
(i) General Procedures for Rhodium Catalysed Hydrogenations (Representative Procedures Employing the Complex of Example 5).
Hydrogenation of Dimethyl Itaconate
[0138]
[0139] The reaction was carried out in an Argonaut Endeavor hydrogenation vessel. The glass liner was charged with dimethyl itaconate (316 mg, 2.0 mmol) and 3,4-bis[(S,S)-2,5-diphenyl-phospholan-1-yl]-furan-2,5-dione-(1,5-cyclooctadiene) rhodium(I) tetrafluoroborate (1.7 mg, 0.002 mmol, S/C 1000). The vessel was charged to 10 bar nitrogen and vented (×5). Degassed methanol (4 ml) was added. The vessel was charged to 10 bar nitrogen and vented (×2). Stirring was commenced at 1000 rpm and the contents were heated to 25° C. The vessel was charged to 10 bar hydrogen. Hydrogen uptake was complete after 16 h. The mixture was vented and evaporated to give (S)-2-methylsuccinic acid dimethyl ester, conversion 100%, ee 96.6% (Chiraldex GTA, 30 m×0.25 mm, injector/detector 180° C., helium 14 psi, 90° C. for 6 min then ramp at 1° C./min to 105° C., retention times S 10.11 minutes, R 10.48 minutes). In comparison, much lower enantioselectivity, of 60.2% ee, is reported by Holz, J. et al, ibid., for the same transformation, at S/C 100 in methanol, catalysed by the corresponding rhodium complex of Me-Malphos [i.e. the analogue of ligand (7) with Me groups at the 2- and 5-position of each phospholane ring]. Holz, J. et al also report that a change of solvent, to THF, increases the enantioselectivity to 86% ee but this still falls short of the 96.6% ee achieved in the current example at a higher S/C ratio.
[0000] Hydrogenation of methyl 2-acetamidoacrylate
[0000]
[0140] (R)-2-Acetylaminopropionic acid methyl ester, conversion 100%, ee 99.7% (Chirasil Dex CB, 25 m×0.25 mm, injector/detector 200° C., helium 20 psi, 130° C. for 10 minutes then ramp at 15° C./min to 200° C., retention times S 2.91 minutes, R 2.98 minutes).
Hydrogenation of Methyl Acetamidocinnamate
[0141]
[0142] (R)-2-Acetylamino-3-phenyl-propionic acid methyl ester, conversion 100%, ee 98.8% (Chirasil Dex CB, 25 m×0.25 mm, injector/detector 200° C., helium 20 psi, 150° C. for 21 minutes then ramp at 15° C./min to 200° C., hold for 5 minutes, retention times R 17.65 minutes, S 17.92 minutes).
[0143] 2-Acetamidoacrylic acid and acetamidocinnamic acid were hydrogenated using the same general procedure, derivatised using TMS-diazomethane and analysed using the same method described for the corresponding methyl esters.
[0144] Similar procedures were applied in the screening of transition metal catalyst complexes of examples 7, 9 & 11. The following are specific procedures demonstrating the catalytic utility of the transition metal complex of example 11.
[0000] Hydrogenation of Methyl 2-acetamido-3,3-diphenylacrylate
[0000]
[0145] (R)-2-Acetylamino-3,3-diphenylpropionic acid methyl ester, reaction time 6 h, conversion 100%. [α] D 25 -101.6 (c=1.02, CHCl 3 ). ee 80.7% (SFC, 2×Chiralpak AD-H columns, 10% methanol, 3000 psi CO 2 , 35° C., flow rate 3 ml/minute, retention times R 5.2 minutes, S 10.1 minutes). Comparative examples have been disclosed by Boulton (Boulton, L. T., WO 2006127273).
[0000] Hydrogenation of (E)-2-Methylcinnamic Acid tert-butylamine Salt
[0000]
[0146] (R)-2-Methyl-3-phenylpropionic acid tert-butylamine salt, reaction time 40 minutes, conversion 100%. The free acid was liberated by partitioning between dichloromethane and 2M HCl. The organic layer was dried (Na 2 SO 4 ), filtered and the solvent was evaporated, then the product was distilled (kugelrohr, 150° C., 0.5 mbar) to give (R)-2-Methyl-3-phenylpropionic acid as a colorless liquid. [α] D 25 -22.7, c=1.02, CHCl 3 . Lit. (E. Tyrell, M. W. H. Tang, G. A. Skinner and J. Fawcett, Tetrahedron, 1996, 52, 9841-9852, [α] D 20 -23.1 c=1, CHCl 3 ). ee 85% (derivatised using TMS-diazomethane, Chirasil Dex CB column, 25 m×0.25 mm, injector/detector 200° C., helium 20 psi, 100° C. for 21 minutes then ramp at 15° C./min to 200° C., hold for 5 minutes, retention times R 30.40 minutes, S 31.06 minutes, (E)-methyl 2-methylcinnamate, 34.79 minutes). 1 H NMR analysis of the (S)-methyl mandelate (E. Tyrell, M. W. H. Tang, G. A. Skinner and J. Fawcett, Tetrahedron, 1996, 52, 9841-9852) confirmed assignment of (R)-configuration.
[0000] Hydrogenation of (E)-2-phenylcinnamic Acid tert-butylamine Salt
[0000]
[0147] (S)-2-Methyl-3-phenylpropionic acid tert-butylamine salt, reaction time 40 minutes, conversion 100%, ee 96.5% (SFC, 2×Chiralpak AD-H columns, 10% methanol, 3000 psi CO 2 , 35° C., flow rate 3 ml/minute, retention times R 7.1 minutes, S 7.7 minutes, (E)-phenylcinnamic acid 12 minutes). The free acid was liberated by partitioning between dichloromethane and 2M HCl. The organic layer was dried (Na 2 SO 4 ), filtered and the solvent was evaporated to give (R)-2-Methyl-3-phenylpropionic acid as a pale yellow solid. [α] D 20 +98.6, c=2.03, CHCl 3 . [α] D 20 +100.6, c=0.54, acetone. [α] D 20 +103.5 (c=1.00, MeOH). Lit. (M. B. Watson and G. W. Youngson, J. Chem. Soc. C, 1968, 258-261; +140.8, c=2.04, CHCl 3 ). 1 H NMR analysis of the (S)-methyl mandelate (E. Tyrell, M. W. H. Tang, G. A. Skinner and J. Fawcett, Tetrahedron, 1996, 52, 9841-9852) confirmed assignment of (S)-configuration.
Hydrogenation of (E)-2-Isopropyl-3-(2-(3-methoxy(propyloxy)-4-methoxyphenyl)acrylic Acid tert-butylamine Salt
For Preparation, see P. Herold, P and S. Stutz, S, WO 2002002500
[0148]
[0149] (S)-2-Isopropyl-3-(2-(3-methoxy(propyloxy)-4-methoxyphenyl)propionic acid tert-butylamine salt, reaction time 1 h, conversion 100%, ee 84.6% (SFC, 2×Chiralpak AD-H columns, 10% methanol, 3000 psi CO 2 , 35° C., flow rate 3 ml/minute, retention times S 4.6 minutes, R 5.0 minutes). The free acid was liberated by partitioning between dichloromethane and 2M HCl. The organic layer was dried (Na 2 SO 4 ), filtered and the solvent was evaporated to (S)-2-Isopropyl-3-(2-(3-methoxy(propyloxy)-4-methoxyphenyl)propionic acid as a pale yellow oil. [α] D 20 −33.0, c=1.01, CH 2 Cl 2 . Lit. (enantiomer, R. Goeschke, S. Stutz, W. Heizelmann and J. Maibaum, Helv. Chim. Acta, 2003, 86, 2848-2870); [α] D 20 +42.5, c=1.0, CH 2 Cl 2 . Comparison with a sample made using (R)-WalPhos (T. Sturm, W. Weissensteiner and F. Spindler, Adv. Synth. Catal., 2003, 455, 160-164) using the assay above confirmed assignment of (R)-configuration.
[0000] (ii) Summary of Asymmetric Hydrogenation Screening with the Transition Metal Catalyst Complex of Example 7.
[0000] Conv. ee Substrate S/C Conditions (%) (%) 1000 MeOH,25° C., 10 barH 2 , 15 mins 100 99.8(S) 1000 MeOH,25° C., 10 barsH 2 , 10 mins 100 99.9(R) 1000 MeOH,25° C., 10 barH 2 , 10 mins 100 98.7(R) 1000 MeOH,30° C., 10 barH 2 , 20 mins 100 >99.5(R) 1000 MeOH,30° C., 10 barH 2 , 25 mins 100 99.5(R)
(iii) Summary of Asymmetric Hydrogenation Screening with the Transition Metal Catalyst Complex of Example 9.
[0000] Conv. ee Substrate S/C Conditions (%) (%) 1000 MeOH,25° C., 10 barH 2 , 18 h 98 78(R) 1000 MeOH,25° C., 10 barH 2 , 18 h 94 94(R)
(iv) Summary of Asymmetric Hydrogenation Screening with the Transition Metal Catalyst Complex of Example 11.
[0000] Conv. ee Substrate S/C Conditions (%) (%) 1000 MeOH, 25° C., 10 barH 2 , 100 mins 100 29(R) 1000 MeOH, 25° C., 10 barH 2 , 80 mins 100 49(R) 1000 MeOH, 30° C., 10 barH 2 , 15 mins 100 56(R) 250 MeOH, 30° C., 10 barH 2 , 40 mins 100 80.7 1000 MeOH, 30° C., 10 barH 2 , 40 mins 100 85(R) 1500 MeOH, 25° C., 10 barH 2 , 40 mins 100 96.5(S) 1000 MeOH, 25° C., 10 barH 2 , 1 h 100 84.6(S)
(v) Comparative Examples for the Transition Metal Catalyst Complex of Example 11 with Substrate Below Using [L Rh(COD)] + Complexes of Different Ligands.
[0000] Conv. ee Ligand S/C Conditions (%) (%) (R,R)-Me-5-Fc 1000 MeOH, 100 52 (R) 25° C., 10 bar H 2 , 18 h. (R,R)-Et-5-Fc 1000 MeOH, 100 45 (R) 25° C., 10 bar H 2 , 18 h. (R,R)-iPr-5-Fc 1000 MeOH, 100 69 (S) 25° C., 10 bar H 2 , 18 h. (R,R)-Ph-BPE 1000 MeOH, 65 25 (S) 25° C., 10 bar H 2 , 18 h. (S,S)-ligand of example 6 1000 MeOH, 10 0 (complex of example 7) 25° C., 10 bar H 2 , 18 h.
(vi) Comparative Examples for the Transition Metal Catalyst Complex of Example 11 with Substrate Below Using [L Rh(COD)] + Complexes of Different Ligands.
[0000] Conv. ee Ligand S/C Conditions (%) (%) (R,R)-Me-5-Fc 1000 MeOH, 100 46 (S) 25° C., 10 bar H 2 , 18 h. (R,R)-Et-5-Fc 1000 MeOH, 100 65 (S) 25° C., 10 bar H 2 , 18 h. (R,R)-Pr-5-Fc 1000 MeOH, 65 65 (R) 25° C., 10 bar H 2 , 18 h. (R,R)-Ph-BPE 1000 MeOH, 50 20 (R) 25° C., 10 bar H 2 , 18 h. (S,S)-ligand of example 6 1000 MeOH, 5 11 (R) (complex of example 7) 25° C., 10 bar H 2 , 18 h.
(vii) Comparative Examples for the Transition Metal Catalyst Complex of Example 11 with Substrate Below Using [L Rh(COD)] + Complexes of Different Ligands.
[0000]
Conv.
ee
Ligand
S/C
Conditions
(%)
(%)
(S,S)-Me-DuPhos
250
MeOH, 25° C., 10 bar
34
0
H 2 , 16 h.
(S,S)-Me-5-Fc
250
MeOH, 25° C., 10 bar
100
61
H 2 , 16 h.
(S,S)-Et-5-Fc
250
MeOH, 25° C., 10 bar
100
57
H 2 , 16 h.
(S,S)-iPr-5-Fc
250
MeOH, 25° C., 10 bar
100
69
H 2 , 16 h.
(R,R)-Ph-BPE
250
MeOH, 25° C., 10 bar
100
25
H 2 , 16 h.
EXAMPLE 13
Asymmetric Hydroformylation Processes
[0150] Hydroformylation solutions were prepared by addition of ligand and Rh(CO) 2 (acac) stock solutions to toluene solvent followed by addition of olefin solution. Total amount of liquids in each reactor cell was 4.5 ml. Ligand solutions (0.03 M for bidentate ligands and Rh(CO) 2 (acac) (0.05 M) were prepared in the dry box by dissolving appropriate amount of compound in toluene at room temperature. The allyl cyanide solution was prepared by mixing 15.3206 g of allyl cyanide, 3.2494 g of dodecane (as a GC internal standard) and 6.3124 g of toluene (1:0.1:0.3 molar ratio). The styrene solution was prepared by mixing 14.221 g of styrene and 6.978 g of dodecane (1:0.3 molar ratio). The vinyl acetate solution was prepared by mixing 13.426 g of vinyl acetate and 7.969 g of dodecane (1:0.3 molar ratio). The styrene:allyl cyanide:vinyl acetate:dodecane solution was prepared by mixing 11.712 g of styrene, 7.544 g of allyl cyanide, 9.681 g of vinyl acetate and 5.747 g of dodecane (1:1:1:0.3 molar ratio).
[0151] Hydroformylation reactions were conducted in an Argonaut Endeavor® reactor system housed in an inert atmosphere glove box. The reactor system consists of eight parallel, mechanically stirred pressure reactors with individual temperature and pressure controls. Upon charging the catalyst solutions, the reactors were pressurized with 150 psi of syn gas (H 2 :CO 1:1) and then heated to the desired temperature while stirring at 800 rpm. The runs were stopped after 3 hrs by venting the system and purging with nitrogen.
[0152] The substrate to catalyst ratio was 3,000:1. 56 μL of 0.05 M Rh(CO) 2 (acac) stock solutions was mixed with 187 μL of 0.03 M ligand stock solution followed by addition of 1 ml of olefin mixture solution. Solution was pressurized at 150 psi with syngas and heated at 80° C. for 3 hr. Syn gas pressure was maintained at 150 psi (gas on demand) throughout the reaction.
[0153] After 3 hrs reactors were cooled and vented. Upon opening the reactor sample from each reactor was taken out and diluted with 1.6 ml of toluene, and this solution was analyzed by gas chromatography. For analysis of styrene and vinyl acetate products Supelco's Beta Dex 225 column was used. Temperature program of 100° C. for 5 min, then 4° C./min to 160° C.; retention times: 2.40 min for vinyl acetate, 6.76 (R) and 8.56 (S) min for the enantiomers of the acetic acid 1-methyl-2-oxo-ethyl ester (branched regioisomer), 11.50 min for acetic acid 3-oxo-propyl ester (linear regioisomer), 12.11 (R) and 12.34 (S) min for the enantiomers of 2-phenyl-propionaldehyde (branched regioisomer) and 16.08 min for 3-phenyl-propionaldehyde (linear regioisomer).
[0154] For allyl cyanide product analysis Astec Chiraldex A-TA column was used. Temperature program of 90° C. for 7 min, then 5° C./min to 180° C.; retention times: 5.55 min for allyl cyanide, 14.79 (S) and 15.28 (R) min for the enantiomers of the 3-methyl-4-oxo-butyronitrile (branched regioisomer), and 19.46 for the 5-oxo-pentanenitrile (linear regioisomer).
[0155] The following table shows Percent conversion (Conv.), branched:linear ratio (b:1), and enantioselectivity (% e.e.) for hydroformylation of styrene, allyl cyanide, and vinyl acetate with chiral phosphorus ligands. Note that Ligand 7 shows remarkably improved results as compared to the similar compound having methyl substituents rather than phenyl substituents.
[0000]
Styrene
Allyl cyanide
Vinyl acetate
Ligand
Conv
b:l
% e.e.
Conv
b:l
% e.e.
Conv.
b:1
% e.e.
7
43
38.5
90(S)
76
8.1
81(S)
48
111
68(S)
9
98
36.4
90(S)
100
6.0
77(R)
96
190
70(S)
8
95
39.7
90(R)
100
7.1
79(R)
92
221
69(S)
6*
12
20
1(S)
44
4.5
2(S)
24
603
24(R)
Comparative
9
14
49(S)
31
6.1
38(S)
16
75
30(R)
example
similar to (7) but
with methyl groups
in the place of the
phenyl groups
*0.5 ml of olefin mixture solution was used and L:Rh was 1.2
|
The invention is a set of novel bisphospholane ligands that can be complexed with transition metals. These complexes are useful as catalysts in asymmetric reactions such as asymmetric hydrogenation.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATIONS
None
FIELD
The present disclosure relates to fasteners for clothing and other apparel items.
BACKGROUND
Fasteners for clothing include zippers, buttons, hook-and-eye fasteners, snap closures, and hook-and-loop fasteners. While these conventional fasteners are adequate for some applications, they have physical limitations that reduce their usefulness and applicability to some clothing and apparel. On the other hand, clothing without fasteners, for example pants with an elastic waistband, relies on the elasticity of the clothing but may sacrifice fit and durability as a result.
SUMMARY
Accordingly, a closure system for apparel and non-apparel items is provided for improved fit comfort, convenience, and functionality.
One example of a closure may comprise a male component comprising a first flange and a plurality of male projections arranged along a first line. Each male projection may comprise a stem having a first base and a first head connecting with the flange at the first base of the stem, and a locking portion, having a second base and a second head, the second base being wider than the stem and the second head, connecting with the first head at the second base. The closure may also comprise a female component comprising a second flange and plurality of female projections arranged along a second line. The interrelationship of flanges on the male components, and the female components permits the closure system to be engaged even if the male components and the female components are slightly off-registration with each other, thereby facilitating use of the closure system. Each of the female projections may comprise a first female stem and a second female stem arranged on opposite sides of the second line, forming a receiving area to fit the locking portion. The first female stem may further comprise a first hooked portion and the second female stem may comprise a second hooked portion, such that the first hooked portion and the second hooked portion face each other to fit the locking portion.
In addition, the plurality of male projections of the male component may comprise a notch in each male projection along the first line extending from the second head of the locking portion through the stem to the first base. The plurality of male projections of the male component may be hooked at the second based of the locking portion to fit the receiving area. The receiving area may comprise an inner surface, and the locking portion may comprise an outer surface. In one example, the outer surface may have a texture that grips the inner surface of the receiving area. In another example, the inner surface may have a texture that grips the outer surface of the locking portion. In another example, the inner surface and the outer surface may be substantially smooth such that when the locking portion may be within the receiving area, the male component and the female component may slide while fastened.
One example of a fastener may comprise a male component comprising a first flange and a plurality of projections arranged on a first line. Each projection may comprise a stem having a first base and a first head, connecting with the flange at the first base of the stem, and a locking portion, having a second base and a second head, the second base being wider than the stem and the second head, connecting with the first head at the second base. The fastener also may comprise a female component comprising a second flange and a pair of rails comprising a first rail and a second rail arranged on opposite sides of a second line. The pair of rails each may have a hooked portion extending towards each other forming a receiving area of the locking portion of the male component.
Additionally, the pair of rails of the female component may comprise a plurality of notches through the pair of rails to the second flange and perpendicular to the second line. The plurality of projections of the male component may comprise a notch in each male projection along the first line extending from the second head of the locking portion through the stem to the first base. The receiving area may comprise an inner surface and the locking portion may comprise an outer surface. The outer surface may have a texture that grips the inner surface of the receiving area. The inner surface of the receiving area may have a texture that grips the outer surface of the locking portion. The outer surface of the locking portion and the inner surface of the receiving area may be substantially smooth such that when the locking portion may be within the receiving area, the male component and the female component may slide while fastened.
In an additional example, the fastener may comprise a male track comprising a first flange and a first rail arranged along a first line. The first rail may extend substantially the length of the first line and may have a first base and a first head, connecting with the flange at the first base of the first rail. The first rail further may comprise a locking portion having a second base and a second head. The second head may be wider than the first base and the second head and connects with the first head at the second base. The female track of the fastener may comprise a second flange and a pair of rails comprising a second rail and a third rail arranged on opposite sides of a second line. The pair of rails may have a pair of hooks projections extending towards each other forming a receiving area for the locking portion of the first rail.
In addition, the pair of rails of the female flange of the fastener may comprise a plurality of notches perpendicular to the second line and through the pair of rails to the second flange. The first rail of the male track may comprise a plurality of first notches perpendicular to the first line and through the first rail to the first flange. The first rail of the male track may comprise a plurality of second notches perpendicular to the first notches along the first line and through the first rail to the first flange. The pair of rails of the female track may comprise a plurality of notches perpendicular to the second line and through the pair of rails to the second flange. The first rail of the male track may comprise a hooked portion of the second base to fit the receiving area of the female track. The receiving area of the fastener may have an inner surface. The locking portion of the fastener may have an outer surface. The outer surface of the locking portion may have a texture that grips the inner surface of the receiving area. The inner surface of the receiving area may have a texture that grips the outer surface of the locking portion. In another example, the outer surface of the locking portion and the inner surface of the receiving area may be substantially smooth such that when the locking portion may be within the receiving area, the male track and the female track may slide while fastened.
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
FIG. 1 is an illustration of a female component or female track.
FIG. 2 is an illustration of a female component or female track.
FIG. 3 is an illustration of a male component or male track.
FIG. 4 is an illustration of a male component or male track.
FIG. 5 is an illustration of a male component or male track.
FIG. 6 is an illustration of a male component or male track.
FIG. 7A-B is an illustration of a fastened male component and female component.
FIG. 8A-B is an illustration of a fastened male component and female component.
FIG. 9A-B is an illustration of a fastened male component and female component.
FIG. 10A-B is an illustration of a fastened male component and female component.
FIG. 11A-B is an illustration of a fastened male component and female component.
FIG. 12A-B is an illustration of a fastened male component and female component.
FIG. 13A-B is an illustration of a fastened male component and female component.
FIG. 14A-B is an illustration of a fastened male component and female component.
FIG. 15 is an illustration of apparel employing a track snap closure in various locations.
FIGS. 16A-D are illustrations of additional closure or fastener profiles.
FIGS. 17A-D are illustrations of additional closure of fastener profiles.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
The track snap closure described herein may be employed to hold together seams edges or surface of apparel or clothing applications. The track snap closure provides a quick and simple fastening means that does not require perfect registration between components of the male track and components of the female track. Moreover, the track snap closure provides improves comfort and aesthetics due to the flexibility and low profile of the male track and female track.
Generally, the spacing and relative dimensions illustrated in the figures may not be to scale. Any proportion of spacing and track snap closure component dimension may be contemplated to fit the track snap closure application desired. Also, generally, FIGS. 1-14 illustrate examples of a track snap closure having sharp edged portions or angled edges for the male and female track components. However, it will be understood that the components of the male and female track may also have rounded portions or curved/blunted edges, which may be employed to prevent snagging and/or increase robustness of the components.
FIG. 1 provides one example of a female component or track of a track snap closure. The female component may have a flange 100 and a pair of rails 101 , 102 arranged on opposite sides of a line 103 . The pair of rails 101 , 102 may have hooked projections 104 , 105 that extend toward each other to form a receiving area 106 . The flange 100 may be constructed separately or integrally with the pair of rails 101 , 102 and may be made of the same or different material. For example, the entire female component or track may be injected molded of one polymer resin. In another example, the flange 100 may be made of a plastic that may be more flexible and the pair of rails 101 , 102 may be made of a plastic that may be more wear-resistant.
FIG. 2 may be another example of a female component or track of a track snap closure. The female component may have a flange 200 and a plurality of female projections 201 arranged along a line 202 . Each female projection 203 may have a pair of stems 204 including a hooked portion 205 of each stem facing each other to form a receiving area 206 . Alternately, the female component or track may be a flange 200 and a pair of rails 201 arranged on opposite sides of a line. The pair of rails may have a hooked portion 205 facing each other to form a receiving area 206 . The female component or track may have a plurality of notches 207 perpendicular to the line and through the pair of rails. The plurality of notches may extend completely through the rails to the flange or may only extend partially through the rails. Alternately, the female component may be a plurality of female projections arranged along a line. Each female projection may form a receiving area to fit a locking portion of a male component or projection. The receiving area may have a hooked appearance or may be another geometry depending on the need of the track snap closure application. The spacing illustrated may be arbitrary and any spacing between the projections may be contemplated to meet the needs of the track snap closure. The flange may be constructed separately or integrally with the pair of rails and may be made of the same or different material.
FIG. 3 may be one example of a male component or track of a track snap closure. The male component may comprise a flange 300 and a rail 301 arranged along a line 302 . The rail may have a first base 303 and a first head 304 connecting with the flange 300 at the base 303 . The rail also may comprise a locking portion 302 having a second base 305 and a second head 306 , the second base 305 being wider than the first base 303 and the second head 306 , connecting with the first head 304 at the second base. The locking portion 307 of the male component may snap into the receiving area of the female component or track. As shown in FIG. 3 , the locking portion 307 may have a hooked portion to secure the locking portion within the receiving area. Alternately, the locking portion may be flat at the second base to provide a slideable fastening. The locking portion of the male component and the receiving area of the female component may be molded or machined to complement each other. The flange may be constructed separately or integrally with the rail and may be made of the same or different material.
FIG. 4 may be another example of a male component or track of a track snap closure. The male component may comprise a flange 400 and a rail 401 arranged along a line 402 . The rail 401 may have a first base 403 and a first head 404 connecting with the flange 400 at the base 403 . The rail 401 also may comprise a locking portion 405 having a second base 406 and a second head 407 , the second base 406 being wider than the first base 404 and the second head 407 , connecting with the first head at the second base. The locking portion 405 of the male component snaps into the receiving area of the female component or track. The rail also may comprise a notch 408 extending down the line 402 or central line of the rail. For example, the notch may divide the rail in half to form two rails. The notch may extend through the rail to the flange or may extend partially through the rail. In another example, a male component may comprise a flange and two rails arranged closely along a line. The space between two rails may be substantially smaller than the width of either rail. Each rail may have a base and a head connecting with the flange at the base. The two rails together form a locking portion having a second base and a second head. The base of the locking portion being wider at the base than at the second head. The flange may be constructed separately or integrally with the rail and may be made of the same or different material.
FIG. 5 may be another example of a male component or track of a track snap closure. In FIG. 5 , one example of a male component may comprise a flange 500 and a plurality of male projections 501 arranged substantially along a line 507 . Each male projection 501 may comprise a stem with a first base 502 and a first head 503 . Each male projection connects with the flange 500 at the first base 502 . In addition, each male projection 501 may have a locking portion 506 having a second base 504 wider than the first base 502 of the stem and wider than the head of the locking portion 506 . In another example, a male component may comprise a flange 500 and a rail 508 arranged along a line 507 . The rail may have a base and a head connecting with the flange at the base. The rail also may comprise a locking portion having a second base and a second head, the second base being wider than the first base and the second head, connecting with the first head at the second base. The locking portion of the male component snaps into the receiving area of the female component or track. The rail also may comprise a plurality of notches 509 perpendicular to the rail or line 507 to divide the rail or track into sections or individual male projections. The notches may extend through the rail to the flange or may extend partially through the rail. The flange may be constructed separately or integrally with the rail and may be made of the same or different material. The locking portion may have a hooked appearance or may be another geometry depending on the need of the track snap closure application. The spacing of the sections or projections illustrated may be arbitrary and any spacing between the projections may be contemplated to meet the needs of the track snap closure.
FIG. 6 may be another example of a male component or track of a track snap closure. The male component may comprise a flange 600 and a rail 601 arranged along a line. The rail 601 may have a base 602 and a head 603 connecting with the flange at the base. The rail 601 also may comprise a locking portion 606 having a second base 604 and a second head 605 , the second base 604 being wider than the first base 602 and the second head 605 , connecting with the first head 603 at the second base 604 . The locking portion 606 of the male component snaps into the receiving area of the female component or track. The rail 601 also may comprise a notch 607 extending down the line or central line of the rail. For example, the notch 607 may divide the rail in half to form two rails. The notch may extend through the rail to the flange or may extend partially through the rail. The rail also may comprise a plurality of notches 608 perpendicular to the rail or the notch 607 to divide the rail or track into sections or individual male projections. The notches may extend through the rail to the flange or may extend partially through the rail. Another example of a male component may comprise a flange and a plurality of male projections arranged along a line. Each male projection may comprise a stem with a first base and a first head. Each male projection connects with the flange at the first base. In addition, each male projection may have a locking portion having a second base wider than the stem and wider than the head of the locking portion. Each male projection may have a notch perpendicular to the line: the notch may extend through the projection to the flange or may extend partially through the projection. The flange may be constructed separately or integrally with the rail and may be made of the same or different material. The locking portion may have a hooked appearance or may be another geometry depending on the need of the track snap closure application. The spacing of the sections or projections illustrated may be arbitrary and any spacing between the projections may be contemplated to meet the needs of the track snap closure.
FIG. 7A-B illustrates one example of a track snap closure with the male component 701 or track and the female component 700 or track assembled. As shown in FIG. 7A , the receiving area 703 of the female component and the locking component 702 of the male component fit together or snap together. FIG. 7B illustrates a female component 704 such as the example in FIG. 1 and the male component 705 similar to the example in FIG. 3 . The two continuous tracks may be fastened by snapping together or by sliding the male component 705 down the female track 704 . Generally, the male component and the female component may be molded or machined of the same or different material.
FIG. 8A-B illustrates another example of a track snap closure with the male component 801 or track and the female component 800 or track assembled. FIG. 8A-B illustrates a male component similar to FIG. 4 and a female component similar to FIG. 1 . As shown in FIG. 8A , the receiving area 803 of the female component and the locking component 802 of the male component fit together or snap together. The two tracks may be fastened either by snapping the male component 806 into the female component 805 or by sliding the male component 806 down the female track 805 . The notch in the male component may provide some “give” in the snap closure.
FIG. 9A-B illustrates another example of a track snap closure with the male component or track and the female component or track assembled. FIG. 9A-B illustrates a male component similar to FIG. 5 and a female component similar to FIG. 1 . As shown in FIG. 9A , the receiving area 902 of the female component 900 and the locking component 903 of the male component 901 fit together or snap together. The two tracks may be fastened either by snapping the male component 905 into the female component 904 or may be fastened by snapping individual male projections 906 or sections of the male component 905 into the female component 904 . The sectioned or notched male component may provide additional flexibility to the track snap closure. For example, it would be possible to form the male component of the track snap closure with a harder plastic without sacrificing comfort and flexibility.
FIG. 10A-B illustrates another example of a track snap closure with the male component or track and the female component or track assembled. FIG. 10A-B illustrates a male component similar to FIG. 6 and a female component similar to FIG. 1 . As shown in FIG. 10A , the receiving area 1002 of the female component 1000 and the locking component 1003 of the male component 1001 fit together or snap together. The two tracks may be fastened either by snapping the male component 1006 into the female component 1005 or may be fastened by snapping individual male projections or sections of the male component 1006 into the female component 1005 . The sectioned or notched male component 1006 may provide additional flexibility to the track snap closure.
FIG. 11A-B illustrates another example of a track snap closure with the male component or track and the female component or track assembled. FIG. 11A-B illustrates a male component similar to FIG. 3 and a female component similar to FIG. 2 . In the configuration illustrated in FIG. 11B , the female component may be notched into individual female projections. As shown in FIG. 11A , the receiving area of the female component and the locking component of the male component fit together or snap together. The two tracks may be fastened either by snapping the male component into the entire female component or by snapping the male component into the individual female projections.
FIG. 12A-B illustrates another example of a track snap closure with the male component or track and the female component or track assembled. FIG. 12A-B illustrates a male component similar to FIG. 4 and a female component similar to FIG. 2 . In the configuration illustrated in FIG. 12B , the female component 1206 may be notched into individual female projections 1208 . The male component 1207 may have a central notch 1209 along the length of the component. As shown in FIG. 12A , the receiving area 1204 of the female component 1200 and the locking component 1203 of the male component 1201 fit together or snap together. The two tracks may be fastened either by snapping the male component 1207 into the female component 1206 simultaneously or by snapping the male component 1207 along the individual projections 1208 of the female component 1206 . The notch 1205 in the male component may provide some “give” in the snap closure.
FIG. 13A-B illustrates another example of a track snap closure with the male component or track and the female component or track assembled. FIG. 13A-B illustrates a male component similar to FIG. 5 and a female component similar to FIG. 2 . In the configuration illustrated in FIG. 13B , the female component 1304 may be notched into individual female projections 1307 and the male component 1305 may be notched into male projections 1306 . As shown in FIG. 13A , the receiving area 1302 of the female component 1300 and the locking component 1303 of the male component 1301 fit together or snap together. The two tracks may be fastened either by snapping the male component 1305 into the female component 1304 or snapping a male projection 1306 into a female projection 1307 . As illustrated in FIG. 13B , perfect registration of one male projection 1306 to one female projection 1307 may not be necessary for the closure to function. There does not have to be an equal number of male projections and female projections. Nor do the male projections and female projection have to be perfectly aligned with each other. Nor do the rails of the male component and the female component have to be the same length. However, in one example, there may be a ratio of one male projection to one female projection. The dual notches in the male component and the female component provide additional flexibility to the track snap closure, which allows for the track snap closure to be made from more rigid and durable materials if desired while preserving comfort and movement.
FIG. 14A-B illustrates another example of a track snap closure with the male component or track and the female component or track assembled. FIG. 14A-B illustrates a male component similar to FIG. 6 and a female component similar to FIG. 2 . In the configuration illustrated in FIG. 14B , the female component 1404 may be notched into individual female projections 1405 and the male component 1406 may be notched into male projections 1407 . The male component 1406 may be also notched 1408 along the length of the component, perpendicular to notches forming the male projections 1407 . As shown in FIG. 14A , the receiving area 1402 of the female component 1400 and the locking component 1403 of the male component 1401 fit together or snap together. The two tracks may be fastened either by snapping the male component 1406 into the female component 1404 or snapping a male projection 1407 into a female projection 1405 . As illustrated in FIG. 14B , perfect registration of one male projection to one female projection may not be necessary for the closure to function. Nor do the male projections and female projection have to be perfectly aligned with each other. The notch dividing the locking portion of the male component may provide some “give” to the male component provide easier snap closure. The dual notches in the male component and the female component provide additional flexibility to the track snap closure, which allows for the track snap closure to be made from more rigid and durable materials if desired while preserving comfort and movement.
The track snap fastener may provide a durable and comfortable form of apparel closure. The track snap fastener may also be employed to hold together various seams, edges, or surfaces in non-apparel applications. The track snap fastener presents numerous advantages in that perfect registration of the male and female portion of the fastener may be unnecessary for closure or fastening. Moreover, as the surfaces of the locking and receiving portions of the fastener may be textured or toothed, the track snap fastener may provide a secure closure with and without registration of the male and female components. The edges of the male component or female component may be raised to form a physical lock or barrier. Having a smooth locking and receiving surface may provide the fastener with a sliding fastening mechanism as well as a snap fastening mechanism.
Each portion or part of the fastener may be integrally formed or separately formed and assembled or any combination thereof. Different portions of the fastener or closure may be constructed of different materials. The fastener or closure may be molded of or machined from one material. For example, the fastener flanges may be formed of one polymer selected for flexibility and fusability with a garment and the rails and/or projections may be formed of one or more additional polymers selected for durability. In another example, the entire closure may be injection molded. Furthermore, a track snap closure may be molded or machined from any appropriate materials, including polyoxymethylene (e.g. Delrin™), polyethylene, polyvinylchloride, aluminum alloys, brass, and nickel alloys, nylon, aramids, etc. The assembled fastener may be affixed to clothing or other apparel items such as shoes, hats, gloves, etc. by fusing, sewing, gluing, or any other means.
The track snap closure may be useful for a number of apparel applications. Generally, a track snap closure may be employed in any location a conventional fastening device is used. However, a track snap closure has benefits that conventional fastening devices cannot offer. FIG. 15 illustrates two examples of applications for track snap closures. For example, a track snap closure may be incorporated into “tear-away” clothing, such as exercise/warm-up pants. The track snap closure may be used on either the inner 1501 or outer seam 1502 or both of a pair of warm-up pants 1500 . For example, one track snap component 1503 may be attached to the one side 1511 of the seam area and the complementary component 1504 may be attached to the opposite side 1510 of the seam area. The track snap closure may be used to seal portions of the seam while leaving portions open for ventilation according to the wearer's needs. The slide-ability of the male and female track of the track snap closure provides a pair of pants that have “tear away” capability and may refrain from bunching or snagging as may occur with traditional snaps or buttons.
In another example, one or more track snap closures may be employed for pockets 1505 of garments, such as outerwear. For example, a pocket may be disposed on the outside of an outwear garment. One track snap component 1506 may be attached to the outer surface 1507 of the outwear garment and the complementary component 1508 may be attached to the inner surface 1509 of the pocket. For a pocket inserted into a garment, the track snap components may be deployed on opposite seams of the pocket. The pocket may lay flat when closed via the track snap closure and may be easy to open and close. By way of further example, a track snap closure may be employed as the fly closure mechanism in a pair of pants or shorts. In another example, the track snap closure may be used to align multi-layered garments, such as a water-resistant shell and insulating liner. The inner surface of the water-resistant shell may be provided with one component (i.e. male or female) and the outer surface of an insulating liner may be provided with a complementary component. The track snap closure will provide fast and simple locking of the shell to the liner but the slide-ability of the track snap closure may also allow the user to align the shell and liner after locking rather than requiring perfect alignment while locking used in typical multi-layered garments.
Additional, non-limiting, examples of geometries or profiles of track snap closures or fasteners are illustrated in FIGS. 16A-D . The male component and female component may also include any of the notched or segmented configurations described above. FIG. 16A illustrates a first flange 1602 attached to a male projection 1604 and a second flange 1601 attached to a pair of female projections 1603 . The hooked portion of the female component may have a slightly rounded profile, while the locking portion of the male component may also have rounded edges and a flatter head area. FIG. 16B illustrates a first flange 1606 attached to a male projections 1608 and a second flange 1605 attached to a pair of female projections 1607 . Alternately, the locking portion of the male component may have a rounded head area. In. FIG. 16C , a second flange 1609 is attached to a pair of female projections 1611 , and a first flange 1610 is attached to a male projection 1612 . The locking portion of the male component may have a tear-drop like profile. In FIG. 16D , the stem area of the projection of the male component 1616 attached to a first flange 1614 may be wider, such that the width of the stem may be greater than the overhanging portion of the locking portion area. The projections of the female component 1615 attached to a second flange 1613 may include a wider receiving area to accommodate this profile.
Further non-limiting examples of geometries or profiles of track snap closures or fasteners are illustrated in FIGS. 17A-D . The male components and female components illustrated in FIGS. 17A-D may include any of the notched configurations described above. FIG. 17A illustrates a first flange 1702 attached to a male component projection 1704 and a second flange 1701 attached to female component projections 1703 . The female component may have a slightly rounded profile, while the locking portion of the male component may also have a larger overhang extending beyond the stem. This overhanging region of the locking portion may also be notched inwards to receive a portion of the female component that curves to fit the notched area. FIG. 17B illustrates a first flange 1706 attached to a male component projection 1708 and a second flange 1705 attached to a pair of female component projections 1707 . The receiving area of the female component may be cut or molded to fit the geometry of the locking portion of the male component conformably or snugly. In. FIG. 17C , a second flange 1709 is attached to female component projections 1711 , which may include hooked portions that are more pointed and hooked to lock with locking portion of the male component 1711 . The first flange 1710 is attached to a male component projection 1712 having a locking portion that may also include a hooked overhang region that locks with the hooked portion of the female component 1711 . In addition, the head of the locking portion of the male component may be pointed or tapered for insertion into the receiving area. In FIG. 17D , the locking portion of the male component projection 1716 attached to a first flange 1714 includes the pointed overhang region and may have a rounder profile than FIG. 17C . The female component projections 1715 attached to a second flange 1713 may have rounded hooked portions.
The foregoing description of the embodiments may have been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and may be used in a selected embodiment, even if not specifically shown or described.
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A closure or fastener is provided for apparel, shoes, equipment, and other applications. The closure may have a female component having a receiving area and a male component having a locking portion. Either or both the male component and female component may have a notched appearance to provide additional flexibility and comfort to the closure. Flanges on the male components and the female components may facilitate off-registration engagement of the closure system. Textures present or absent in the closure system may permit or prevent sliding by the male components and female components when the closure is engaged.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to hand-held insulated enclosures for beverage containers, and more particularly to a hand-held insulated enclosure for beverage containers having pivotal closure means to selectively expose the opening of said container.
2. Brief Description of the Prior Art
Insulated enclosures or coolers for beverage cans and devices having closures are known in the art. One common type of cooler consists merely of a cylindrical cup shaped can holder formed of polyurethane material. Another common insulating enclosure having a closure means is a plastic "travel cup" for beverages which has a lid containing an opening which is normally closed by a plug and is uncovered by pressing a plastic button disposed on the sidewall of the container. There are several patents which disclose various coolers and closures.
Goulding, U.S. Pat. No. 414,699 discloses a cover for ink bottles with a scissors type closure comprising a lever pivoted on a horizontal pivot during the dipping of an ink pen into a bottle of ink to laterally separate a pair of cover plates which are normally held closed by a spring joining them together.
Widener, U.S. Pat. No. 3,155,260 discloses a heat control device designed for warming a baby bottle. The device comprises a a pair of opposing cup shaped cylindrical members of thermally insulating material which when joined together form an air tight enclosure. The walls of the enclosure are spaced from the bottle and the space therebetween is filled with hot water to raise the temperature of the liquid in the bottle.
Vevirit et al, U.S. Pat. No. 3,481,506 discloses an ashtray employing a pair of laterally pivoting or scissors type closure plates. An actuating arm for the plates is mounted for rocking movement on the ashtray cover and is provided with a laterally projecting lower end to underlie and protect the pivot connection of the closure plates. An intermediate portion of the actuating arm carries a C-shaped link connected to the closure plates.
Brownson, U.S. Pat. No. 1,152,286 discloses a garbage can cover which fits onto a concrete case and supports a pail. The cover is provided with a circular opening and a pair of ears which receive a lid which may be swung upwardly and rearwardly. The lid comprises a pair of closures mounted on a pair of intermeshed gears which form pivot elements to separate the closures which are normally held closed by a spring joining them together. The closures are separated by pushing together two rearwardly projecting extension portions. In order to facilitate movement of the closures, a track containing ball bearings is disposed on the cover underneath the closures.
Bretney, U.S. Pat. No. 2,552,397 discloses a lid and operating mechanism therefor which may be attached to drinking glasses and the like. The device comprises a lid support having an inverted hook at its upper end to receive the lip of a tumbler and a C-shaped clamp member at its lower end to grip the tumbler. A lid is rotatably mounted at the top of the support and the lower end of a lever having its upper end free to move is connected to the support. The lid has an arm projecting radially outward from the point of rotation which is provided with a cam slot disposed at an angle to the line of motion of the free end of the lever. The free end of the lever has a projection which fits into the slot whereby on flexing of the lever the lid may be turned to cover and uncover the tumbler.
The prior art in general, and none of these patents in particular, disclose the present insulated enclosure and scissors type closure combination.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a hand-held insulated enclosure for beverage containers which will maintain the contents at a relatively constant temperature while being consumed.
Another object of this invention is to provide an insulated enclosure for beverage containers having a closure means which will allow the container to be enclosed except when drinking therefrom.
Another object of this invention is to provide an insulated enclosure for beverage containers which is adaptable to receive and enclose beverage containers of various size.
Another object of this invention is to provide an insulated enclosure having a durable outer casing and a thermal insulating inner lining.
Another object of this invention is to provide an insulated enclosure for beverage containers which is simple in construction and inexpensive to manufacture.
Other objects of the invention will become apparent from time to time throughout the specification and claims as hereinafter related.
The above noted objects and other objects of the invention are accomplished by the present insulated enclosure for beverage containers comprising upper and lower cup shaped cylindrical members each having a durable plastic outer casing and an inner lining of thermal insulating material which receive and substantially enclose said beverage container, an opening in the upper member exposing a portion of the beverage container adjacent its opening, and a pair of pivot members mounted on the upper member which are operated by a lever disposed on the sidewall to selectively expose the opening of the beverage container.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of an insulated cooler for beverage cans in accordance with the present invention.
FIG. 2 is sectional view of the insulated cooler for beverage cans taken along line 2--2 of FIG. 1.
FIG. 3 is a top plan view of the insulated cooler of FIG. 1 showing the lid closure in the closed position.
FIG. 4 is a top plan view of the insulated cooler of FIG. 1 showing the the closure in the opened position.
FIG. 5 is a side-elevation, detail view of an alternate lid closure mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings by numerals of reference, there is shown a preferred embodiment of an insulated cooler 10 for beverage cans. Cooler 10 comprises a lower cup-shaped cylindrical member 11 having an outer casing 12 and an upper inverted cup-shaped cylindrical member 13 having an outer casing 14. The outer casings 12 and 14 are formed of durable plastic material such as polyethylene.
The lower outer casing 14 has a cylindrical side wall 15 and a planar bottom wall 16 which has a central aperture 17 therein for fluid drainage and to allow air to escape for easy insertion and removal of beverage cans. A cylindrical cup-shaped inner lining 18 having a cylindrical side wall 19 and a bottom wall 20 lines the inner surfaces of the outer casing 12. The bottom wall 20 is provided with an aperture 21 in axial alignment with the aperture 17. The lining 18 is formed of thermal insulating material such as polyurethane foam or expanded polystyrene, and may be molded into the casing or secured therein by a conventional bonding agent.
The upper casing 14 comprises a cylindrical side wall 22 and a planar top wall 23. The top wall 23 has a horizontal arcuate opening 24, with a bead 24a, curved inwardly from the outer circumference to expose a portion of the top surface of a beverage can 25. The side wall 22 is provided with a circumferentially disposed vertical arcuate opening 26 which adjoins the horizontal opening 24 and extends downwardly therefrom to expose a portion of the side of the beverage can 25. Openings 24 and 26 cooperate to form a single opening which exposes a portion of the side and top of the beverage can 25 permitting access thereto for drinking.
A cylindrical cup-shaped inner lining 27 having a cylindrical side wall 28 and a top wall 29 lines the upper casing 14. Lining 27 has top and side openings 30 and 31 aligned with the openings 24 and 26 in the upper casing 14. The lining 27 is formed of thermal insulating material such as polyurethane foam or expanded polystyrene, and may be molded into the casing or secured therein by a conventional bonding agent. A circumferential depending lip or flange 32 extends radially outward and longitudinally from the bottom of the side wall 22 of the upper casing 14 to define a shoulder 33 therebetween. The inner diameter of the lip or flange 32 is not lined and is sized to slidably receive the top portion of the side wall 15 of the lower casing 12.
A lid closure assembly 34 is attached to the top surface of the upper casing 14 and covers the openings 24 and 26. The closure assembly 34 comprises a pair of pivot members 35 each having a generally pie shaped or semi-arcuate horizontal top portion 36 and a circumferential vertically-extending semi-arcuate skirt portion 37. The top portions 36 of the pivot members 35 are overlapped and mounted on the top wall 23 of the upper casing 14 by a pivot pin or rivet 38 which extends through an aperture in the top wall 23 and apertures in the members 35 to commonly join them in a scissors relationship. When assembled, the lateral surfaces of the top portions 36 and skirt portions 37 conform to, and extend slightly beyond, the periphery of openings 24 and 26.
The top portions 36 of the pivot members 35 are provided with flat rearwardly protruding, diverging extensions or ears 39. A flat rectangular lever member 40 is supported on the side wall 22 of the upper casing 14. Lever member 40 is of molded plastic having a hinged bottom portion 41, a straight intermediate portion 42, and a laterally projecting top portion in the form of a pivot yoke 43. The lever 40 is secured at its hinged bottom portion 41 to the side wall 22 by a suitable bonding agent.
A pair of thin flat straps 44 of resilient plastic material having apertures in opposing ends are each pivotally connected at one of their ends to one of the ears 39 by a pivot pin or rivet 45. The straps 44 extend from the ears 39 rearwardly beyond the circumference of the upper casing 14. The extended ends of the straps 44 are overlapped and pivotally joined into the yoke 43 of the lever 40 by a pivot pin or rivet 46 extended therethrough. In this manner, the intermediate portion 42 of the lever 40 extends angularly upward and outward from the side wall 22 and the straps 44 are slightly curved downward to the yoke 43. A compression spring 47 positioned between the side wall 22 and the intermediate portion 42 of the lever 40 biases the lever outward to retain the pivot members 35 in the closed position.
A semi-annular lower adapter ring 48 may be removably placed into the lower member 11 to reside against the bottom 20 and side wall 19 of the lining 18, and a similar upper adapter ring 49 into the upper member 12 against the top wall 29 and side wall 28 to adapt the cooler 10 to various beverage container sizes. A container of smaller diameter would fit within the interior of the adapters 48 and 49, a taller container would extend vertically inside the adapters, and the ends of a shorter container would rest on the upper and lower surfaces of the adapters.
FIG. 5 illustrates an alternate closure mechanism 50 which does not require a compression spring. A flat rectangular lever member 51 of molded plastic is positioned on the side wall 22 of the upper casing 14. Lever member 51 has a hinged bottom portion 52, a straight intermediate portion 53, and a laterally projecting top portion in the form of a yoke 54. A small bead 55 extends laterally from each side of the hinged bottom portion to be snapped into a pair of apertured ears 56 which extend outwardly from the side wall 22. A small bracket 57 extends outwardly from the side wall 22 and is provided with a small upwardly extending lip 58. The bottom of the hinged portion 52 of the lever 51 is placed into the bracket 57 and the beads 55 are snapped into the ears 56.
A pair of thin flat straps 60 of resilient plastic material having apertures in opposing ends are each connected to the ears 39 and to the yoke 54 as previously described. In this embodiment, the intermediate portion 53 of the lever 51 extends angularly upward and outward from the side wall 22 and the straps 60 are curved sufficiently downward to the yoke 54 whereby the curvature of the resilient plastic straps 60 creates an expansion force to bias the intermediate portion 53 of the lever 51 outward from the side wall 22 and retain the pivot members 35 in the closed position.
OPERATION
With the upper and lower members 11 and 12 separated, a beverage can 25 is placed into the bottom member 11. The upper member 12 is placed over the can 25 with the pivot members 35 aligned with the opening 61 in the top of the can 25. The upper member 12 is then pressed down until shoulder 33 of the lip 32 rests on the top of the side wall 15 of the lower casing 12. To expose the opening 61 of the can 25, the intermediate portion 42 of the lever 40 is pressed inwardly by the index finger of the user causing the straps 44 to move forward and pivotally separate the members 35 laterally until the opening 61 of the can 25 is exposed and the user can drink therefrom. To cover the opening 61, pressure is removed from the intermediate portion 42 of the lever 40, allowing the spring 47 to push the lever outward causing the straps to move rearward and pivotally close the pivot members 35 over the opening 61. The bead 24a around opening 24 provide a protective seal within the underside of lid members 35.
While this invention has been described fully and completely with special emphasis upon a preferred embodiment, it should be understood that within the scope of the appended claims the invention may be practiced otherwise than is specifically described herein.
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An insulated enclosure for beverage containers comprises upper and lower cup shaped cylindrical members each having a durable plastic outer casing and an inner lining of thermal insulating material receive and substantially enclose said beverage container. An opening in the upper member exposes a portion of the beverage container adjacent its opening. A pair of pivot members mounted on the upper member are operated by a level disposed on the sidewall to selectively expose the opening of the beverage container.
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The present invention is related to co-owned U.S. Pat. Nos. 4,994,671 to Safinya et al., No. 5,167,149 to Mullins et al., 5,201,220 to Mullins et al., No. 5,266,800 to Mullins et al., and No. 5,331,156 to Hines et al., all of which are hereby incorporated by reference herein in their entireties.
This application is also related to co-owned, application Ser. No. 08/827,647, filed Apr. 10, 1997 now U.S. Pat. No. 5,859,430.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the analysis of downhole borehole fluids. More particularly, the present invention relates to apparatus and methods for the in situ determination of gas-oil ratio of fluids in a geological formation.
2. State of the Art
Those skilled in the art will appreciate that the ability to conduct an analysis of formation fluids downhole (in situ) is extremely desirable. With that in mind, the assignee of this application has provided a commercially successful borehole tool, the MDT (a trademark of Schlumberger) which extracts and analyzes a flow stream of fluid from a formation in a manner substantially as set forth in co-owned U.S. Pat. Nos. 3,859,851 and 3,780,575 to Urbanosky which are hereby incorporated by reference herein in their entireties. The OFA (a trademark of Schlumberger), which is a module of the MDT, determines the identity of the fluids in the MDT flow stream and quantifies the oil and water content based on the previously incorporated related patents. In particular, previously incorporated U.S. Pat. No. 4,994,671 to Safinya et al. provides a borehole apparatus which includes a testing chamber, means for directing a sample of fluid into the chamber, a light source preferably emitting near infrared rays and visible light, a spectral detector, a data base means, and a processing means. Fluids drawn from the formation into the testing chamber are analyzed by directing the light at the fluids, detecting the spectrum of the transmitted and/or backscattered light, and processing the information accordingly (and preferably based on the information in the data base relating to different spectra), in order to quantify the amount of water and oil in the fluid. As set forth in previously incorporated U.S. Pat. No. 5,266,800 to Mullins, by monitoring optical absorption spectrum of the fluid samples obtained over time, a determination can be made as to when a formation oil is being obtained as opposed to a mud filtrate. Thus, the formation oil can be properly analyzed and quantified by type. Further, as set forth in the previously incorporated U.S. Pat. No. 5,331,156 to Hines et al., by making optical density measurements of the fluid stream at certain predetermined energies, oil and water fractions of a two-phase fluid stream may be quantified.
While the Safinya et al., Mullins, and Hines et al. patents represent great advances in downhole fluid analysis, and are particularly useful in the analysis of oils and water present in the formation, they do not address in detail the gases which may be plentiful in the formation. The issue of in situ gas quantification is addressed in the previously incorporated U.S. Pat. Nos. 5,167,149 to Mullins et al., and 5,201,220 to Mullins et al., and in O. C. Mullins et al., "Effects of high pressure on the optical detection of gas by index-of-refraction methods", Applied Optics, Vol. 33, No. 34, pp. 7963-7970 (Dec. 1, 1994) which is also incorporated by reference herein in its entirety, where a rough estimate of the quantity of gas present in the flow stream can be obtained by providing a gas detection module having a detector array which detects light rays having certain angles of incidence. While rough estimates of gas quantities are helpful, it will be appreciated that more accurate measurements are often necessary.
One particularly important measurement for newly discovered oil is the gas-oil ratio (GOR). The GOR is conventionally defined as the volume of gas at STP (standard temperature and pressure) in cubic feet divided by the number of stock tank barrels of oil in a quantity of formation fluid. A GOR of 6,000 ft 3 /bbl represents approximately equal mass fractional amounts of gas and oil. The GOR must be known in order to establish the size and type of production facilities required for processing the newly discovered oil. For example, a very large GOR of approximately 11,000 ft 3 /bbl will require the construction of expensive gas handling facilities. It is therefore important to make an accurate measurement of GOR in newly discovered oil so that the appropriate financial investment in production facilities is made.
Currently, the most accurate and preferred method of establishing GOR is to take several samples of formation fluid and subject the samples to laboratory analysis. It is understood that the samples taken must be an accurate statistical representation of the formation fluid in order for the analysis to provide accurate results. In order to enhance the accuracy of the laboratory analysis, many samples are taken from different locations in the formation. However, sample collection of high GOR fluids can be very difficult as samples are not valid if phase separation occurs during sampling. Furthermore, in the process of shipping gas containing samples and performing laboratory analysis, gas can leak from the containers and ruin the samples.
Recently, downhole fluid analysis has been used, providing rough estimates of GOR, in order to aid in the selection of samples for laboratory testing. Theoretically, if estimates of GOR at several locations in the formation are the same or similar, a single fluid sample may be sufficient to provide an accurate laboratory analysis of GOR. One of the recently used methods for estimating GOR relies primarily on the coloration of the fluid sample. Lighter color oils tend to have high gas fractions, generally, although not necessarily indicating a larger GOR. Moreover, this method is indirect and prone to error because the coloration measures the heavy aromatic content whereas, for GOR, one actually wants to measure the methane and light hydrocarbon fractions.
Co-owned U.S. Pat. No. 4,994,671 discloses an apparatus and method for analyzing the composition of formation fluids through the use of spectroscopy. Spectroscopy has been used downhole for distinguishing between oil and water (in the near infrared spectrum), and for distinguishing among oils (in the visible spectrum). However, for several reasons, downhole spectroscopy has not been suggested for distinguishing between gas and oil or for distinguishing among different hydrocarbon gases such as methane (CH 4 ), ethane (having methyl components (CH 3 )), and higher hydrocarbons which contain predominantly methylene (CH 2 ). First, because the density of a gas is a function of pressure, and because downhole pressures can vary by a factor of thirty or more, the dynamic range of the gas densities likely to be encountered downhole is extremely large. As a result, it is believed that the dynamic range of the spectral absorption at frequencies of interest is also extremely large such as to make a measurement unfeasible; i.e., the sensitivity of the downhole spectroscopy equipment is typically incapable of handling the large dynamic ranges that are expected to be encountered. Second, due to fact that the condensed phase of hydrocarbon (oil) has a much higher density at downhole pressures than the gas phase, it is believed that a thin film of liquid oil on the OFA window can yield significant absorption. Thus, where an oil film was present, interpretation of the results would yield a determination of a rich gas mixture, where no or little amount of hydrocarbon gas was actually present. Third, the type of spectral analysis typically done uphole to distinguish among hydrocarbon gases cannot be done downhole. In particular, in uphole applications, individual gas constituents are detected by modulating a narrow band source on and off of mid-infrared absorption lines of the gas, where a resulting oscillation in absorption at each modulation frequency would indicate a positive detection of a particular gas. However, at the high pressures encountered downhole, not only are the narrow gas absorption spectral lines merged, but mid-infrared spectroscopy is hindered by the extreme magnitude of the absorption features. Fourth, spectrometers are typically sensitive to changes in temperature, and elevated temperatures encountered downhole can induce spectral changes of the gas sample, thereby complicating any data base utilized.
Co-owned application Ser. No. 08/827,647 now U.S. Pat. No. 5,859,430 discloses a method and apparatus for the downhole compositional analysis of formation gases which utilizes a flow diverter and spectrographic analysis. More particularly, the apparatus includes diverter means for diverting formation gas into a separate stream, and a separate gas analysis module for analyzing the formation gas in that stream. By providing a diverter means and a separate gas analysis module, the likelihood of a having a thin film of oil on the cell window is decreased substantially, thereby improving analysis results. Also, by providing one or more cells with different path lengths, issues of dynamic range are obviated, because where the pressure is higher, light will not be fully absorbed in the cell having a short path length, whereas where the pressure is lower, there will be some absorption in the cell having the longer path length. The methods and apparatus of the '647 application are useful in determining what types of gas are present in the formation fluid, but are not particularly useful in determining GOR.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide methods and apparatus for determining gas-oil ratio in formation fluids.
It is also an object of the invention to provide methods and apparatus for the in situ determination of the gas-oil ratio of formation fluids.
It is another object of the invention to provide methods and apparatus for the downhole spectroscopic determination of gas-oil ratio of formation fluids.
It is a further object of the invention to provide methods and apparatus for the downhole determination gas-oil ratio in formation fluids, which methods and apparatus remain relatively accurate in high temperature and high pressure environments.
In accord with these objects which will be discussed in detail below, the methods and apparatus of the present invention arise from several discoveries about the nature of a supercritical gas-oil mixture, i.e. a mixture of methane (CH 4 ) molecularly dispersed in oil (CH 2 ) at high temperature and pressure, also known as "live crude oil". In particular, it was discovered that the NIR (near infrared) absorption spectrum of such a single phase or supercritical mixture is equal to the sum of the NIR absorption spectra for the oil component and the methane component. In other words, the spectral position of methane dissolved in crude oil is the same as methane gas. In addition, it was discovered that the effects of high temperature and pressure on the spectrum of methane are less significant with regard to peak positions than with regard to peak intensities. In particular, it was observed that the characteristic absorption peak at about wavenumber 6,000 cm -1 (wavelength 1.667 microns) of methane remained relatively constant through temperatures over 200° C. and pressures over 20,000 psi. In addition, the characteristic absorption peak at about wavenumber 5,800 cm -1 (wavelength 1.720 microns) of crude oil remained relatively constant through the same temperatures and pressures. Most significantly, it was discovered that the absorption peak area of methane is linearly related to the density of gas and that this relationship holds true over a very large range of densities.
Therefore, methods according to the invention include providing an OFA-type tool which subjects formation fluids to NIR illumination and which provides a spectral measurement of peaks at and/or around about 6,000 cm -1 and about 5,800 cm -1 (the absorption peaks of methane and crude oil respectively). The methods according to the invention also include calculating a ratio of the amplitudes of the absorption peaks to determine GOR. According to an alternate embodiment of the invention, the methods of calculating the gas-oil ratio include referring to a database of spectra of hydrocarbons found in formation fluid and adjusting the amplitudes of the methane and oil peaks to account for the influences of other hydrocarbons on the spectrum of the formation fluid.
According to the invention, a borehole apparatus for measuring the spectral peaks of oil and methane includes a testing region, a conduit for directing formation fluid into the testing region, a light source emitting at least near infrared rays into the testing region, a spectral detector optically coupled to the testing region, and a processor coupled to the spectral detector. The testing region is a transparent tube or chamber which is located between the light source and the spectral detector such that light directed from the light source to the spectral detector is interrupted by formation fluid. The spectral detector is preferably a spectrometer which measures the spectrum of the light which has been transmitted through the formation fluid in the testing region. The processor is preferably a microprocessor and is also preferably provided with a database of information about the spectra of different hydrocarbons found in formation fluids.
Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a borehole apparatus for analyzing formation fluids;
FIG. 2 is a schematic diagram of the preferred near infrared fluid analysis module of FIG. 1;
FIG. 3 is a graph of the NIR absorption spectrum of methane at low pressure and low temperature;
FIG. 4 is a graph of the NIR absorption spectrum of methane at high pressure and high temperature;
FIG. 5 is a composite graph showing the spectra of crude oil containing no methane, dilute methane gas, the weighted sum of the spectra of oil and methane, and the spectrum of oil containing methane;
FIG. 6 is a plot of experimental values and a linear function extrapolated from the values;
FIG. 7 is a schematic flow chart illustrating one method of the invention; and
FIG. 8 is a schematic flow chart illustrating another method of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, a borehole tool 10 for analyzing fluids from the formation 14 is suspended in the borehole 12 from the lower end of a typical multiconductor cable 15 that is spooled in a usual fashion on a suitable winch (not shown) on the formation surface. On the surface, the cable 15 is preferably electrically coupled to an electrical control system 18. The tool 10 includes an elongated body 19 which encloses the downhole portion of the tool control system 16. The elongated body 19 also carries a selectively extendable fluid admitting assembly 20 and a selectively extendable tool anchoring member 21 which are respectively arranged on opposite sides of the body. The fluid admitting assembly 20 is equipped for selectively sealing off or isolating selected portions of the wall of the borehole 12 such that pressure or fluid communication with the adjacent earth formation is established. Also included with tool 10 are a fluid analysis module 25 through which the obtained fluid flows. The fluid may thereafter be expelled through a port (not shown) or it may be sent to one or more fluid collecting chambers 22 and 23 which may receive and retain the fluids obtained from the formation. Control of the fluid admitting assembly, the fluid analysis section, and the flow path to the collecting chambers is maintained by the electrical control systems 16 and 18.
Additional details of methods and apparatus for obtaining formation fluid samples may be had by reference to U.S. Pat. Nos. 3,859,851 and 3,780,575 to Urbanosky, and U.S. Pat. No. 4,994,671 to Safinya et al. which are hereby incorporated by reference herein. It should be appreciated, however, that it is not intended that the invention be limited to any particular method or apparatus for obtaining the formation fluids.
Turning now to FIG. 2, a preferred fluid analysis module 25 includes a light source 30, a fluid sample tube 32, optical fibers 34, and a filter spectrograph 39 which includes a fiber coupler or distributor 36 and an associated detector array 38. The light source 30 is preferably an incandescent tungsten-halogen lamp which is kept at near atmospheric pressure. The light source 30 is relatively bright throughout the near infrared wavelength region of 1 to 2.5 microns and down to approximately 0.5 microns, and has acceptable emissions from 0.35 to 0.5 microns. Light rays from the light source 30 are preferably transported from the source to the fluid sample by at least part of a fiber optic bundle 34. The fiber optic bundle 34 is preferably split into various sections. A first small section 34a goes directly from the light source 30 to the distributor 36 and is used to sample the light source. A second section 34b is directed into an optical cell 37 through which the sample tube 32 runs and is used to illuminate the fluid sample. A third bundle 34d collects light transmitted or scattered through the fluid sample and provides the filter spectrograph with the light for determining the absorption spectrum of the fluid sample. Optionally, though not necessarily preferred, a fourth fiber optic bundle 34c collects light substantially backscattered from the sample for spectrographic analysis. The backscattered spectrum may be useful if multiple phases are present simultaneously. Preferably, however, this determination is made with a separate gas detector as described in previously incorporated U.S. Pat. No. 5,167,149. A three position solenoid (not shown) is used to select which fiber optic bundle is directed toward the filter spectrograph 39. Preferably, a light chopper (not shown) modulates the light directed at the spectrograph at 500 Hz to avoid low frequency noise in the detectors.
As mentioned above, optical bundle 34b directs the light towards the fluid sample. The fluid sample is obtained from the formation by the fluid admitting assembly and is sent to the fluid analysis section 25 in tube 32. The sample tube 32 is preferably a two by six millimeter rectangular channel which includes a section 40 with windows made of sapphire. This window section 40 is located in the optical cell 37 where the light rays are arranged to illuminate the sample. Sapphire is chosen for the windows because it is substantially transparent to the spectrum of the preferred light source. and because it is highly resistant to abrasion. As indicated schematically in FIG. 2, the window areas 40 may be relatively thick compared to the rest of the tube 32 to withstand high internal pressure. The fiber optic bundles 32b and 32d are preferably not perpendicular to the window areas 40 so as to avoid specular reflection. The window areas are slightly offset as shown in FIG. 2 to keep them centered in the path of the transmitted light. The signals from the detectors are digitized, multiplexed, and transmitted uphole via the cable 15 to the processing electronics 18 shown in FIG. 1.
Those skilled in the art will appreciate that each element in the detector array 38 is provided with a band pass filter for a particular wavelength band. According to a presently preferred embodiment, the detector array has ten elements which detect light at or about the following wavenumbers: 21000 cm -1 , 18600 cm -1 , 15450 cm -1 , 9350 cm -1 , 7750 cm -1 , 6920 cm -1 , 6250 cm -1 , 6000 cm -1 , 5800 cm -1 , and 5180 cm -1 . It will be appreciated that the first three wavenumbers represent visible blue, green, and red light and are preferably used to perform the type of analysis described in previously incorporated U.S. Pat. No. 5,266,800. The remaining wavenumbers are in the NIR spectrum and are used to perform analyses as described herein.
As previously indicated, the detector array elements determine the intensity of the light passing through the fluid in the tube 32 at the ten different wavebands. For purposes of the present invention, however, it is only necessary that there be two detectors, one which detects light around wavenumber 5800 cm -1 and another which detects light around wavenumber 6000 cm -1 . Preferably, one or two detectors are provided which measure a baseline intensity, i.e. the intensity of a wavelength of light which is not absorbed by formation fluid, e.g. the detector at 9350 cm -1 which is not absorbed by any formation fluid or 6920 cm -1 which is not absorbed by hydrocarbons but is absorbed by water. The optical density of the fluid at particular wavelengths is determined according to Equation 1. ##EQU1## Thus, if the intensity at wavelength λ is equal to the intensity of the source, there is no absorption, and the fraction in Equation 1 will be equal to 1 while the OD(λ) will equal 0. If the intensity at wavelength λ is one tenth the intensity of the source, the fraction in Equation 1 will be equal to 10 and the OD(λ) will equal 1. It will be appreciated that as the intensity at λ decreases, the optical density OD(λ) will increase.
As mentioned above, the intensity of the source is preferably measured by measuring the light passing through the sample at a wavelength where no absorption occurs. This compensates for any light loss due to backscattering and provides a more accurate measure of optical density.
As mentioned above, the methods of the invention include measuring the absorption spectra of formation fluid at wavenumbers in the vicinity of 6.0×10 3 cm -1 and 5.8×10 3 cm -1 . It has been discovered by the inventor that absorption at these wavenumbers is indicative of the presence of methane and oil, respectively, even at the extremely high temperatures and pressures encountered downhole in the formation. For example, with reference to FIG. 3, the NIR absorption spectrum for methane at room temperature and low pressure exhibits a characteristic peak optical density at 6.0×10 3 cm -1 . This characteristic peak is also exhibited by methane under high pressure and temperature as seen in FIG. 4 which shows the NIR absorption spectrum for methane at 20,000 psi and 204° C. In FIG. 4, the characteristic peak for methane is still located at 6.0×10 3 cm -1 although the amplitude of the peak is significantly increased. Similar results were discovered for crude oil which exhibited a characteristic absorption peak at 5.8×10 3 cm -1 .
The inventor also discovered that the absorption spectrum of live oil exhibits an identifiable peak at 6.0×10 3 cm -1 and an identifiable peak at 5.8×10 3 cm -1 . More particularly, FIG. 5 illustrates the spectrum of 100% crude oil without methane (shown in chain-dot line), the spectrum of an 8-10% condensed phase density methane without oil (shown in chain-dash line), and the spectrum of a "live oil" mixture of oil with 8-10% methane (shown in dashed line). In addition, FIG. 6 shows that the weighted sum (solid line) of the methane spectrum and the oil spectrum is substantially equal to the spectrum of the live oil (dashed line).
Most significantly, the inventor also discovered that the absorption peak area of methane is linearly related to the density of gas and that this relationship holds true over a very large range of densities. Experiments were conducted using a Mattson Cygnus 100 FTIR spectrometer with a tungsten-iodide light source and a quartz beam splitter. The collimated optical beam from the spectrometer was steered to an optical bench adjacent to a high pressure, high temperature autoclave. The focused optical beam traversed a 3 mm optical cell having two 7 mm thick sapphire windows. The optical cell was located in the autoclave and optical beam, after exiting the autoclave, was focused onto a nitrogen-cooled detector. Several measurements were made of absorption strength in the 5800 cm -1 to 6200 cm -1 window at different temperatures and pressures of methane. The absorption strength measurements were made by integrating the amplitude of the absorption spectrum on the waveband 5800 cm -1 to 6200 cm -1 . The integrated amplitude provides a more accurate measure of absorption than amplitude by itself. While the effects of temperature and pressure tend to broaden peaks as their amplitude is decreased, the area under the peaks remains an accurate indicator of the absorption strength. The test results are summarized in Table 1 below.
______________________________________T (° C.) P (psi) OD Z ρ (g/cc)______________________________________24 1,975 0.150 0.87 0.10124 3,900 0.267 0.92 0.18924 9,900 0.418 1.50 0.29565 10,130 0.404 1.41 0.282107 10,200 0.384 1.40 0.254149 10,050 0.349 1.38 0.229204 10,160 0.323 1.35 0.209211 20,150 9.407 2.00 0.276______________________________________
Table 1 shows the measured optical density OD of methane in the 5800 cm -1 to 6200 cm -1 window at different temperatures T and pressures P. Table 1 also shows the compressibility factor Z (=PV/RT) for methane for the temperatures and pressures at which measurements were made. Given the temperature T, the pressure P, and the compressibility factor Z, the mass density ρ was computed for each measurement. The measured optical densities and corresponding calculated mass densities were plotted relative to each other as shown in FIG. 6. It should be noted that the mass densities used in the plot of FIG. 6 are one third the values shown in Table 1. This scaling of the mass densities relates to the fact that the length of the chamber in which measurements were made was 3 mm. Scaling the mass densities of Table 1 converts the values to mass per unit area rather than mass per unit volume so that the measurements may be applied to chambers of different lengths. As clearly illustrated in FIG. 6, measured optical densities are linearly related to the calculated mass densities.
The inventor has also considered the issue of absorption per unit density (mass per unit area) of methane (gas) and heptane (oil). The absorption peak intensities for equal volumes of methane and heptane will be different unless the peak intensities are normalized to account for the different absorption strengths. One method of normalizing the peak intensities is to normalize by mass per unit area. Using this method, it is recognized that the integrated peak intensity for methane is 4.69 OD/g/cm 2 and the integrated peak intensity for heptane is 3.72 OD/g/cm 2 . Using these relative absorption per unit density values, the peak intensities can easily be normalized. One could also normalize with absorption per unit mole of CH 4 for methane and --CH 2 -- for oil depending on the desired final units. In either case, the peak intensities for methane and heptane are within 25% of each other.
Given the discoveries made regarding the spectra of oil and methane, and the OFA tool described herein with optical windows at 6000 cm -1 and 5800 cm -1 , those skilled in the art will appreciate that the absorption spectra of oil and methane can be used to determine the GOR of fluid samples deep in a geological formation.
Turning now to FIG. 7, an exemplary method of the present invention is illustrated in the form of a flow chart. According to the invention as shown at 100 in FIG. 7, the OFA tool is lowered into the borehole of a formation and located at a location for taking a fluid sample. A sample of fluid is captured at 102 and the sample is illuminated at 104. The spectrum of light transmitted through the sample is detected at 106. The methane absorption peak is measured at 110 and the oil absorption peak is measured at 114. The peak ratio is calculated at 120 which may include normalization of the peaks as described above. The (normalized) ratio of the methane absorption peak to the oil absorption peak is directly proportional to the GOR. In fact, the peak to peak ratio is simply converted to GOR at 122 by scaling it by a factor of 6,000, this number being the number of ft 3 /bbl for a 1:1 ratio of gas to oil. Typically, several samples of downhole fluid will be analyzed. Therefore, as shown in FIG. 7, the method returns a 124 to locating the tool at 100 so that an additional sample may be taken and analyzed as described above.
As mentioned above, additional analyses and manipulation of the spectra may be performed to enhance the accuracy of the GOR determination. Some optional steps are illustrated in the method shown in FIG. 8. As shown in FIG. 8, prior to measuring the methane peak at 110, an oil baseline spectrum is subtracted from the spectrum detected at 106. This may enhance the analysis of the methane peak by removing any oil spectrum influence which might exist. Similarly, before measuring the oil peak at 114, a methane baseline spectrum is subtracted from the spectrum detected at 106. This may enhance the analysis of the oil peak by removing any methane spectrum influence which might exist. It will be appreciated that the baseline subtractions may be performed iteratively. Further, in order to remove any adverse spectral effects of other hydrocarbons which may be present in the formation fluid, the spectrum may be compared at 116 to a database of spectra to account for the presence of other hydrocarbons in the sample which may have influenced the magnitude of the oil and methane peaks. When such a database is used, the peak measurements will be corrected accordingly at 118 prior to calculating a peak ratio at 120.
It will be appreciated that the database correction step(s) discussed above may be performed on the detected spectrum prior to measuring peaks or may be arranged to directly correct the measured peaks. The database may include spectral information for ethane and wet gases which contain a large mass fraction of the methyl group --CH 3 to distinguish these absorption spectra from crude oils which contain mostly --CH 2 --.
Those skilled in the art will appreciate that the disclosed apparatus for detecting the absorption spectrum described herein inherently produces an integrated amplitude. This occurs because the spectral detectors used do not detect at a single wavelength, but detect all light within a waveband which may be relatively narrow or relatively broad depending on the detector and which may be centered around a particular wavelength. Thus, the steps of measuring the absorption peaks described above automatically integrates the absorption peaks over a bandwidth. It will be understood that it is possible to avoid the integration through filtering and still obtain similar results. However, it is believed that allowing integration will provide more accurate results.
There have been described and illustrated herein several embodiments of methods and apparatus for determining gas-oil ratio in a geological formation. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while particular light source and spectral detector have been disclosed, it will be appreciated that other spectral detectors and light sources could be utilized provided that they perform the same functions as described herein. Also, while a particular borehole apparatus has been shown, it will be recognized that other types of borehole apparatus could be used to make spectral analyses of formation fluids in accord with the concepts of the invention. Moreover, while particular steps have been disclosed in reference to "correcting" the spectrum of downhole fluid, it will be appreciated that other "corrective" steps could be used as well. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as so claimed.
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Methods according to the invention include providing an OFA tool which subjects formation fluids to NIR illumination and which provides a spectral measurement of peaks at about 6,000 cm -1 and about 5,800 cm -1 . The methods according to the invention also include calculating a ratio of the amplitudes of the absorption peaks to determine GOR. According to an alternate embodiment, the methods of calculating the ratio include referring to a database of spectra of hydrocarbons found in formation fluid and adjusting the amplitudes of the methane and oil peaks to account for the influences of other hydrocarbons on the spectrum of the formation fluid. A borehole apparatus for measuring the spectral peaks of oil and methane includes a testing region, a conduit for directing formation fluid into the testing region, a light source emitting at least near infrared rays into the testing region, a spectral detector optically coupled to the testing region, and a processor coupled to the spectral detector. The testing region is a transparent tube or chamber which is located between the light source and the spectral detector such that light directed from the light source to the spectral detector is interrupted by formation fluid. The spectral detector is preferably a filter spectrograph which measures the spectrum of the light which has been transmitted through the formation fluid in the testing region.
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FIELD OF THE INVENTION
This invention relates to polypeptides useful in the therapy and diagnosis of diseases, especially acquired immunodeficiency disease (AIDS), for which human immunodeficiency virus (HIV) is the etiological agent.
BACKGROUND INFORMATION
Human Immunodeficiency Virus, type 1 (HIV) is the etiologic agent associated with acquired immunodeficiency syndrome (AIDS). It is lymphotropic for cells expressing the CD4 molecule.
In vitro infection by HIV can be blocked by serum antibodies obtained from infected individuals (1-3), although a precise relationship between antibody titers and disease course is not presently apparent. Several reports have also demonstrated that HIV-neutralizing antibodies can be developed against various immunogens, including glycoprotein extracts (4), recombinant proteins (5-6), and synthetic peptides (1, 7-8). These antibodies react with HIV env gene products, thus solidifying the role of viral surface glycoproteins and cell receptor interactions. In addition, antibodies to the CD4 molecule are capable of inhibiting viral binding activity, as are antiidiotypic reagents to these antibodies (9).
Although HIV envelope glycoproteins are of strong interest with respect to viral inhibition, recent information indicates that gag-encoded proteins may participate as a target for the neutralizing immune response. Gag encodes for a precursor protein of 55,000 molecular weight (p55) which is further degraded into three small proteins with molecular weights of approximately 17,000, 24,000 and 15,000 (p17, p24 and p15, respectively). These three proteins are termed the viral "core" proteins.
The present invention is related to polypeptides found in the p17 core protein of HIV. As demonstrated previously (17) the p17 core protein is comprised of 132 amino acids (more or less depending upon the strain of HIV examined) (FIG. 5), and residues at the 5' end of the gag gene of HIV and at the amino terminal portion of the p55 precursor protein. Certain regions of the p17 core protein (amino acid residues #88-115; TVAT . . . KKKA), exhibit homology with a peptide hormone produced by the human thymus termed thymosin alpha-1 (28). The same authors showed that antiserum to thymosin alpha-1 can neutralize the replication of HIV in vitro, as accounted for by the partial sequence homology between the hormone and the HIV p17 core protein. Further, heterologous antiserum to a 30-amino acid synthetic peptide analogue reacted with the p17 core protein of HIV in a manner identical to that seen with an HIV p17-specific antibody (12).
Previous work had resulted in the isolation of monoclonal antibodies against the p17 protein and the demonstration that those monoclonal antibodies could neutralize the virus. Nevertheless, the p17 protein is a relatively large entity of approximately 132 amino acids. The current invention reflects the discovery (described below in the Examples section) that certain short polypeptides, approximately 11 amino acids or even less in length, are the only ones that react with some monoclonal antibodies capable of neutralizing the biological activity of the HIV virus. The discovery that such short sequences exist and the identification of their structure allows one to construct proteins made exclusively or predominantly of antibody-reactive sequences and to use them as either diagnostic agents or inducers of anti-HIV antibodies. The resulting anti-HIV antibodies can, in turn be used to induce anti-idiotype antibodies themselves useful as antibody inducers.
The presently described immunoreactive polypeptides correspond to the following amino acids, numbered as to their position in the p17 protein (See FIG. 5 for the p17 sequence):
______________________________________ Amino acid numbers in p17______________________________________Polypeptide #1 12-19Polypeptide #1a 12-17Polypeptide #1b 13-18Polypeptide #1c 14-19Polypeptide #2 17-22Polypeptide #3 12-22Polypeptide #4 100-105______________________________________
When administered in the presence of adjuvants and/or carrier proteins, these peptides represent HIV vaccines of use to control or inhibit the spread of HIV contagion. In similar form, these peptides represent valuable immunogens with which to generate antibodies of use as diagnostic reagents. Alternatively, they can be used diagnostically to detect anti-HIV antibodies. Further, anti-HIV peptide antibodies are of use to develop anti-idiotype antibodies which themselves represent HIV vaccines when administered in the presence of appropriate adjuvants and/or carrier proteins.
Peptides #1, 1a, 1b, 1c, 2 and 3 represent sequences from the amino terminal region of the p17 HIV core protein. (i.e. the 5' region of the gag gene of HIV). Peptide #3 represents a combination of peptides #1, 1a, 1b and 2. Peptide #4 represents a region of the p17 core protein which bears some sequence homology to the thymic hormone, Thymosin alpha-1.
SUMMARY OF THE INVENTION
In its first aspect, the invention is a protein that comprises at least one polypeptide selected from the group consisting of ##STR1## provided that said protein is not one found in a naturally occurring human immunodeficiency virus or other animal virus.
Another aspect of the invention is the use of protein that comprises at least one polypeptide selected from the group, consisting of ##STR2## as an immunogen or vaccine in order to produce either antibodies with reactivity against a portion of human immunodeficiency virus (HIV) or cells capable of producing said antibodies provided said protein is not part of naturally occurring HIV or other animal virus.
Still another aspect of the invention is the use of protein that comprises at least one polypeptide selected from the group consisting of ##STR3## to detect the presence in an animal of entities (such as antibodies) that will bind to said polypeptide or polypeptides providing said protein is not part of naturally occurring human immunodeficiency virus or other animal virus.
A related invention is the process of making a monoclonal antibody with specificity against a portion of HIV which comprises injecting an animal with a protein that contains at least one polypeptide selected from the group consisting of ##STR4## isolating a spleen lymphocyte that makes the antibodies with specificity against the selected polypeptide, fusing that lymphocyte with a myeloma or other self-perpetuating cell to make a hybridoma and culturing the hybridoma under conditions where the desired monoclonal antibody is produced, provided said protein is not part of naturally occurring HIV or other animal virus. The invention is also the process of making anti-idiotypic monoclonal antibodies with specificity against anti-human immunodeficiency virus antibodies which comprises the aforesaid process of making monoclonal antibodies against a portion of HIV and the subsequent steps of injecting an animal with the anti-HIV monoclonal antibody, selecting a spleen lymphocyte that makes antibodies with the desired specificity, fusing the spleen lymphocyte with a myeloma or other self-perpetuating cell to make a hybridoma and culturing the hybridoma under conditions where the desired anti-idiotypic monoclonal antibody is produced.
Another process aspect of the invention is the process of inducing immunity against HIV which comprises injecting a human with a protein which comprises at least one polypeptide selected from the group consisting of ##STR5## provided said protein is not part of naturally occurring HIV or other animal virus. Closely related is the invention that is the process of inducing immunity against HIV which comprises injecting a human with a monoclonal antibody made by the aforementioned process of making a monoclonal antibody against HIV.
Another aspect of the invention is the process of reacting a protein that comprises at least one polypeptide selected from the group consisting of ##STR6## with an antibody or blood cell provided said protein is not part of naturally occurring (HIV) or other animal virus.
Another aspect of the invention is a monoclonal antibody made from a hybridoma crating by cell fusion of a myeloma or other self-perpetuating cell with a spleen lymphocyte isolated from an animal exposed to a protein comprising at least one polypeptide selected from the group consisting of ##STR7## said monoclonal antibodies being reactive with said selected polypeptide, provided said protein is not part of naturally occurring HIV or other animal virus. The resulting antibody is part of the definition of a related aspect of the invention: a monoclonal anti-idiotypic antibody made from a hybridoma created by cell fusion of a myeloma or other self-perpetuating cell with a spleen lymphocyte isolated from an animal exposed to said resulting monoclonal antibody. The resulting anti-idiotype antibody is part of the definition of a further related aspect of the invention: An anti-anti-idiotypic antibody generated as a result of using a said resulting anti-idiotype antibody as an immunogen or vaccine.
In all of the above inventions involving a protein that comprises at least one polypeptide selected from the group consisting of ##STR8## provided said protein is not part of naturally occurring HIV or other animal virus, there are subgeneric aspects to the invention, wherein:
(1) the protein comprises a multimer of either ##STR9##
(2) the protein comprises a polymer of either ##STR10##
(3) the protein is a multimer of either ##STR11##
(4) the protein is a polymer of either ##STR12##
(5) the protein has at least two copies of one polypeptide selected from the group ##STR13## but does not comprise a multimer of that polypeptide or polymer of that polypeptide.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1. Reactivity of HIV with monoclonal antibodies as determined using Western blot analysis. (lane A), HIV-seropositive human serum #H-731 diluted 1/1000; (lane B) monoclonal anti-p17 antibody, clone 32/5.8.42; (lane C), monoclonal anti-p17 antibody, clone 32/1.24.89; (lane D), monoclonal anti-gp160 antibody, clone 10E9; (lane E), monoclonal anti-p24 antibody, clone 32.5.17.76; (lane F) control, IgG-subclass monoclonal antibody, clone F5 (anti-prostate antibody, ref. 26).
FIG. 2. Inhibition of the cell-free HIV infectivity of HUT-102 cells by monoclonal anti-p17 antibodies. HUT-102 cells were challenged with 10 3 TCID 50 units of HIV in the presence of antibodies as described in Materials and Methods. Reverse transcriptase measurements were taken at 10 days post-infection. Abscissa, concentration of control or experimental antibodies; ordinate, reverse transcriptase activity (mean of triplicates) as a percentage of positive control cultures (virus only, no inhibitor). HIV + , IgG fraction of seropositive human serum; HIV - IgG fraction of seronegative human serum.
Results shown are the mean and s.e.m. of two separate experiments. Control reverse transcriptase levels (cpm) were 2.6×10 6 (experiment #1) and 1.6×10 6 (experiment #2).
FIG. 3. Neutralization of the cell-free HIV infectivity of T-lymphocytes by monoclonal antibodies. Normal donor peripheral blood mononuculear cells were pre-stimulated with PHA/IL-2 as described in Materials and Methods, washed and challenged with 10 3 TCID 50 doses of HIV in the presence of antibodies or control immunoglobulins. After ten days, viral replication was measured by reverse transcriptase measurements. Same antibodies as in FIG. 2. Control reverse transcriptase (cpm), 3.5×10 5 .
FIG. 4. Reciprocal, competitive binding inhibition analysis of monoclonal anti-p17 antibodies. Increasing concentrations of biotin-antibodies (abscissa) were allowed to react with solid-phase HIV in the absence or presence of competing antibodies, each at 5 ug/ml. Thereafter, the reactions were developed using streptavidin-peroxidase, substrate, and absorbance was measured at 450 nm (ordinate). Results were expressed as optical density versus input level of biotin-labeled monoclonal antibody in the presence of absence of inhibitors.
Top: reactivity of biotin-labeled monoclonal anti-p17 antibody, clone 32/1.24.89.
Bottom: reactivity of biotin-labeled anti-p17 antibody, clone 32/5.8.42.
Buffer, no inhibitor; 32/5.17.76, anti-p24 monoclonal antibody.
FIG. 5. Epitope mapping of monoclonal antibodies to p17 using epitope scanning (Geysen technique). A series of sequential, overlapping hexapeptides were synthesized in situ on solid phase pins, as described in Materials and Methods. The peptide series corresponds to the entire HIV p17 reading frame, beginning at the ATG (met) start codon. The peptides were probed for immunoreactivity against monoclonal anti-p17 antibodies (clones 32/5.8.42 and 32/1.24.89) at 10 ug/ml. The reactions were developed using biotin-labeled goat antibodies to murine IgG followed by streptavidin-peroxidase and then substrate. Results are expressed as optical density (ordinate) versus peptide number (abscissa).
Control monoclonal antibodies F5 (26) and 32/5.17.76 (anti-p24) demonstrated no reactivity versus any peptide (not shown).
FIG. 6. Competitive inhibition of monoclonal anti-p17 antibodies by soluble, synthetic peptides. Peptides were synthesized which corresponded to the antibody-reactive epitopes identified using epitope scanning (FIG. 5). Increasing concentrations of soluble peptides (abscissa) were allowed to compete for the reaction of monoclonal antibodies versus HIV target antigen. The reactions were developed using biotin-avidin enzyme reagents and then substrate.
SP-17-A, synthetic peptide corresponding to the reactive site of monoclonal anti-p17 antibody clone 32/5.8.42. (Glu Leu Asp Arg Trp Glu Lys Ile) (SEQ ID NO:1).
SP-17-B, synthetic peptide corresponding to the reactive site of monoclonal anti-p17 antibody clone 32/1.24.89. (Glu Lys Ile Arg Leu Arg) (SEQ ID NO:5).
SP-17-A/B, synthetic peptide containing both antibody-reactive sites above. (Glu Leu Asp Arg Trp Glu Lys Ile Arg Leu Arg) (SEQ ID NO:6).
MAb 32/5.8.42
MAb 32/1.24.89
The concentrations of peptides which produced a 50% inhibition of antibody binding activity (ID 50 ) are indicated in the Figure.
DETAILED DESCRIPTION
Definitions
A "substantially pure" preparation of a protein is one that has the purity achievable by normal chemical or biochemical procedures, such as the ones described herein, and is to be distinguished from a "natural" preparation of a protein, such as a protein that is part of a virus, a living cell, or a mammal or other animal, and is therefore in close proximity with other species of biochemical molecules.
All amino acids identified herein are in the natural or L-configuration. In keeping with standard nomeclature, abbreviations for amino acid residues are as follows:
______________________________________1-LETTER 3-LETTERSYMBOL SYMBOL AMINO ACID______________________________________A Ala L-alanineC Cys L-cysteineD Asp L-aspartic acidE Glu L-glutamic acidF Phe L-phenylalanineG Gly L-glycineH His L-histidineI Ile L-isoleucineK Lys L-lysineL Leu L-leucineM Met L-methionineN Asn L-asparagineP Pro L-prolineQ Gln L-glutamineR Arg L-arginineS Ser L-serineT Thr L-threonineV Val L-valineW Trp L-tryptophanY Tyr L-tyrosine______________________________________
Sequences defined by formula (e.g., Glu-Leu-Asp-Arg-Trp-Glu-Lys-Ile) (SEQ ID NO:1) are, left to right, in the direction of amino terminus to carboxy terminus.
The polypeptides of this invention are also referred to herein simply as "peptides".
The term "antigenically related variants" is used to designate polypeptides of differing overall amino acid residue sequence that share at least a portion of one antigenic determinant and are therefore immunologically cross-reactive.
The term "antigenic determinant", designates the structural component of a molecule that is responsible for specific interaction with corresponding antibody (immunoglobulin) molecules elicited by the same or related antigen or immunogen.
The term "immunogenic determinant", as used herein, designates the structural component of a molecule that is responsible for the induction in a host of an antibody containing an antibody combining site (idiotype) that binds with the immunogen when used as an antigen.
The term "antigen", as used herein, means an entity that is bound by an antibody.
The term "immunogen", as used herein, describes an entity that induces antibody production in the host animal. In some instances, the antigen and immunogen are the same entity, while in other instances, the two entities are different.
The word "inoculum" is used herein to describe a composition containing a polypeptide of this invention as an active ingredient used for the preparation of antibodies against HIV. When a polypeptide is used to induce antibodies it is to be understood that the polypeptide may be used alone, or linked to a carrier.
The word "vaccine" is used herein to described a type of inoculum containing a polypeptide of this invention as an active ingredient that is used to induce active immunity in a host mammal.
The phrase "pharmaceutically acceptable salts", as used herein, refers to non-toxic alkali metal, alkaline earth metal and ammonium salts used in the pharmaceutical industry, including the sodium, potassium lithium, calcium, magnesium and ammonium salts and the like that are prepared by methods well-known in the art. The phrase also includes non-toxic acid addition salts that are generally prepared by reacting components of this invention with a suitable organic or inorganic acid. Representative salts include the hydrochloride, hydrobromide, sulfate, bisulfate, acetate, oxalate, valerate, oleate, laurate, vorate, benzoate, lactate, phosphate, tosylate, citrate, maleate, fumarate, succinate, tartrate, and the like.
A "multimer" is a chain of two or more identical polypeptides joined in a head-to-tail manner by peptide bonds. A multimer may either represent the entire structure of a protein or represent part of the structure of a protein.
A "polymer" is a molecule that contains a two or more polypeptides joined together by bonds other than peptide bonds. A polymer may represent the entire structure of a protein or represent part of the structure of a protein.
The word "protein" is understood to include multimers and polymers.
The term "unit dose" refers to physically discrete units suitable as unitary dosages for animals, each unit containing a predetermined quantity of active material calculated to produce the desired therapeutic effect in association with the required diluent; i.e., carrier, or vehicle. The specifications for the novel unit dose of this invention are dictated by and are directly dependent on the unique characteristics of the active material and the particular therapeutic effect to be achieved.
Embodiments of the Invention
Embodiments of the present invention include the proteins of the invention described herein, the pharmaceutically acceptable salts thereof, and antigenically related variants thereof. Each of the embodiments is capable of inducing, in humans, rabbits and mice, antibodies that bind to the protein of the invention represented in that embodiment.
The polypeptides of this invention can be part of proteins whose structure includes other polypeptides yet still retain their immunogenic properties.
The present invention also contemplates a multimer containing at least two joined synthetic polypeptide repeating units wherein at least one of the repeating units is a polypeptide as described within.
The multimers of this invention, alone or linked to a carrier, when introduced in an effective amount into a host, are capable of inducing the production of antibodies that bind to HIV.
Thus, the multimers of this invention, like the polypeptide, are immunogenic. Those multimers may therefore be used to induce the production of anti-HIV antibodies that are useful in the diagnostic methods and systems discussed hereinafter, and may also be used as an antigen in appropriate diagnostic methods and systems.
Multimers that contain fewer than about 35 amino acid residues in the total multimer are typically linked to a carrier for use as an immunogen. Those multimers that contain more than a total of about 35 amino acid residues are typically sufficiently immunogenic to be used without a carrier.
Polypeptide multimers may be prepared by bonding together the synthesized polypeptide monomers in a head-to-tail manner using the aforementioned solid phase method; i.e., one complete polypeptide sequence can be synthesized on the resin, followed by one or more of the same or different polypeptide sequences, with the entire multimeric unit thereafter being cleaved from the resin and used as described herein. Such head-to-tail polypeptide multimers preferably contain about 2 to 4 polypeptide repeating units.
An exemplary polymer of this invention can be synthesized using a polypeptide of this invention that contains added cysteine residues at both the amino- and carboxy-termini (diCys polypeptide). The diCys polypeptide may be bonded together by intramolecular, interpolypeptide cysteine disulfide bonds utilizing an oxidation procedure to form an immunogenic, antigenic polymer. The polymer so prepared contains two or more polypeptides of this invention as repeating units. Those repeating units are bonded together by the above-discussed oxidized cysteine (cystine) residues.
The presence of one or two terminal Cys residues in a polypeptide of this invention for the purposes of binding the polypeptide to a carrier or for preparing a polymer is not to be construed as altering the amino acid sequence of polypeptide repeating units of this invention.
The polypeptides of this invention are used in a pharmaceutically acceptable diluent to form an inoculum or a vaccine that, when administered in an effective amount, is capable of inducing antibodies that immunoreact with HIV.
For polypeptides that contain fewer than about 35 amino acid residues, it is preferable to use a carrier for the purpose of inducing the production of antibodies.
Active immunity involves the production of antibodies. Thus, a vaccine or inoculum may contain identical ingredients through their uses are different. Alternatively, in some cases, the ingredients of a vaccine and of an inoculum are different because many adjuvants useful in animals may not be used in humans.
The present inoculum or vaccine contains an effective amount of a polypeptide of this invention. The effective amount of polypeptide per unit dose depends, among other things, on the species of animal inoculated, the body weight of the animal and the chosen inoculation regimen as is well known in the art. Inocula and vaccines typically contain polypeptide concentrations of about 100 micrograms to about 500 milligrams per inoculation (dose). The stated amounts of polypeptide refer to the weight of polypeptide without the weight of a carrier, when a carrier is used. Specific, exemplary inocula are described hereinafter with weight of carrier plus polypeptide (conjugate) being given.
Antibodies and substantially whole antibodies raised to (induced by) the polypeptides of this invention as well as antibody combining sites prepared from such antibodies constitute still another embodiment of this invention. Antibodies are raised in mammalian hosts such as mice, guinea pigs, rabbits, hoses and the like by immunization using the inocula described hereinabove.
Monoclonal antibodies need not only be obtained from hybridoma supernatants, but may also be obtained in generally more concentrated form from ascites fluid of mammals into which the desired hybridoma has been introduced. Production of monoclonal antibodies using ascites fluid is well known and will not be dealt with further herein.
An antibody of this invention binds both to the polypeptide to which it was raised and also binds to the corresponding HIV antigenic determinant site that the polypeptide of this invention immunologically mimics. Thus, a polypeptide of this invention may be both an immunogen and an antigen.
The antibodies of this invention may be described as being oligoclonal as compared to naturally occurring polyclonal antibodies since they are raised to an immunogen having relatively few epitopes as compared to the epitopes of an intact HIV antigenic molecule. Consequently, antibodies of this invention bind to epitopes of the polypeptide while naturally occurring antibodies raised to antigens of HIV bind to epitopes throughout the HIV antigenic molecule.
The polypeptides, antibodies and antibody combining sites raised to the before described polypeptides, and methods of the present invention may also be used for diagnostic test, such as immunoassys. Such diagnostic techniques include, for example, enzyme immune assay, enzyme multiplied immunoassay technique (EMIT), enzyme-linked immunosorbent (ELISA), radio-immune assay (RIA), fluorescence immune assay, either single or double antibody techniques, and other techniques in which either the receptor or the antigen is labeled with some detectable tag or indicating means. See generally Maggio, Enzyme Immunoassay, CRC Press, Cleveland, Ohio (1981); and Goldman, M., Fluorescent Antibody Methods, Academic Press, New York, N.Y. (1980).
Vaccines can also be produced using antibodies which are immunologically specific to the anti-peptide antibodies described above. These "anti-antibodies" are termed anti-idiotypic antibodies (anti-ids) and may be monoclonal or polyclonal in nature. Such approaches to vaccine construction have been reviewed before (29) and are described in the Materials and Methods section.
Synthesis of Polypeptides
The polypeptides of this invention are chemically synthesized by solid-phase methods as previously described (18, 30) [See also U.S. Pat. No. 4,316,891, issued to Guillemin et al.] The solid phase method of polypeptide synthesis is practiced utilizing a Beckman Model 990B Polypeptide Synthesizer, available commercially from Beckman Instrument Co., Berkeley, Calif., or an equivalent instrument.
For polypeptides having fewer than 35 residues that are used in inocula, a cysteine residue is added to the carboxy-terminus or the amino-terminus or both the amino-terminus and the carboxy-terminus to assist in coupling to a protein carrier as described below. The compositions of all polypeptides are confirmed by amino acid analysis.
In preparing a synthetic polypeptide of this invention by the above solid phase method, the amino acid residues are linked to a resin (solid phase) through an ester linkage from the carboxy-terminal residue. When the polypeptide is to be linked to a carrier via a Cys residue or polymerized via terminal Cys residues, it is convenient to utilize that Cys residue as the carboxy-terminal residue that is ester-bonded to the resin.
The alpha-amino group of each added amino acid is typically protected by a tertiary-butoxcarbonyl (t-BOC) group prior to the amino acid being added into the growing polypeptide chain. The t-BOC group is then removed prior to addition of the next amino acid to the growing polypeptide chain.
Reactive amino acid side chains are also protected during synthesis of the polypeptides. Usual side-chain protecting groups used for the remaining amino acid residues are as follows: O-(bromobenzyloxycarbonyl) for tyrosine; O-benzyl for threonine, serine, aspartic acid and glutamic acid; S-methoxybenzyl for cysteine, dinitrophenyl for histidine; 2-chlorobenzoxycarbonyl for lysine and tosyl for arginine.
Protected amino acids are recrystallized from appropriate solvents to give single spots by thin layer chromatography. Couplings are typically carried out using a ten-fold molar excess of both protected amino acid and dicyclohexyl carbodiimide over the number of milliequivalents of initial N-terminal amino acid. A two molar excess of both reagents may also be used. For asparagine, an equal molar amount of N-hydroxy-benzotriazole is added to the protected amino acid and dimethyl formamide is used as the solvent.
After preparation of a desired polypeptide, a portion of the resulting, protected polypeptide (about 1 gram) is treated with two milliliters of anisole, and anhydrous hydrogen fluoride, about 20 milliliters, is condensed into the reaction vessel at dry ice temperature. The resulting mixture is stirred at about 4 degrees C., for about one hour to cleave the protecting groups and to remove the polypeptide from the resin. After evaporating the hydrogen fluoride at a temperature of 4 degrees C., with a stream of N2, the residue is extracted with anhydrous diethyl ether three times to remove the anisole, and the residue is dried in vacuo.
The vacuum dried material is extracted with 5% aqueous acetic acid (3 times with 50 milliliters) to separate the free polypeptide from the resin. The extract-containing solution is lyophilized to provide a monomeric unoxidized polypeptide.
The produced synthetic polypeptide may be used as a reagent in an enzyme-linked immumosorbent assay (ELISA) to detect anti-HIV antibodies. The synthetic polypeptide may also be used to produce an inoculum, usually by linking it to a carrier to form conjugate and then dispersing an effective amount of the conjugate in a physiologically tolerable diluent, as is discussed hereinafter.
It is also to be noted that a synthetic multimer of this invention can be prepared by the solid phase, synthesis of a plurality of the polypeptides of this invention linked together end-to-end (head-to-tail) by an amide bond between the carboxyl-terminal residue of one polypeptide and the amino-terminal residue of a second polypeptide "peptide bond". Such synthetic multimers are preferably synthesized as a single long polypeptide multimer, but can also be prepared as individual polypeptides that are linked together subsequent to their individual synthesis, using a carbodiimide reagent such as 1-(3-dimethylaminopropyl)-3-ethyl-carbodiimide hydrochloride in water. The total number of amino acid residues contained in a multimer prepared as a single polypeptide chain is preferably less than about 50. A synthetic head-to-tail multimer more preferably contains two to about four blocks of linked, synthetic, random copolymer polypeptides of this invention, and a total of less than about 40 amino acid residues.
Preparation of Polymers
The polypeptides of the present invention may be connected together to form an antigenic and/or immunogenic polymer comprising a plurality of the polypeptide repeating units. Such a polymer typically has the advantage of increased immunogenicity and antigenicity. In addition, a carrier is typically not needed when a polymeric immunogen is utilized. Where different polypeptide monomers are used to make up the polymer, the ability to immunoreact with antibodies to several HIV antigenic determinants is obtained. A still further advantage is the ability of such a polymer when used in an inoculum to induce antibodies that immunoreact with several antigenic determinants of a HIV antigen.
A polymer of this invention may be prepared by synthesizing the polypeptides as discussed above and including cysteine residues at both amino- and carboxy-termini to form a "diCys-terminated" polypeptide. After synthesis, in a typical laboratory preparation, 10 milligrams of the diCys polypeptide (containing cysteine residues in un-oxidized form) are dissolved in 250 milliliters (ml) of 0.1 molar (M) ammonium bicarbonate buffer. The dissolved diCys-terminated polypeptide is then air oxidized by stirring the resulting solution gently for a period of about 18 hours in the air, or until there is no detectable free mercaptan by the Ellman test [See (31)]
The polymer so prepared contains a plurality of the synthetic, random copolymer polypeptide repeating units that are bonded together by oxidizing cysteine (cystine) residues. Such polymers typically contain their polypeptide repeating units bonded together in a head-to-tail manner as well as in head-to-head and tail-to-tail manners; i.e., the amino-termini of two polypeptide repeating units may be bonded together through a a single cystine residue as may two carboxyl-termini since the linking groups at both polypeptide termini are identical.
Coupling to Carriers
The synthetic polypeptides are coupled to keyhole limpet hemocyanin (KLH) as carrier by the method described in (32). Briefly, 4 milligrams (mg) of the carrier are activated with 0.51 mg of m-maleimidobenzoyl-N-hydroxysuccinimide ester and subsequently reacted with 5 mg of the polypeptide through an amino- or carboxy-terminal cysteine to provide a conjugate containing about 10 to about 35 percent by weight polypeptide.
One or more additional amino acid residues may be added to the amino- or carboxy-termini of the synthetic polypeptide to assist in binding the polypeptide to a carrier. Cysteine residues have been found to be particularly useful for forming polymers via disulfide bonds. However, other methods well known in the art for preparing conjugates can also be used. Exemplary additional linking procedures include the use of Michael addition reaction products, dialdehydes such as glutaraldehyde [See (33)], and the like, or the use of carbodiimide technology as in the use of a water-soluble carbodiimide to form amide links to the carrier, as discussed before for linking a plurality of polypeptides together to form a synthetic multimer.
Useful carriers are well known in the art, and are generally proteins themselves. Exemplary of such carriers are keyhole hemocyanin (KLH), edestin, thyroglobulin, albumins such as bovine serum albumin (BSA) or human serum albumin (HSA), red blood cells such as sheep erythrocytes (SRBC), tetanus toxoid, cholera toxoid as well as polyamino acid such as poly (D-lysine:D-glutaminic acid), and the like.
As is also well known in the art, it is often beneficial to bind a synthetic polypeptide to its carrier by means of an intermediate, linking group. As noted above, glutaraldehyde is one such linking group. However, when cysteine is used, the intermediate linking group is preferably an m-maleimidobenxoyl N-hydroxy succinimide (MBS) as was used herein.
Additionally, MBS may be first added to the carrier by an ester-amide interchange reaction as disclosed by Lie et al., supra. Thereafter, the addition can be followed by addition of a blocked mercapto group such as thiolacetic acid (CH3COSH) across the maleimido-double bond. After cleavage of the acyl blocking group, a disulfide bond is formed between the deblocked linking group mercaptan and the mercaptan of the added cysteine residue of the synthetic polypeptide.
The choice of carrier is more dependent upon the ultimate use of the immunogen than upon the determinant portion of the immunogen, and is based upon criteria not particularly involved in the present invention. For example, if a inoculum is to be used in animals, a carrier that does not generate an untoward reaction in the particular animal should be selected.
ELISA
Anti-polypeptide antibody binding and inhibition studies may be prepared by an enzyme-linked immunosorbent assay (ELISA) as described below.
Briefly, microtiter wells (Costar, #3590, Cambridge, Mass.) are coated with individual polypeptides as antigens by adding 100 microliters (ul) of BBS [10 millimoler (mM) sodium borate (pH 8.3), 150 mM NaCl] containing polypeptide at a concentration of 10 micrograms per milliliter (ug/ml). Contact between the wells and antigen-containing solution is maintained for a predetermined time, typically 1-18 hr., and at 20 degrees C., to form an antigen-coated solid phase. The solid and liquid phases are separated and the wells are washed three times with BBS.
Non-specific binding sites are blocked by admixing 200 microliters of 1 percent bovine serum albumin (BSA) in each well to form another solid-liquid phase admixture, and maintaining the solid-liquid phase admixture for approximately 30 minutes, at 20 degrees C. The phases are separated and excess, unbound BSA is removed by washing three times with BBS.
Rabbit (or guinea pig) and human sera (body sample aliquots) are assayed for anti-polypeptide activity by adding 100 microliters of serum diluted 1:20 in BBS per well to form a solid/liquid phase composition. Contact between the diluted sera and the antigen-coated solid phase is maintained for a predetermined time such as 1 hour, and at 20 degrees C., for an immunoreactant to form. The solid and liquid phases are separated, and the solid phase; i.e., antigen-coated, immunoreactant containing wells, is then washed three time with BBS.
The antibodies in human sera that immunoreact with an adsorbed polypeptide may be detected using an indicating means comprising alkaline phosphatase-conjugated goat anti-human Ig antibody (Tago, Burlington, Calif.). The antibodies in rabbit sera that immunoreact with an adsorbed polypeptide may be detected using an indicating means comprising alkaline phosphatase-conjugated goat anti-rabbit Ig antibody (Kirkegard & Perry Laboratories, Inc., Gaithersburg, Md.). In either instance, 100 microliters of the indicating antibody diluted 1:300 in BBS are added per well to form a further solid-liquid phase composition. This solid-liquid phase composition is maintained for a predetermined time, one hour, for the formation of a reaction product between the human antibodies bound to the solid phase and the indicating means, and at 20 degrees C. The phases are separated, and the solid phase is washed 3 washed with BBS.
Alkaline phosphatase-conjugated antibody bound to polypeptide specific antibody may be detected by spectrophotometrically measuring the enzymatic hydrolysis of p-nitrophenyl phosphate to p-nitrophenol. Briefly, 100 microliters of p-nitrophenyl phosphate [1 milligram per milliliter in 2 mM magnesium chloride (pH 9.8), 50 mM sodium carbonate] are added to each well. The enzymatic reaction is allowed to proceed 1 hour and then the optical density at 405 nm is determined in a TITERTEK spectrophotometer available from FLOW Laboratories, Inglewood, Calif.
Immunizations
Antibodies of this invention include whole antibodies raised in mammals by immunizing them with inocula including a polypeptide and/or multimer as describer hereinabove. Both polypeptides and multimers may be used included in inocula alone or conjugated to a carrier protein such as keyhole limpet hemocyamin (KLH). However, polypeptides are preferably used as a conjugate and multimers are preferably used alone.
Rabbits may be immunized with inocula containing 1.0 mg of conjugate in complete Freund's adjuvant (CFA), and boosted one month later with 1.0 mg of conjugate in incomplete Freund's adjuvant (IFA). Each immunization consistent of one subcutaneous injection, on the back hip. Rabbits are bled 1 and 2 months subsequent to the boost.
Individual inocula are prepared with CFA or IFA as follows: An amount of conjugate sufficient to provide the desired amount of polypeptide per inoculation (e.g., 1 mg) is dissolved in PBS (at about 0.5 ml) at pH 7.2. Equal volumes of CFA or IFA are then mixed with the conjugate solutions to provide an inoculum containing conjugate, water and adjuvant in which the water to oil ratio was 1:1. The mixture is thereafter homogenized to provide the inocula. The volume of an inoculum so prepared is typically greater than 1 ml, and some of the conjugate, PBS and adjuvant may be lost during the emulsification. Substantially all of the emulsion that can be recovered is placed into a syringe, and then is introduced into the rabbits as discussed before. The amount of inoculum introduced into the rabbits should be at least about 90 percent of that present prior to the emulsification step.
Sera containing immunologically active antibodies are produced from the bleeds by methods well known in the art. These anti-peptide antibodies are immunoreactive with one or more of the polypeptides of this invention, with HIV antigenic determinants and will also specifically neutralize HIV infectivity. The immunizations will also induce a cell-medicated immunity against peptides and HIV antigenic determinants, as commonly monitored by delayed-type hypersensitivity reaction.
Delayed Type Hypersensitivity Test (Skin Reaction Test)
The above inocula stock solutions are illustrative of the inocula of this invention. As demonstrated herein, they may be used to produce antibody molecules that immunoreact with HIV antigens.
The previously described diagnostic systems and assays are based on in vitro assays. Although particular steps of the assays can be carried out in vivo, the actual immune response is measured in tissue culture. The present invention, however, can also be applied to diagnostic systems involving the in vivo measurement of T cell responses. One example of such a system is a delayed-type cutaneous hypersensitivity (DCH) reaction or what is more commonly known as a skin reaction test.
A DCH reaction can only occur in an individual previously exposed (sensitized) to a given antigen. The first exposure of an individual to the antigen produces no visible change, but the immune status of the individual is altered in that hypersensitivity to renewed exposure to that antigen results. Thus, upon intradermal or subcutaneous injection of the antigen (preferably in a buffered saline solution) a characteristic skin lesion develops at the injection site-a lesion that would not develop after a first antigen exposure. Because the response to the second (or challenge) antigen inoculum is typically delayed by 24 to 48 hours, the reaction is referred to as delayed-type hypersensitivity.
In humans, exposure to a sensitizing antigen takes place upon contact with the microorganism responsible for the disease (e.g. tuberculin from Mycobacterium tuberculosis, typhoidin from Salmonella typhi and abortin from Brucella abortus), and sensitization occurs as a result of a chronic infection. In animals, sensitization can be achieved by inoculation of an antigen emulsified in water, saline or an adjuvant.
In both humans and animals, hypersensitivity is tested in vivo by the injection of the antigen dissolved in a physiologically tolerable diluent such as saline solution into the skin (either intradermally or subcutaneously). DCH is usually a more sensitive diagnostic assay than the determination or measurement of the amount of antibody produced to an antigen. For example, only minute amounts of protein (a few hundred nanograms) are necessary for DCH sensitization of a mouse, while a much larger dose is needed to induce antibody production.
Since the polypeptides of the present invention stimulate the proliferation of T cells following immunization (sensitization) with a polypeptide of the invention, a skin reaction test using one or more of the present synthetic polypeptides as a challenge antigen is employed.
Polypeptides of the invention will elicit an erythematous area and an induration of at least about 10 millimeters in diameter about the injection site, Unimmunized animals will demonstrate no DCH reaction upon intradermal injection of a polypeptide.
Production of Anti-idiotype Antibodies
Whole antibodies, or their fragments, raised against polypeptides of the present invention are of use to develop anti-idiotypic antibodies (anti-ids). These anti-ids may be monoclonal or polyclonal in nature and will specifically react with the immunizing anti-peptide antibodies. Further, the anti-ids bear the "internal image" of the nominal antigen (i.e. the polypeptides antigenic determinants) and will, when used as the immunogen, further induce an immunity to the nominal antigen. This immunity will be both humoral and cell-mediated in nature, and will effectively react with HIV antigenic determinants and result in HIV neutralization, as measured in vitro.
Monoclonal anti-ids are produced and characterized according to strategies previously reported (34, 35, 36) Balb/c mice are immunized i.p. with 50 ug of anti-peptide antibody conjugated to a carrier protein such as keyhole limpet hemocyanin (KLH), dissolved in monophosphoryl lipid A-trehalose dimycolate (MLA-TDM) and boosted on a biweekly basis with a similar does in TDM. Three days after after the third injection, spleen cells are fused with P3X63.Ag8.653 myeloma cells in the presence of polyethylene glycol. Selection of cells in HAT medium, cloning, isotype analysis and antibody purification have been described above and in the published literature (14,26).
For the detection of anti-idiotypes, microplates previously coated with purified goat anti-murine Ig are incubated with 100 ul of hybridoma supernatants for 2 hr. Excess idiotypic-negative normal mouse serum is then added for 1 hr to block excess anti-Ig. After washes with PBS-Tween 20, 100 ul of the immunogen coupled to alkaline phosphatase is added to each well for 1 hr. Following washing, wells are incubated with substrate containing p-nitrophenyl phosphate and absorbance is measured at 405 nm on an ELISA plate reader.
Anti-idiotypic antibodies directed at or near the combining site of the idiotypic-positive MABs will be identified using a competition assay: Microwells are coated with purified idiotype at 4 ug/ml, washed and then counter-coated with 1% BSA. Ten nanograms of radio-iodine labeled anti-idiotype is added to the plates. Unlabeled antigen, representing the polypeptides of this invention, are preincubated with the plates for 30 minutes before the addition of labeled anti-idiotype.
Inasmuch as the anti-ids bear the internal image of the nominal antigen (i.e. the polypeptides of this invention), they may be used as immunogens to generate anti-anti-idiotypic antibodies (anti-anti-ids). Anti-anti-ids will be immunoreactive with the polypeptides of this invention and react with HIV antigenic determinants. Thus, anti-ids are effective vaccines with which to generate anti-HIV immunity and protection.
In mice, anti-anti-ids are produced by immunizing animals i.p. with 50 ug doses of anti-id-KLH conjugates in MLA-TDM. At biweekly intervals the same immunogen is administered in TDM. Sera are collected after the third boost and tested for anti-anti-id activity by means of an ELISA using microwells coated with anti-id, polypeptides of this invention or HIV antigens. Sera are also titrated for HIV neutralization using the HIV transmission assay described below.
Analysis of Sera for Activity Which Specifically Neutralizes HIV Infectivity
Antipeptide anti-sera and anti-anti-id antibodies are shown to inhibit the in-vitro replication of HIV using a viral transmission assay (19). Serial dilutions of immune and pre-immune sera are mixed with 10 3 tissue culture infectious doses/ml of HIV and incubated for 1 hr. at 4 degrees C. One ml of the mixture is then used to infect 10 7 permissive cells in the presence of 2 ug/ml Polybrene. Permissive cells may be one of the following continuous T cells lines: Molt-3, CEM, Ti7.4 or HUT-78 (37). After a one hour incubation, the cells are washed and set up in culture. Virus spread is monitored at 10 and 20 days by measuring culture supernatant levels of reverse transcrystase and released viral antigens.
Hybridoma formation
Suitable monoclonal antibodies, typically whole antibodies, may also be prepared using hybridoma technology previously described ((27). Briefly, to form the hybridoma from which the monoclonal antibody is produced, a myeloma or other self-perpetuating cell line is fused with lymphocytes obtained from the spleen of a mammal hyperimmunized with a polypeptide of this invention.
It is preferred that the myeloma cell line be from the same species as the lymphocytes. Typically, a mouse of the strain BALB/c is the preferred mammal. Suitable mouse myelomas for use in the present invention include hypoxanthine-aminopterin-thymidine-sensitive (HAT) cell lines P3X63-Ag8.653 (ATCC CRL 580), and Sp2/0-Ag14 (ATCC CRL 1581).
Splenocytes are typically fused with myeloma cells using a polyethylene glycol such as PEG 1500 or PEG 6000. Fused hybrids are selected by their sensitivity to HAT. Hybridomas producing the antibody molecules of this invention are identified using the enzyme linked immunosorbent assay (ELISA) described in the Materials and Methods section hereinafter.
Inocula
Inocula are typically prepared from the dried solid polypeptide-conjugate or polypeptide polymer by suspending the polymer in a physiologically tolerable (acceptable) diluent such as water, saline or phosphated-buffered saline.
Inocula may also include an adjuvant. Adjuvants such as complete Freund's adjuvant (CFA), incomplete Freund's adjuvant (IFA) and alum are materials well known in the art, and are available commercially from several sources.
EXAMPLES
Monoclonal antibody production. HIV was purified from the supernatant of a producer cell line as described previously (13). Virions were disrupted in detergent/high salt (0.5% Triton X-100/0.6M KCl) under sonication and then ether-extracted in order to remove detergent. Female Balb/c mice were primed with 100 ug of viral protein emulsified in complete Freund's adjuvant and boosted at monthly intervals with 50 ug protein in incomplete adjuvant. Three days following the fourth boost, the spleens were obtained for cell fusion. The fusion protocol, utilizing Sp2/0-Ag14 myeloma cells in the presence of 50% polyethylene glycol, was as described previously (14).
Immunologic assays. Western blotting (WB) was performed essentially as described before (13), using antigen strips provided by DuPont, Biotechnology Systems Division, Wilmington, Del. Briefly, Western blot strips were incubated for 18 hours at room temperature with MAbs at 10 ug/ml. Strips were washed in PBS-T (50 mM sodium phosphate, pH 7.2/150 mM sodium chloride/0.05% Tween-20) and then allowed to react with biotin-labeled goat antibody to murine IgG (Jackson Labs; West Grone, Pa.) for 1 hour at 37 degrees C. After washing, streptavidin-peroxidase conjugate (Jackson Labs) was applied for 1/2 hour at 37 degrees C. Washed strips were developed in a solution containing PBS/0.01% 4-chloro-1-naphtol/0.03% hydrogen peroxide.
Solid-phase synthetic peptides were examined for their immunoreactivity using enzyme immunoassay (EIA). Polyethylene pins, with peptides on their surface (see below), were counter-coated in EIA buffer (PBS/1% ovalbumin/1% bovine serum albumin/0.1% Tween-20) for 18 hours at 4 degrees C. After washing with PBS-T (4×10 min), the pins were incubated in microplates containing MAb or control antibody, each at 10 ug/ml, for 18 hours at 4° C. After washing as above, incubation was allowed to proceed for 1 hour in enzyme-conjugated antiglobulin (anti-murine IgG: peroxidase; Jackson Labs). The washed pins were next immersed into wells containing ABTS substrate solution (azino-bis-3-ethylbenzthiazoline-6-sulfonic acid, 0.5 mg/ml in pH 4.0 citrate buffer/0.03% hydrogen peroxide). Reactions were stopped after 30 minutes by removing the pins and absorbance measurements were taken at 450 nm using a microplate reader.
Competitive inhibition experiments were performed with soluble, synthetic peptides dissolved in PBS-T. Solid-phase target antigen represented 96-well microplates which were coated with HIV (5 ug/ml) for 18 hours at 4 degrees C. For competition analysis, various concentrations of synthetic peptides were allowed to react within HIV-coated microwells in the presence of biotin-labeled MAbs for 90 minutes at 37 degrees C. Biotin derivitization was performed using N-hydroxysuccinimide-d-biotin (Calbiochem, La Jolla, Calif.) (15). The concentration of biotin-MAb chosen corresponded to approximately 40% of maximal binding activity. After aspiration of the probe:inhibitor mixture, the wells were washed five times with PBS-T and streptavidin-peroxidase (Jackson Labs) was added for a further 30 minutes. Thereafter, washed wells received ABTS substrate solution and absorbance was monitored as above. Specific inhibition was calculated according to the formula:
% specific inhibition=100×(A max-Ax) / (A max-A min)
where, A max=maximal absorbance in the presence of buffer; A min=minimal (background) absorbance in the presence of specific inhibitor (10 ug/ml of homologous, unlabeled MAb); Ax=absorbance in the presence of the test peptide.
Epitope scanning. The strategy employed consisted of the construction of sequential, overlapping hexapeptides which completely spanned the entire HIV p17 amino acid sequence (16). Since the anti-p17 MAbs under study strongly reacted with the prototype HTLV-IIIB strain of HIV, its published sequences were used to construct peptide homologs (17). Peptides were synthesized in situ on plastic pins which conform in configuration to a standard 96-well microplate, using reagents and a kit (Epitope Mapping Kit) provided by Cambridge Research Biochemicals, Inc., Valley Stream, N.Y. After step-wise, solid-phase syntheses, the peptides were de-protected (20%) piperidine in dimethyl formamide), washed and air-dried. Included in the experiment was the use of concurrently-synthesized peptide controls with known reactivity versus available antisera. These peptides represented the sequences Pro Leu Ala Gln and Gly Leu Ala Gln. One of these peptides (Pro Leu Ala Gln) is known to react with antibody to sperm whale myoglobin, while the other is non-reactive but similar in structure. These EIA-testable peptides were included in each assay run.
Soluble, synthetic peptides. Peptides were synthesized following the strategy of Merrifield (18) at Peninsula Laboratories, Inc., Belmont, Calif. The acid-labile, tert-butyloxycarbonyl group was used for temporary amino-terminal protection. Peptides were cleaved from the resin using HF/anisole (9:1) containing 2% ethanedithiol and purified by gel filtration (Sephadex G-25 in 0.1M acetic acid) followed by reversed-phase high performance liquid chromatography. The sequence of each peptide was confirmed using amino acid analysis.
HIV infectivity assay. Serial dilutions of various MAbs or control antibodies were mixed with 10 3 TCID 50 doses (19) of infectious HIV and incubated for 1 hour at 4 degrees C. One ml of the mixture was utilized to infect 1×10 6 permissive HUT-102 cells in the presence of polybrene (2 ug/ml in RPMI-1640). After a one hour incubation at 37 degrees C. the cells were washed and placed in culture in complete medium containing RPMI-1640/10% fetal bovine serum/antibiotics. Virus spread was monitored at 10 days by measuring reverse transcriptase (20).
For some experiments, peripheral blood mononuclear cells, pre-stimulated with phytohemagglutinin (PHA) were employed as the permissive cell substrate, as previously described (21). In brief, washed lymphocytes at 1×10 6 cells/ml were incubated for 3 days in the presence of 1 ug/ml PHA-P (Defco, Detroit, Mich.). Thereafter, the washed cells were resuspended in infectivity media [complete medium containing 10% interleukin-2 (Cellular Products, Inc.), and 2 ug/ml Polybrene]. The lymphocyte cultures containing activated T-cells were then employed for viral transmission experiments.
Results
Spleen cells from an animal immunized with HIV lysate were subjected to cell fusion and the resultant crude hybridoma cultures were screened for antibody activity using solid-phase EIA and WB. Cultures of interest were cloned, re-assayed and subcloned. Three cloned lines were studied in more detail; two hybridomas secreted anti-p17 antibodies (clones 32/5.8/42 and 32/1.24.89) and one produced antibody reactive with p24 (clone 32/5.17.76), each of the IgG class of immunoglobulin. On WB examination (FIG. 1), the p17 MAbs bound to polyprotein precursor in addition to mature viral core protein. No cross-reactivity was observed with HTLV-I infected T-cells.
In order to study the biological activity of the MAbs, HIV infectivity assays were performed. Assays were performed using cell-free virus which was allowed to propagate in HUT-102 permissive cells. In addition to the anti-core MAbs, the neutralizing capacity of IgG purified from seropositive (HIV + IgG) and seronegative (HIV - IgG) donors was evaluated. As shown in FIG. 2, MAb 32/5.17.76 (anti-p24) and HIV-IgG failed to perturb the infectivity of cell-free virus. In contrast, submicrogram concentrations of HIV+ IgG and MAb 32/1.24.89 were potent inhibitors of viral replication. The other anti-p17 antibody (MAb 32/5.8.42) also demonstrated a significant level of viral inhibition, although at higher input levels of immunoglobulin. Indistinguishable results were obtained when PHA-stimulated peripheral blood lymphocytes were employed as the permissive cell (FIG. 3), indicating that antibody-mediated viral inhibition was a cell substrate-independent event.
To determine if the two MAb reagents against p17 were identifying the same antigenic site on the core protein, antibody competition assays were run. As seen in FIG. 4, the reactivity of biotin-conjugated MAb 32/1.24.89 versus solid-phase HIV was undisturbed in the presence of 1000-fold excess levels of anti-p24 MAb. In contrast, complete binding inhibition was observed with homologous, unlabeled antibody 32/1.24.89. Of interest, anti-p17 MAb 32/5.8.42 also produced a significant inhibition (approximately 80%), indicating that these antibodies reacted with sterically-related epitopes of the p17 molecule. Reciprocal inhibition experiments (FIG. 4, bottom) yielded similar data.
To precisely define the p17 epitopes of interest, epitope scanning was performed using a series of overlapping, hexapeptides which completely spanned the HIV p17 gene product. The solid-phase peptides were individually screened for their reactivity against each p17 MAb using EIA (FIG. 5). Results clearly indicated that MAb 32/5.8.42 strongly bound to 3 adjacent peptides occupying the amino-terminal region of p17 and to a single hexapeptide much further downstream. Antibody 32/1.24.89 produced a distinct pattern of binding (FIG. 5); that MAb strongly bound to a single peptide which partially overlapped the antigenic region recognized by MAb 32/5.8.42. No downstream binding was observed with MAb 32/1.24.89.
To confirm the data obtained from epitope scanning experiments, soluble peptides were synthesized which corresponded to the amino-terminal, MAb 32/5.8.42-binding site (epitope "A"; residues 12-19); the MAb 32/1.24.89-binding site (epitope "B"; residues 17-22); and to a region containing both binding sites (epitope "A/B"; residues 12-22): these synthetic peptides were termed SP-17-A, SP-17-B and SP-17-A/B, respectively. At the experimental level, each soluble peptide was allowed to compete with solid-phase HIV for the binding of both MAbs. As shown in FIG. 6, SP-17-A effectively inhibited the binding activity of MAb 32/5.8.42, exhibiting an ID 50 dose of approximately 1 ug/ml. This peptide was immunologically specific, inasmuch as no effect was noted on the reactivity of MAb 32/1.24.89. SP-17-B, corresponding to the binding site of MAb 32/1.24.89, was capable of inhibiting homologous antibody but only at very high concentrations (ID 50 of approximately 3.2×10 3 ug/ml), indicating a low affinity interaction. However, the inhibition was immunologically specific. Further studies was a synthetic peptide which contained both MAb binding sites. This peptide, SP-17-A/B was a strong inhibitor of each anti-p17 antibody (FIG. 6). The ID 50 dose versus MAb 32/5.8.42 was similar to that observed with SP-17-A (0.4 versus 1.06 ug/ml). In distinction, SP-7-A/B was almost 500 times more effective than SP-17-B with respect to its capacity to compete MAb 32/1.24.89 (ID 50 dose 6.03 ug/ml versus 3.2×10 3 ug/ml). Of the three synthetic peptides studied, none demonstrated any detechable inhibition of an irrelevant MAb (anti-HIV p24, clone 32/5.17.76), at dose ranges of up to 10 3 ug/ml.
LITERATURE CITED
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__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 6(vi) CURRENT APPLICATION DATA:(A) APPLICATION NUMBER: US 07/234381(B) FILING DATE: 19-AUG-88(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 8 amino acids (B) TYPE: amino acid(C) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:GluLeuAspArgTrpGluLysIle15(2) INFORMATION FOR SEQ ID NO:2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 6 amino acids (B) TYPE: amino acid(C) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:GluLeuAspArgTrpGlu15(2) INFORMATION FOR SEQ ID NO:3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 6 amino acids(B ) TYPE: amino acid(C) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:LeuAspArgTrpGluLys15(2) INFORMATION FOR SEQ ID NO:4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 6 amino acids(B) TYPE: amino acid (C) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:4:AspArgTrpGluLysIle15(2) INFORMATION FOR SEQ ID NO:5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 6 amino acids(B) TYPE: amino acid (C) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:5:GluLysIleArgLeuArg15(2) INFORMATION FOR SEQ ID NO:6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 11 amino acids(B) TYPE: amino acid(C) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:6:GluLeuAspArgTrpGluLysIleArgLeuArg1510
34. Reilly et al., Hybridoma 6:461 (1987).
35. McNamara-Ward, J. Immunology 139:2775 (1987).
36. Nelson et al., J. Immunology 139:2110 (1987)).
37. Gallo, R. C. et. al., U.S. Pat. No. 4,652,599 issued Mar. 24, 1987.
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Polypeptides in the size range 6-11 amino acids from discrete regions of the human immunodeficiency virus p17 protein are immunogenic and form the basis for diagnosis and therapy of HIV-related disease.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of the French patent application No. 1355784 filed on Jun. 19, 2013, the entire disclosures of which are incorporated herein by way of reference.
BACKGROUND OF THE INVENTION
The present invention relates to a folding table system, in particular for an aircraft such as an airplane.
Designers of aircraft, in particular airplanes, are constantly faced with the challenge of optimizing the use of the space available within the cabins of the aircraft.
In particular, certain cabin areas can form transit areas for the passengers during the boarding, deplaning and emergency evacuation phases, but not be required for such transit in the course of the flight.
Areas of this type may in particular be found close to certain doors of the aircraft.
It can thus be desirable to design a folding table system in such an area, to make use of the corresponding space in the course of the flight.
In particular, when a kitchen space is designed in such an area a folding table system can enable an additional working surface to be provided for the crew during the flight.
However, areas located near the doors can be obstructed with one or more fixed elements of the aircraft, such as a door hinge system, a unit, a caisson or any other type of element.
And such a fixed element forms an obstacle which may hinder the deployment of such a folding table system of a conventional type, consequently limiting the extent of a folding table which can be used in such an area.
SUMMARY OF THE INVENTION
One aim of the invention is notably to provide a simple, economic and efficient solution to this problem.
Its aim in particular is to propose a folding table system which can be used in an aircraft, where the extent of the table system is not limited by the presence of fixed elements of the aircraft in proximity.
To this end the invention proposes a folding table system including:
a bracket,
a table including a first end rotationally mounted on the bracket, such that the table can be moved between a storage position in which the table covers a first side of the bracket, and a deployment position in which the table is separated from said first side of the bracket,
a removable extension having a first end able to be connected to a second end of the table opposite said first end of the table, such that the removable extension extends the table when the table is in its deployment position,
first retention means able alternatively to hold the table in its storage position, and to release the table so as to enable the table to be moved to its deployment position, and
at least one rigidification element slidably mounted within a cavity formed within the table, and open in said second end of the table, such that an end portion of said rigidification element can be moved outside the cavity, and be inserted into a housing made in the removable extension, when said first end of the removable extension is connected to said second end of the table.
The system notably has the advantage that it occupies a small volume in its storage position, and provides a modular working surface by means of the removable extension, which enables the working surface formed by the table in its deployment position to be extended. The system is thus particularly useful to equip an area of the aircraft cabin used by passengers during boarding and deplaning, but which can be used for other purposes during the cruise phase.
In addition, since the extension is removable, i.e., independent of the table, the assembly formed of the table and the removable extension can pass around any obstacles, provided an appropriate conformation is given to at least one edge of this assembly. Indeed, such obstacles would form an obstacle to the deployment of a system of a known type, in which the extension is connected permanently to the table, for example by means of hinges. By allowing the connection between the table and the removable extension to be broken completely the invention enables the dimensional limits imposed by such obstacles on folding table systems of known types to be overcome.
Said at least one rigidification element preferably takes the form of a single rigidification panel.
The rigidification panel enables optimum rigidity to be given to the assembly formed of the table and the removable extension when the latter is connected to the table.
As a variant, said at least one rigidification element can take the form of multiple rigidification struts, without going beyond the scope of the invention.
Said first retention means preferentially include said at least one rigidification element and also a holding wall which is carried by said bracket and cooperating with said end portion of said rigidification element so as to hold said table in its storage position.
In one preferred embodiment of the invention said bracket includes a housing which is open on said first side of said bracket, and said housing is configured so that said removable extension can be housed in said housing, notably when said table is in its storage position.
The system advantageously includes second retention means able alternatively to hold said removable extension in said housing, and to release said removable extension.
In addition, the system preferably includes a notch one portion of which is formed of an edge of said folding table, and another portion of which is formed of an edge of said removable extension, where this latter edge extends from said edge of said folding table when said first end of said removable extension is connected to said second end of said table.
The system preferably includes a supporting device connected to said table in such a way that it is movable between a storage position, in which said supporting device is retracted in a housing formed in said table, and a deployed position, in which said supporting device extends outside said housing in order to contribute to holding said table in its deployment position.
The invention also relates to an aircraft including at least one folding table system of the type described above.
As explained above, said system preferably has a notch a portion of which is formed of an edge of said folding table, and another portion of which is formed of an edge of said removable extension, where this latter edge extends from said edge of said folding table when said first end of said removable extension is connected to said second end of said table.
In this case, a fixed element of the aircraft preferably extends at least partly into said notch.
Such a fixed element may consist of a door hinge system, or of any other element, such as a unit, a caisson, etc.
Furthermore, said removable extension advantageously has a second end, opposite said first end of the removable extension, which is supported on a fixed structure of the aircraft when said table is in its deployment position, and when said first end of said removable extension is connected to said table.
By way of example, the fixed structure may be formed of a shelf or of any other element forming a portion of a kitchen unit.
Said bracket also preferably extends orthogonally to a floor of said aircraft.
In this manner the encumbrance of the system in its storage position can be reduced optimally.
Said bracket can be attached to a pre-existing wall in the aircraft, in particular a wall connected to the floor of the aircraft, such as a side wall of a unit.
As a variant, the bracket may be incorporated into such a wall. The wall itself then constitute said bracket.
Furthermore, said predetermined position of the table in its deployment position is preferably a position in which said table extends horizontally, i.e., parallel to said floor.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood, and other details, advantages and characteristics of it will appear, on reading the following description given as a non-restrictive example, with reference to the appended illustrations, in which:
FIG. 1 is a schematic exploded view of a folding table system according to a preferred embodiment of the invention;
FIGS. 1 a and 1 b are partial schematic views at a larger scale of a removable extension belonging to the system of FIG. 1 ;
FIG. 1 c is a partial schematic view at a larger scale of a plate forming a part of the table belonging to the system of FIG. 1 ;
FIG. 2 is a partial schematic perspective view of a cabin of an aircraft including the folding table system of FIG. 1 , where the latter is illustrated in a state of storage;
FIGS. 3 to 6 are partial schematic perspective views of the aircraft cabin of FIG. 2 , illustrating respectively successive steps of a method of deployment of said folding table system;
FIG. 7 is a view of the folding table system belonging to the aircraft cabin of FIG. 2 , but represented isolated, where this figure illustrates a last step of the method of deployment of said folding table system;
FIG. 8 is a partial schematic perspective view of the aircraft cabin of FIG. 2 , illustrating said folding table system in a state of deployment.
In all these figures, identical references may designate identical or comparable elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a folding table system 10 according to a preferred embodiment of the present invention.
This system includes a bracket 12 , a table 14 having a first end 16 rotationally mounted on bracket 12 on a joint pin 18 , a supporting device 20 , a removable extension 22 having a first end 24 able to be connected to a second end 26 of table 14 opposite first end 16 of the latter, and a rigidification panel 28 slidably mounted in a cavity 30 of table 14 emerging outside in the area of second end 26 of table 14 .
Table 14 can thus be moved between a storage position in which the table covers a first side 32 of bracket 12 ( FIG. 2 ), and a deployment position in which the table is separate from first side 32 of the bracket ( FIG. 5 ).
Table 14 comprises a table panel formed of a first plate 34 ( FIG. 1 ) intended to be positioned on an upper side of the table when the table is in its deployment position, to act as a working surface, and of a second plate 36 opposite. In the storage position first plate 34 is opposite first side 32 of bracket 12 . The two plates 34 and 36 delimit cavity 30 of table 14 . Second plate 36 includes a main portion having a shape roughly identical to first plate 34 and an extension portion which extends beyond first plate 34 in the area of second end 26 of the table, so that the first end of removable extension 22 can rest on this extension portion. The two plates 34 and 36 are connected to one another by their side edges. These plates are preferably formed of a single block. In this case the table is made from a single plate in which a recess is made from an edge of the plate so as to form cavity 30 .
Bracket 12 has, overall, the shape of a plate having a second side 38 opposite first side 32 , and intended to be attached to a wall, preferably a vertical wall, as will be shown more clearly in what follows.
Bracket 12 includes, near its lower end 40 , a bore 41 to receive joint pin 18 .
In addition, bracket 12 includes a holding wall 42 at its upper end 44 . This holding wall 42 is intended to form a stop with regard to an end portion 46 of rigidification panel 28 so as to hold table 14 in its storage position, as will be shown more clearly in what follows. Rigidification panel 28 and holding wall 42 thus form jointly “first retention means,” in the terminology of the invention.
Furthermore, bracket 12 includes a recess which has a shape which is roughly conjugate with the shape of removable extension 22 , and thus forming a housing 48 open at least on first side 32 of bracket 12 , in which removable extension 22 can be housed, notably when table 14 is in its storage position. Housing 48 is surrounded by edges of the plate forming bracket 12 .
Bracket 12 includes two handles 50 ( FIG. 1 ) positioned either side of housing 48 and slidably mounted in a direction parallel to joint pin 18 . These handles 50 are fitted with respective tongues 52 which can penetrate into corresponding cavities 53 formed in two opposite edges 54 of the removable extension 22 ( FIGS. 1 and 1 b ) so as to hold removable extension 22 within housing 48 . Bracket 12 also includes elastic means (not represented) each of which applies force to handles 50 in the direction of housing 48 .
Handles 50 form “second retaining means” in the terminology of the invention.
Removable extension 22 consists of an extension panel which has a first face 56 ( FIG. 1 ) intended to be pointing upwards when first end 24 of the removable extension is connected to second end 26 of table 14 , and a second opposite face 58 .
Removable extension 22 includes a groove 60 ( FIG. 1 a ) formed in its second face 58 near a second end 62 of the removable extension opposite its first end 24 and intended to receive an element of conjugate shape coupled with a fixed structure of the aircraft such as a kitchen unit to contribute to holding removable extension 22 in position, as will be shown more clearly in what follows.
In addition, removable extension 22 includes a recess 64 ( FIG. 1 b ) formed in its second face 58 , and extending as far as first end 24 of the removable extension. This recess 64 forms a housing intended to receive a portion of rigidification panel 28 so as to rigidify the assembly formed of table 14 and removable extension 22 .
This rigidification panel 28 includes a handle 66 ( FIG. 1 ) which is, for example, screwed on to a rod (not visible in the figures) traversing a slot 67 formed in second plate 36 of table 14 ( FIG. 1 c ). In addition, handle 66 has two stop pins (not visible in the figures) extending from either side of the abovementioned rod and parallel to it, i.e., orthogonally to second plate 36 . Slot 67 communicates with two slot extensions 68 a , 68 b ( FIG. 1 c ), which take, for example, the form of disks or circles centered on slot 67 and separated from one another. These slot extensions 68 a , 68 b are intended to receive the abovementioned stop pins when handle 66 is pointing roughly orthogonally relative to slot 67 , so as to prevent the handle sliding unexpectedly along slot 67 . Conversely, when the handle is pointing roughly parallel to slot 67 the stop pins penetrate in slot 67 themselves such that handle 66 can be moved along slot 67 and carry rigidification panel 28 with it.
When first end 24 of the removable extension is connected to second end 26 of table 14 , the assembly formed by table 14 and removable extension 22 has a notch or cut-out, a portion of which is formed of an edge 70 of table 14 , and another portion of which is formed of an edge 72 of removable extension 22 extending from abovementioned edge 70 of table 14 , as will be shown more clearly in what follows.
Supporting device 20 includes, for example, a first strut 74 connected to second plate 36 of table 14 , a second strut 76 roughly orthogonal to first strut 74 and having a first end connected to a first end of first strut 74 , and a third strut 78 connecting a second end of first strut 74 to a second end of second strut 76 and forming by this manner a support leg for table 14 . In the illustrated example first and third struts 74 and 78 are also connected to one another by two reinforcement struts 80 .
Table 14 includes a housing 82 formed in its second plate 36 to receive supporting device 20 in the storage position. This housing is formed of an assembly of grooves arranged such that the housing has a shape which is roughly complementary to the shape of supporting device 20 .
Table 14 also includes a handle 84 similar to handles 50 , and associated with elastic means in a comparable manner, so as to hold supporting device 20 in housing 82 .
FIGS. 2 to 6 illustrate the interior of a cabin of an aircraft, such as a commercial airplane, and show in particular an area equipped with folding table system 10 described above.
Bracket 12 of this system extends orthogonally to a floor 85 of the cabin of the aircraft. In the illustrated example bracket 12 is attached to a vertical wall 86 which constitutes, for example, a side panel of a column of shelves 88 ( FIG. 5 ). This vertical wall is attached to floor 85 . In addition, vertical wall 86 is positioned near a door 90 of the aircraft.
FIG. 2 illustrates system 10 in a storage state. Removable extension 22 is housed in housing 48 ( FIG. 1 ) of support 12 , and is masked by table 14 which is folded so as to cover first side 32 of the bracket.
Table 14 is itself held in storage position by the portion of end 46 of rigidification panel 28 which protrudes from cavity 30 of the table and cooperates by reciprocal stop with holding wall 42 of bracket 12 . Handle 66 of the rigidification panel is pointing roughly orthogonally with slot 67 such that the stop pins coupled with this handle extend within a first 68 a of the slot extensions and by this means prevent handle 66 from moving along slot 67 , thus preventing end portion 46 of rigidification panel 28 from being retracted into cavity 30 of table 14 .
In addition, supporting device 20 is folded in housing 82 and blocked by handle 84 .
FIG. 3 illustrates a first step of a method of deployment of folding table system 10 .
This step relates to the deployment of supporting device 20 , and involves manipulating handle 84 so as to move this handle in the direction opposite supporting device 20 in order to release the latter, followed by the pivoting of supporting device 20 .
FIG. 4 illustrates a subsequent step of the method, in which handle 66 is rotated such that the stop pins extend into slot 67 , and then handle 66 is moved downwards, i.e., towards first end 16 of table 14 such that rigidification panel 28 is retracted fully into cavity 30 and ceases by this means to cooperate by reciprocal stop with holding wall 42 of bracket 12 .
FIG. 5 illustrates a subsequent step of the method, in which table 14 is deployed by pivoting around joint pin 18 , until supporting device 20 comes to a stop against vertical wall 86 on to which bracket 12 is attached.
FIG. 6 illustrates a subsequent step of the method, in which handles 50 are manipulated simultaneously so as to release removable extension 22 , and then the latter is positioned to extend table 14 such that first end 24 of removable extension 22 is in contact with second end 26 of table 14 , and is in particular placed on the extension portion of second plate 36 of table 14 which extends beyond first plate 34 of the latter, and such that first face 56 of removable extension 22 is pointing upwards. In the illustrated example the extension portion of second plate 36 is engaged in an end portion of recess 64 of removable extension 22 .
Second end 62 of removable extension 22 lies on a fixed structure 92 of the aircraft, such as a shelf belonging to a kitchen unit 94 . Groove 60 in second face 58 of extension 22 pointing downwards may receive an element coupled with said shelf 92 (not visible in the figures), so as to stabilize removable extension 22 .
FIG. 7 illustrates a subsequent step of the method, in which handle 66 which is coupled with rigidification panel 28 is moved along slot 67 in the direction of second end of table 14 , so as to introduce a portion of rigidification panel 28 (including said end portion 46 ) in recess 64 of extension 22 , until the stop pins coupled with handle 66 are engaged in the second extension of slot 68 b so as once again to block handle 66 against any movement along slot 67 . When handle 66 reaches this position rigidification panel 28 preferably occupies roughly the entire recess 64 .
Rigidification panel 28 consequently contributes effectively to the rigidification of the assembly formed by table 14 and removable extension 22 .
FIG. 8 illustrates folding table system 10 in its state of deployment within the aircraft cabin. This figure in particular allows notch or cut-out 96 , formed jointly by edge 70 of folding table 14 and edge 72 of removable extension 22 , to be seen.
A fixed element 98 of the aircraft, such as a system for connecting door 90 to the fuselage, occupies a portion of the space delimited by abovementioned notch 96 .
Folding table system 10 thus has the advantage that it can pass round such a fixed element 98 without the latter hindering the deployment and storage of the system.
This results in optimized use of the space available on board the aircraft.
The system can in particular be deployed during the phases of flight at altitude, called the “cruise” phases, and be stored during the phases of landing and takeoff, and on the ground, when the area otherwise occupied by the system in its deployment position is used by the passengers of the aircraft for boarding or deplaning.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.
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A folding table system includes a table and a removable extension, together with a rigidification element slidably mounted within a cavity made in the table such that a portion of the rigidification element can be inserted in a housing made in the removable extension so as to rigidify the assembly formed by the table and the removable extension. The removable character of the removable extension in particular allows the system to be deployed by passing around possible obstacles by an appropriate conformation of at least one edge of the abovementioned assembly.
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OBJECT OF THE INVENTION
The present invention, as expressed in the wording of this specification, relates to a stackable container of the type comprising a bottom, two long lateral walls or side panels and two short lateral walls or front panels.
The object of the invention is a container that can be stackable with improvements that help stabilizing and reinforcing the assembly of the container itself, and that also help to improve the stacking by distributing the weight of the containers when stacked in a more homogeneous way, while the fitting thereof is facilitated during stacking.
Another object of the invention is the characteristic details in the assembly structure between the bottom and the lateral walls.
Therefore, the invention provides a better container in terms of resistance to elevated weights and optimizes automatic manipulation.
BACKGROUND OF THE INVENTION
Several types of boxes and containers manufactured with corrugated cardboard, as well as with other more consistent materials are currently known, so that, in all cases, containers generally comprising a bottom, two long lateral walls or side panels and two short lateral walls or front panels, are formed.
The European invention patent under publication number 2322075 is also known, which relates to a mono-material container for horticultural use with a lid, which basically describes fixation means between the lateral walls and the bottom by means of a tongue and groove joint, also incorporating an upper part in the form of a lid arranged in correspondence with its mouthpiece.
Conventional containers or boxes, and more specifically, those corresponding to the aforementioned invention patent under publication number 2322075, have resistance and stability problems in the case of high weights in a stacking situation.
Therefore, in a column of stacked containers full of product, it is desirable that the weight is appropriately transmitted from the upper container all the way through the intermediate containers and down to the ground or support surface, so that its mechanical resistance is considerably greater and the breakage or fall of the column or stack is prevented, which would make its use unadvisable with high weights.
DESCRIPTION OF THE INVENTION
The stackable container that constitutes the object of the invention is determined based on independent laminar bodies made from cardboard or any other laminar material, said laminar structure comprising a bottom, two long lateral walls or side panels and two short lateral walls or front panels.
The stackable container of the present invention can also be made from wood, DM agglomerated plastic, etc.
The invention is characterized in that it incorporates projections starting from the free edges of the front and side panels, said projections being supplemented by notches established in the lower part of the side and front panels.
In addition, the front and side panels incorporate anchoring means in their adjacent lateral edges. These anchoring means are a combination of projections. The combination of the front panel projections comprises at least one upper front panel projection, one front panel projection and one lower front panel projection. The combination of side panel projections comprises at least one upper side panel projection, one side panel projection and one lower side panel projection. In addition, the container has at least one front panel notch and one side panel notch. The projections of the front and side panels are arranged alternatively on the adjacent lateral edges of the front and side panels, so that the front panel projections fit in the side panel notches and the side panel projections fit in the front panels notches.
The lower front panel projection delimits a front panel hole and the upper side panel projection delimits a side panel hole.
In addition, the lateral edges of the front panels incorporate angular ledges in which the straight ends of the side panel notch are positioned (R 2 ).
The projections and the notches starting from the free edges of the front and side panels can present a trapezoidal configuration with rounded vertexes.
The side ( 2 ) panels and the front ( 3 ) panels are linked to the bottom ( 1 ) by means of projections that are adjusted in complementary slots. The bottom incorporates bottom side panel projections ( 35 ) in its edges, which match the side panels. Said projections are introduced in the lower side panel slots ( 36 ).
In turn, the front and side panels are linked to the bottom by means of projections that are adjusted in complementary slots.
In a first preferred embodiment of the invention, in order to improve the resistance conditions when the container is stacked, said container incorporates point support feet in its cornered areas in correspondence with its bottom, which are part of the lateral walls and are complemented by point support areas established in the cornered areas of the container in correspondence with its top opening. This way, when several containers full of products are stacked, the weight is transmitted point by point from the first container to the ones below until reaching the ground in correspondence with the cornered areas of the containers in a vertical linear direction, in which the aforementioned point feet and seats are located.
In an embodiment of the first preferred embodiment of the invention, the point feet are incorporated to the lower side panel projections, while the point seats are located in the upper front panel notches.
The function of the side panel notches can be, in addition to completing the side panel projections of an upper container when stacked, to delimit the lower part of the lower side panel projections and to also delimit the point feet incorporated to said lower side panel projections.
In another embodiment of the first preferred embodiment of the invention, the point feet are incorporated to the lower front panel projections ( 13 ′), while the point seats are located in the upper side panel projections (R 6 ).
Other characteristics of the invention relate to the incorporation, in the cornered areas, of projections in the top opening of the box, which complement recesses established in correspondence with the bottom, recesses established on the lateral walls, so that, during stacking, the projections of a lower box are fitted and adjusted to the recesses of an upper box, said flaps and recesses favouring the convergence and alignment of the point feet and seats.
The projections that participate in the anchoring between the bottom and the lateral walls of the container may incorporate a barbed structure that considerably improves safety during the assembly of the container, preventing the accidental disassembly of said boxes.
In a second preferred embodiment of the invention, in order to improve the resistance conditions of the container when stacked, said container incorporates a base plank on the free upper edges of the front and side panels.
In a possible embodiment of the second preferred embodiment, the base plank incorporated by the container comprises two end base planks which ensure its positioning by means of characteristic projections that are part of the front and side panels and emerge towards the top of the same, said projections fitting in the complementary slots of the base planks. Another characteristic of the invention according to this possible embodiment of the second embodiment is that these projections are complemented with lower notches established in the lateral walls of the container themselves, so that when several containers are stacked, the projections of a lower container complimentarily fit the lower notches of an upper container, thus achieving a safe, reliable and precise stacking. This way, the projections generate retention stops to improve the stability of the stacking in terms of lateral movements, since they complement the notches provided for that purpose in the lateral walls themselves.
These end base planks are able to extend the support surface of the bottom of the upper containers, so that when several containers are stacked, the weight of said stacked containers is more uniformly distributed, while facilitating the fitting of the same at the same time. In addition, it should be noted that said projections present rounded vertexes that also contribute to the centring of the container.
All of the foregoing improves the container of the invention in terms of resistance to elevated weights, while also optimizing automatic manipulation.
The new structure of the container of the invention prevents deformations during the lateral compression of the containers when stacked. On the other hand, it should be noted that the side and front panel walls are connected to one another by means of characteristic anchoring means.
In another possible embodiment of the second preferred embodiment, the base planks are cornered base planks.
In another possible embodiment of the second preferred embodiment, the base planks comprise a complete base plank. Said complete base plank is provided with cornered slots where upper projections are adjusted, which are arranged in the end sections of the side panels by forming a part thereof, said connection of upper projections and cornered slots being complemented by other characteristic centred slots located in the vicinity of the short sides of the complete base plank, where characteristic centred projections starting from the free edge of the front panels are adjusted on the centred slots, forming an integral part thereof.
Another characteristic of this possible embodiment of the second preferred embodiment is that the centred projections of the front panels are provided with slots where projections of the complete base plank, which interrupt the continuity of the centred slots of said complete base plank, are fitted.
In order to complement said connection between the slots and the projections, the centred slots have end chamfers so that when the complete base plank is fitted in the top opening of the container, said end chamfers of the centred slots press and force the feet of the centred projections of the front panels to bend slightly inwards.
Therefore, the characteristic centred slots, thanks to the projections they include and also thanks to the end chamfers, present a characteristic specific geometry, so that, as indicated above, the end chamfers compress and softly curve the centred projections of the front panels, softly forcing them towards the interior of the container, thus improving the anchoring and the function of the projections themselves, which are adjusted on the slots of the centred projections of the front panels.
In a specific embodiment of this possible embodiment of the second preferred embodiment of the invention, the cornered slots of the complete base plank include notches for the introduction of the centring elements. These centring elements are used when there is a machine that places the complete base plank in its position in the container automatically. These notches essentially present a semicircular configuration.
The centred projections of the front panels are slightly trapezoidal in order to improve the introduction of the base plank and have an anchoring slotting for the corresponding projection and external steps to stabilize and retain the complete base plank to leave it coplanar to said steps. The complete base plank rests on the free upper edges of the later walls.
The complete base plank has grasping and aeration apertures, as well as longitudinal recesses to improve the sight of the product and aeration.
The complete base plank serves to improve the rigidity and the stacking when several containers are stacked.
In turn, the side panels and the front panels are linked to the bottom by means of projections that are adjusted in complementary slots.
Next, in order to facilitate a better comprehension of this specification and being an integral part thereof, figures representing the object of the invention in an illustrative rather than limitative manner, accompanies the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 . Shows a perspective view of a stackable container with a flat element comprising two end base planks.
FIG. 2 . Shows a perspective view of a stackable container with a flat element comprising two pairs of cornered base planks
FIG. 3 . Shows a perspective view of a stackable container with a flat element comprising a complete base plank.
FIG. 4 . Shows a perspective view of the stacking of two stackable containers, each one of which constitutes the object of the invention.
FIG. 5 . Shows another embodiment of the container of the invention.
FIG. 6 . Shows a view showing the anchoring means between the side panels and the front panels constituting the lateral walls of the container.
FIG. 7 . Shows a perspective view of the stackable container object of the invention. It basically comprises a bottom, two long lateral walls or side panels and two short lateral walls or front panels, the complete base plank being coupled in correspondence with the top opening of the container.
FIG. 8 . Shows a plant view of the complete base plank.
FIG. 9 . Shows a plant view of the complete base plank with another embodiment, different than the one shown in the previous figure.
FIG. 10 . Shows a lateral view of the stackable container showing a side panel frontally.
FIG. 11 . Shows a lateral view of the stackable container showing a front panel frontally.
FIG. 12 . Shows a perspective view of the container with a complete base plank in an embodiment incorporating projections so that the complete base plank remains secured in its position.
FIG. 13 . Shows a perspective view of the stackable container object of the invention.
FIG. 14 . Shows a frontal view of the container of the invention.
FIG. 15 . Shows a perspective view of the stacking of two containers of the invention.
REFERENCES
1 . Bottom
2 . Side panel
3 . Front panel
4 . Centred opening
5 . Top opening
6 . Centred projection
6 ′. Front panel projection
7 . Side panel projection
8 . Centred notch
8 ′. Front panel notch
9 . Side panel notch
10 . End base plank
10 ′. Cornered base plank
10 ″. Complete base plank
11 . Centred slot
11 ′. Front panel slot
12 . Side panel slot
13 . Front panel projection
13 ′. Lower front panel projection
13 ″. Upper front panel projection
14 . Side panel projection
14 ′. Upper side panel projection
14 ″. Lower side panel projection
15 . Front panel notch
16 . Side panel notch
17 . Second projection
18 . Longitudinal recess
19 . Front panel hole
20 . Side panel hole
21 . Angular ledge
22 . Straight end
23 . Point feet
24 . Point seats
25 . Projection with a barbed structure
26 . Bottom slot
27 . First projection
28 . Slot of the centred projection
29 . End chamfer
30 . End step
31 . Recess
32 . Grasping aperture
33 . Ventilation aperture
34 . Cornered cuts
35 . Bottom projection on the side panel
36 . Lower side panel slots
37 . Notches in the upper edge of the front panels
DESCRIPTION OF THE PREFERRED EMBODIMENT
Taking into account the numeration adopted in the figures, the stackable container comprises a bottom ( 1 ), two long lateral walls or side panels ( 2 ) and two short lateral walls or front panels ( 3 ), the front panels ( 3 ) having centred apertures ( 4 ) like handles to manipulate the container comfortably. Each one of these elements (lateral walls and bottom) is independent pieces connected to each other by their adjacent edges.
In turn, the side panels ( 2 ) incorporate wide trapezoidal mouthpieces ( 5 ) in their free edges.
The stackable container of the present invention is characterized in that it incorporates flat elements ( 10 , 10 ′, 10 ″) that rest on at least the end portions of the free edges of the front ( 3 ) and side ( 2 ) panels, said flat elements ( 10 , 10 ′, 10 ″) incorporating slots ( 11 , 11 ′, 12 ) where the lower portions of projections ( 6 , 6 ′, 7 ) starting from said free edges of the front ( 3 ) and side ( 2 ) panels are fitted. The bottom ( 1 ) of an upper container rests on the flat elements ( 10 , 10 ′, 10 ″) of another lower container when several containers are stacked.
The incorporation of these flat elements ( 10 , 10 ′, 10 ″) is the essential characteristic of the present invention, since no other container with flat elements of this type is known in the state of the art, which, aside from serving as support when stacking more than one container, serve to give strength to the container itself and to prevent said container from breaking or deforming when other containers carrying much weight are stacked on top.
These flat elements can comprise two end base planks ( 10 ), as shown in FIG. 15 , two pairs of cornered base planks ( 10 ′), as shown in FIG. 14 , or may comprise a complete base plank ( 10 ″), as the one shown in FIG. 13 .
The container incorporates projections ( 6 , 6 ′, 7 ), which start from the free edges of the front ( 3 ) and side ( 2 ) panels, being said projections complemented by notches ( 8 , 8 ′, 9 ) established in the lower part of the side ( 2 ) and front ( 3 ) panels. In addition, the side ( 2 ) and front ( 3 ) panels incorporate anchoring means in their adjacent lateral edges, which comprise a combination of projections comprising at least one front panel projection ( 13 ) and one side panel projection ( 14 ) and one front panel notch ( 15 ) and one side panel notch ( 16 ). The projections are arranged alternatively on the adjacent lateral edges of the side ( 2 ) and front ( 3 ) panels, so that the front panel projections ( 13 ) are fitted in the side panel notches ( 16 ) and the side panel projections ( 14 ) are fitted in the front panel notches ( 15 ), the front panel projections ( 13 ) incorporating a lower front panel projection ( 13 ′) delimiting a front panel hole ( 19 ) and the side panel projections ( 14 ) incorporating an upper side panel projection ( 14 ″) delimiting a side panel hole ( 20 ). As shown in the figures, the front and side panel projections ( 13 , 14 ) are preferably hook-shaped.
The lateral edges of the front panels ( 3 ) can incorporate angular ledges ( 21 ) in which straight ends ( 22 ) of the side panel notch ( 16 ) are positioned.
The projections ( 6 , 6 ′, 7 ) and the notches ( 8 , 8 ′, 9 ) can present a trapezoidal configuration of rounded vertexes.
In a first embodiment of the invention, shown in FIGS. 1, 2 and 3 , the lower part of the container corresponding to its bottom incorporates point feet ( 23 ) arranged in the same vertical direction than point seats ( 24 ) arranged in the upper part of the container in correspondence with its top opening, being said point seats ( 24 ) and point feet ( 23 ) in the same vertical corners of the containers where the side ( 2 ) and front ( 3 ) panels converge.
When several containers are stacked, the point feet ( 23 ) of an upper container rest on the point seats ( 24 ) of a lower container. This way, the load is transmitted to the ground precisely in the vertical directions of these point seats ( 24 ) and point feet ( 23 ).
In a possible embodiment of this first preferred embodiment, the point feet ( 23 ) are incorporated to the lower side panel projections ( 14 ′), while the point seats ( 24 ) are located on the upper front panel projections ( 13 ″).
In this first preferred embodiment, the lower edges of the front panels ( 3 ) incorporate projections with a barbed structure ( 25 ), which are adjusted in the bottom slots ( 26 ) complementary to the projections with the barbed structure ( 25 ).
In a second preferred embodiment of the invention, the container comprises at least one flat element.
In an embodiment of this second preferred embodiment, shown in FIG. 4 , the flat element comprises two end base planks ( 10 ), which incorporate at least one centred slot ( 11 ), one front panel slot ( 11 ′) and one side panel slot ( 12 ). The lower portions of at least one centred projection ( 6 ), one front panel projection ( 6 ′) and one side panel projection ( 7 ) are fitted in said slots, which start from the free edges of the front panels ( 3 ) and side panels ( 2 ), respectively. In this embodiment, the container also contains at least one centred notch ( 8 ), one front panel notch ( 8 ′) and one side panel notch ( 9 ), established in the lower part of the side ( 2 ) and front ( 3 ) panels.
The centred projections ( 6 ) are located in the upper free edges of the centre of the front panels ( 3 ). The front panel projections ( 6 ′) are located at the end of the upper free edges of the front panels ( 3 ). The side panel projections ( 7 ) are located at the end of the upper free edges of the side panels ( 2 ).
The centred slots ( 8 ) are located on the lower free edge of the front panels ( 3 ) in the position complementary to the centred projections ( 6 ). The front panel slots ( 8 ′) are located in the lower free edge of the front panels ( 3 ) in the position complementary to the front panel projections ( 6 ′). The side panel slots ( 9 ) are located on the lower free edge of the side panels ( 2 ) in the position complementary to the side panel projections ( 7 ).
In this embodiment of the second preferred embodiment, when several containers are stacked, an upper container rests through its bottom ( 1 ) on the two end base planks ( 10 ), while the centred projection ( 6 ) and the side panel projection ( 7 ) of the upper container fit the centred notch ( 8 ), and the side panel notch ( 9 ) of the respective upper container. In addition, there are notches in the upper edge of the front panels ( 37 ), which are complementary to the projections with a barbed structure ( 25 ) located on the front panels ( 3 ).
This way, total stability and safety in the stacking of the containers are achieved, as well as great rigidity and strength in the assembly of the container.
In another possible embodiment of this second preferred embodiment, shown in FIG. 5 , the flat element comprises two pairs of cornered base planks ( 10 ′) that rest on the end portions of the free edges of the front panels ( 3 ) and also on the end portions of the free edges of the side panels ( 2 ). In this case, said cornered base planks ( 10 ′) comprise a front panel slot ( 11 ′) and a side panel slot ( 12 ) to allow the passage and fitting of the front panel projections ( 6 ′) and the side panel projections ( 7 ).
In addition, the container also comprises at least one front panel notch ( 8 ′) and one side panel notch ( 9 ), established in the lower part of the side ( 2 ) and front ( 3 ) panels.
On the other hand, the side ( 2 ) and the front ( 3 ) panels are connected to each other by means of characteristic anchoring means, as shown more clearly in FIG. 7 .
In turn, the lateral edges of the front panels ( 3 ) incorporate angular ledges ( 21 ) where the straight tips ( 22 ) of the side panel notches ( 16 ) are positioned.
When several containers are stacked, the bottom ( 1 ) of the upper container rests on the base plank ( 10 ′) of the lower container and the projections ( 6 , 6 ′, 7 ) of said lower container fit in the notches ( 8 , 8 ′, 9 ) of the upper container.
In another preferred embodiment of this second preferred embodiment, shown in FIG. 7 , the flat element comprises a complete base plank. According to this possible embodiment of the invention, the container incorporates at least one centred slot ( 11 ) and one side panel slot ( 12 ) to allow the passage and fitting of at least one centred projection ( 6 ) and one side panel projection ( 6 ′), and the container comprises at least one front panel notch ( 8 ′) and one side panel notch ( 9 ) established in the lower part of the side panels ( 2 ) and front panels ( 3 ).
When several containers of this type are stacked, the projections of a lower container fit in the notches of a higher container.
In this embodiment example, the contour of the centred slot ( 11 ) of the complete base plank ( 10 ″) has at least one first projection ( 27 ), which is fitted in at least one slot of the centred projection ( 28 ), said centred slot ( 11 ) including end chamfers ( 29 ) intended to bend the centred projections ( 6 ) inward by their extremities and also intended to bend the front panels ( 3 ) inward.
The centred projections ( 6 ) can present a trapezoidal configuration and have end steps ( 30 ), which are levelled with the complete base plank ( 10 ″).
The side panel slots ( 14 ) can have recesses ( 31 ). In a possible embodiment, said recesses are circular in shape.
In addition, the complete base plank ( 10 ″) may have grasping ( 32 ) and aeration ( 33 ) apertures, as well as longitudinal recesses ( 18 ) in correspondence with the long edges of the complete base plank in order to improve the sight and aeration of the product.
In a possible embodiment of the invention, the side panel projections ( 7 ) incorporate a second rib ( 17 ), which is fitted in the side panel slot ( 12 ) of the complete base plank ( 10 ″).
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The invention relates to a stackable container that includes a lower part, base or bottom ( 1 ), two long lateral walls or side panels ( 2 ) and two short lateral walls or front panels ( 3 ) that include a flat element that can consist of two end base planks ( 10 ), of two pairs of cornered base planks ( 10 ′) or one complete base plank ( 10 ″) shaped such that when a plurality of containers are stacked, the bottom of an upper container ( 1 ) rests on the flat element ( 10, 10′, 10 ″) of a lower container. The flat element ( 10, 10′, 10 ″) acts as a support surface for an upper container when it is stacked and as a reinforcement of the container structure, giving it strength and avoiding breakage during stacking.
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The present application claims the benefit of U.S. provisional Application No. 60/477,106, filed Jun. 9, 2003, and U.S. provisional Application No. 60/513,518, filed Oct. 21, 2003, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to mechanical devices used in surgical procedures to obtain ligation or hemostasis, and more particularly, to low profile tools that can apply a pre-formed, spring loaded ligation clip used during surgery to clamp around a vessel or duct, such as the cystic duct, and thereby obtain ligation.
2. Description of the Prior Art
It will be appreciated by those skilled in the art that the use of ligation clips to control bleeding during surgical procedures is well known. As described, for example, in U.S. Pat. Nos. 4,976,722 and 4,979,950, prior art clips are generally formed of metal wire, usually a titanium alloy, having a “U-shaped” rectangular cross-section. Such prior art clips often include a grooved pattern machined into the inner or clamping surfaces of the clip, in an attempt to enhance the ability of the clip to remain in position after it is closed around the vessel. Application of the clip to the vessel is normally effected by means of a crushing action produced by a clip applier, such as disclosed in U.S. Pat. No. 5,030,226. Such crushing actions, of course, permanently deform the clips, making them difficult to remove or re-position.
Prior art surgical ligation clips have several inherent problems. For example, the force applied by the clip to the vessel can be variable and inconsistent from one clip to the next, because of the variation in crushing force applied to the clip by the user. Further, prior art clips have a tendency to slip off the end of the blood vessel stub (i.e., perpendicular to the axis of the vessel) to which it has been applied, because of the low coefficient of friction associated with the clip, and lack of adequate restraining force provided by the clip. Because of this, separation of the clip from the vessel to which it has been applied, after the wound has been closed, is not uncommon. A related problem found in the prior art is the fact that the ligating or restraining force offered by the crushed clip varies along the length of the clip, decreasing toward the open end. Thus, the section of the vessel near the open end of the clip can be inadequately ligated.
It is also common in the prior art to actually form and crush the clip only at the time of its application to the targeted blood vessel. It is often required that the vessels of 4 mm and larger diameter be ligated. Because most clips of the prior art have no spring action it is required that the inside clearance dimension of the clip, prior to crushing, be larger than the vessel. This does not lend itself to clip applier designs that will pass through small 5 mm trocars. The applier must be inserted through a trocar, placed through the patient's external tissues, and into the surgical field. Thus, prior art ligation clip appliers used in laparoscopic procedures typically consist of a 10 mm diameter clip applier that can fit only through a trocar having a 10 to 11 mm diameter entry port. Because one goal of laparoscopic surgery is to minimize the size of the entry wound, a surgical ligation clip and clip applier that can be used within a 5 mm or even a 2.5 mm diameter trocar port is highly desirable.
New minimally invasive surgical procedures and the need for less invasiveness for current procedures require the development of smaller and smaller devices. The harvesting of saphalous veins and certain cardiovascular procedures would benefit from reduced diameters trocars, below 3 mm diameter.
To address these problems a spring action surgical clip was designed, and is disclosed in U.S. Pat. No. 5,593,414, titled “Method of Applying a Surgical Ligation Clip,” the disclosure of which is incorporated herein by reference. One embodiment of the clip disclosed in the '414 patent is shown in FIGS. 1 and 2 . Clip 50 has a vessel clamping arm 52 , a vessel support member 54 , and at least one tension coil 56 integrally joining the arm and support member. Clip 50 is pre-formed so that in its equilibrium state, it can be easily placed within the surgical field, including through an endoscopic trocar port with a diameter as little as 5 mm. After the clip is placed proximate the blood vessel or duct to be clamped, clamping arm 52 is moved from its equilibrium position to a position under higher tension, allowing positioning of the vessel between arm 52 and support member 54 . When correct placement and positioning is achieved, arm 52 is released and, as the arm tends to move back towards its equilibrium position, it clamps the vessel between the arm's curved lower surface and the supporting upper surface of vessel support member 54 .
To enhance the performance of the tension coil(s), vessel support member 54 includes first and second arms 58 , 60 , one of which terminates in a 180-degree bend section. Minimal cross-sectional area of the clip is achieved by substantially longitudinally aligning the vessel support member, the clamping arm, the 180-degree bend section 62 , and the tension coil.
The clamping arm is pre-formed into an equilibrium that generally aligns with the horizontal plane of the support member. A second embodiment of the clip pre-loads the clamping arm into a pre-loaded equilibrium position where the free end of the arm rests against the upper surface of the support member.
There exists a relationship between the diameter of the trocar (hence the applier tube) and the maximum diameter of a vessel that can be ligated. Older crush clip technology limits the ratio of wound size to maximum diameter to be ligated to greater than 2. That is, to ligate a 5 mm vessel, a puncture wound of 10-12 mm is required. U.S. Pat. No. 5,593,414 teaches the method of using a spring clip that is inserted into the surgical field in the closed state, opened over a vessel, the diameter of which has been reduced, or pre-clamped, by the tool, and closed over the pre-clamped vessel. This method allows an entry wound to vessel diameter ratio of 1 or smaller. Thus, a 5 mm vessel can be ligated through a 5 mm trocar. This is substantially less invasive as compared to the older crush clip technology. For a trocar diameter of 2.5 mm, the clip can be scaled down to approximately half size on the wire diameter, coil height, and length, yet still supply an acceptable ligation force on a 2.5 mm vessel.
Unfortunately, several problems are encountered in applying the spring-action ligation clip of U.S. Pat. No. 5,593,414 to a vessel through a 5 mm or smaller trocar port. First, the nominal 5 mm cross-section of the clip that is inserted through the trocar places severe design restrictions on any applier mechanism. Second, care must be taken so that the elastic limit of the spring material is not exceeded when the clip is opened up so that it can be placed over the vessel diameter. For a titanium wire of diameter 0.75 mm, for example, lifting a distal end of a spring clip much above a few mm will exceed the elastic limit. Secondly, these spring clips are small and compact and owing to the preload, have a great deal of energy stored in the spring. As these clips are opened to place them over a vessel the stored energy increases substantially, in some cases more than doubling. This energy makes controlling the clip, to insure proper installation, difficult. Undesirable translation or rotation can result in misplacement or dropping of the clip inside the body.
Another approach which has been proposed to provide smaller diameter endoscopic clip application is that of U.S. Pat. No. 5,601,573 to Fogelberg et al. Fogelberg et al. still struggles with the complex manipulation required to advance the clip in a closed position and then open the clip prior to placement. Fogelberg et al. also has an overly complex multi-stage trigger arrangement for actuation of the jaws and the clip advancement mechanism. The present invention presents several improvements over Fogelberg et al. including: (1) advancement of the clips in their open position rather then a closed position; and (2) a smooth single stage trigger action which simultaneously closes the jaws and advances the forward most clip into the jaws. Another difference between the present invention and Fogelberg et al. is that Fogelberg et al. pushes a stack of clips, whereas the present invention individually engages and pushes each clip simultaneously, thus yielding better control of the clips.
The clip and clip applier disclosed in U.S. Pat. No. 6,350,269, titled “Ligation Clip and Clip Applier,” the disclosure of which is incorporated herein by reference, represents a further improvement over the Fogelberg et al. device. The '269 patent discloses a clip having wire loops at one end thereof and a clip applier that utilizes the loop width to open and release the clip around a vessel.
There are several problems associated with the spring clip applicators of the prior art. First, the jaws are usually designed such that either one is stationary and the other rotates closed about the fixed jaw, or both jaws rotate in a scissor-like fashion about a common axis. This creates a severe pinching force on tissue that might be located near the axis or pivot point. This pinching force can cause a hematoma or otherwise damage the tissue. Secondly, the diverging surfaces of the jaws often obstruct the surgeon's view of the tissue to be ligated owing to the acute angle of the laparoscopic camera and the clip applier.
What is also needed is a clip applier with jaws that are substantially parallel to each other in an open position so that the surgeon has a better view of the tissue to be ligated.
SUMMARY OF THE INVENTION
In one preferred embodiment of the present invention, a surgical ligation apparatus for compressing a fluid carrying structure includes a proximal end, an opposite distal end, a mid-longitudinal axis passing through the proximal and distal ends, and a shaft having a passage adapted to receive at least one surgical ligation clip therein. The apparatus further includes upper and lower compression members proximate the distal end of the apparatus, each of the upper and lower compression members having a clamping surface for contacting the fluid carrying structure. The clamping surfaces each have a forward portion proximate the distal end of the apparatus and an opposite rearward portion. The rearward portions of the upper and lower clamping surfaces are moveable relative to one another a distance that is generally equal to a distance that the forward portions of the upper and lower clamping surfaces are moveable relative to one another to compress the fluid carrying structure between the clamping surfaces.
In another preferred embodiment of the present invention, a method of ligating a fluid carrying structure having a width includes inserting into a patient a surgical ligation instrument having upper and lower clamping surfaces moveable relative to one another between an open position for receiving the fluid carrying structure and a closed position for compressing the fluid carrying structure therebetween. The upper and lower clamping surfaces are adapted to contact the fluid carrying structure. The method further includes positioning the fluid carrying structure between clamping surfaces of the instrument; applying a substantially uniform compression across the width of the fluid carrying structure; moving a ligation clip over a portion of the clamping surfaces of the instrument, the ligation clip being resiliently biased to a closed position; and releasing the ligation clip to permit the ligation clip to move to the closed position.
These and other objects of the present invention will be apparent from review of the following specification and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of a surgical ligation clip disclosed in the prior art.
FIG. 2 is a side elevation view of the surgical ligation clip of FIG. 1 .
FIG. 3 is a top plan view of a surgical ligation clip in accordance with another embodiment of the present invention, the surgical ligation clip being engaged about a vessel.
FIG. 4 is a perspective view of the surgical ligation clip of FIG. 3 .
FIG. 5 is a side elevation view of a clip applier having a distal end with a pair of compression members in an open position in accordance with one embodiment of the present invention.
FIG. 6 is a side elevation view of the clip applier of FIG. 5 with the compression members in a closed position.
FIG. 7 is an enlarged view of a push rod for individually engaging a plurality of surgical ligation clips.
FIG. 8A is a partial side cross sectional view of the clip applier of FIG. 5 .
FIG. 8B is an enlarged fragmentary cross sectional view of the distal end of the clip applier of FIG. 8A .
FIG. 8C is a cross sectional view along line 8 C- 8 C of FIG. 8B .
FIG. 9A is a partial side cross sectional view of the clip applier after discharging the clip.
FIG. 9B is an enlarged fragmentary cross sectional view of the distal end of the clip applier of FIG. 9A .
FIG. 9C is a cross sectional view along line 9 C- 9 C of FIG. 9B .
FIG. 10 is an exploded perspective view of the upper and lower compression members of the clip applier of FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the present preferred embodiments (exemplary embodiments) of the invention, examples of which are illustrated in the accompanying drawings.
FIGS. 3 and 4 show an example of a surgical ligation clip 100 usable with a preferred embodiment of the clip applier of the present invention. Surgical ligation clip 100 includes a clamping arm 106 and a support member 108 . A coil tension spring 110 , which may also be generally referred to as a connector, joins clamping arm 106 and support member 108 .
Clamping arm 106 has a first enlarged end 102 defined thereon. Support member 108 has a second enlarged end 104 defined thereon. The first and second enlarged ends 102 , 104 are first and second wire loops which are integrally formed with clamping arm 106 and support member 108 of clip 100 .
Loops 102 , 104 , and particularly the laterally outer portions thereof, may be described as first and second control surfaces being received in and trapped within the first and second channels of a clip carrier 216 . As best seen in FIG. 8A , a plurality of ligating clips 100 are received in clip carrier 216 , in a semi-open position. For ease of identification, consecutive clips beginning with the forward-most one are designated as 100 A, 100 B, 100 C, etc. The control surfaces, as engaged by the channels of clip carrier 216 , prevent rotation and yawing of clip 100 as the clip is moved through the clip carrier.
The connector of clamping arm 106 and support member 108 is preferably a coil spring 110 which has a preload that biases the support member 108 and clamping arm 106 toward each other. The preload is preferably such that when clip 100 is in the fully closed or pre-loaded equilibrium position shown in FIG. 9B , there is still a spring preload in the connector which forces wire loops 102 , 104 against each other.
FIGS. 5 and 6 show one preferred embodiment of a clip applier 200 in accordance with the present invention. Clip applier 200 includes a distal end 202 , a proximal end 204 , and a tubular shaft 206 therebetween. Distal end 202 includes upper and lower compression members 208 , 210 that are moveable between an open position, shown in FIG. 5 , and a closed position, shown in FIG. 6 .
FIG. 7 shows a pusher rod 212 which has a plurality of prongs 214 extending therefrom for engagement with clips 100 contained in a clip carrier 216 as seen in FIG. 8A . Pusher rod 212 is preferably an elongated flat bar. Pusher rod 212 is slidably received in a channel within passage 218 of shaft 206 .
As shown in FIGS. 8A and 8C , clip carrier 216 includes a pair of opposed rails 220 , 222 projecting from the interior sides of the clip carrier which define partially closed upper and lower channels. Rails 220 , 222 extend along the length of clip carrier 216 and are configured to maintain clips 100 in a slightly open position as they are moved along the length of clip carrier 216 and into engagement with compression members 208 , 210 .
FIG. 10 shows upper and lower compression members 208 , 210 . Compression members 208 , 210 each include a clamping surface 224 configured to contact a fluid carrying structure. Clamping surface 224 includes a forward portion 226 proximate the distal end of the compression member and a rearward portion 228 . If desired, clamping surface 224 may include a plurality of grooves and ridges 225 along the length of the clamping surface to provide additional grip. Upper and lower compression members 208 , 210 also include an extension rail 230 vertically opposite clamping surface 224 that leads to a loop releasing openings 232 , 233 . The exterior surface of the forward end of each compression member is preferably blunt-shaped to minimize interference with surrounding tissue structures.
Upper and lower compression members 208 , 210 are attached to the distal end of clip carrier 216 by a pair of laterally extending pins 234 , 236 , respectively. Pins 234 , 236 are configured for engagement with a slot 238 positioned proximate the distal end of clip carrier 216 in the interior sidewall of the clip carrier. Upper and lower compression members 208 , 210 are biased to an open position by a pair of springs 240 receivable in spring receiving openings 242 . The proximal end of each of upper and lower compression members 208 , 210 include a ramp 244 , 246 , respectively. Ramps 244 , 246 each include longitudinal recesses 248 , 250 , respectively, configured to receive portions 252 , 254 , respectively, of clip carrier 216 as shown in FIGS. 8C and 9C .
With reference to FIGS. 8A-8C and 9 A- 9 C, the operation of clip applier 200 will now be described. FIGS. 6 and 8 A- 8 C show clip applier 200 with upper and lower compression members 208 , 210 in the open position. After a surgeon has inserted clip applier 200 through a trocar and into a patient, the surgeon positions a fluid carrying structure such as a vessel V or stub end of a tissue between upper and lower compression members 208 , 210 . Squeezing trigger 256 on the handle of clip applier 200 will cause shaft 206 to move forward relative to clip carrier 216 and upper and lower compression members 208 , 210 . At the same time, crimp features 258 , 260 , located on the interior wall of passage 218 of shaft 206 , advance guide 262 forward with shaft 206 . Trigger 256 is preferably a two-stage trigger so that a first squeeze will pre-clamp vessel V, as will be described below, and a continued second squeeze of trigger 256 will discharge clip 100 . A two-stage trigger permits the surgeon the opportunity to evaluate whether vessel V is sufficiently pre-clamped before discharging a clip. It will be appreciated by those skilled in the art that other trigger actuation mechanisms are within the scope of the present invention and that a two-stage trigger is only a preferred embodiment of the present invention.
Guide 262 preferably has a circular outer diameter to match the interior diameter of passage 218 . Guide 262 has a central opening configured to permit passage of clip 100 therethrough and is defined at least in part by upper and lower guide surfaces 264 , 266 , which are configured to move, preferably slide, against upper and lower ramps 244 , 246 of upper and lower compression members 208 , 210 , respectively, as shown in FIGS. 8B and 9B . The central opening of guide 262 is preferably generally curved to match the curve of each of upper and lower ramps 246 , 248 (see FIG. 8C ).
As guide 262 moves forward along the mid-longitudinal axis of clip applier 200 , ramps 244 , 246 slide against guide surfaces 264 , 266 , forcing an inward motion of upper and lower compression members 208 , 210 toward one another. Laterally extending pins 234 , 236 of upper and lower compression members 208 , 210 , respectively, slide within slot 238 of clip carrier 216 , which acts as a guide surface for pins 234 , 236 and maintains the horizontal parallel alignment of upper and lower compression members 208 , 210 while the upper and lower compression members move toward each other. The inward force caused by guide 262 sliding against ramps 244 , 246 overcomes the biasing force provided by springs 240 , which acts to keep upper and lower compression members 208 , 210 in an open position. As would be appreciated by those skilled in the art, the length and slope of upper and lower ramps 244 , 246 may be modified according to the dimensions of the clip to be used with the clip applier.
The forward-most clip 100 A is pushed out of clip carrier 216 into upper and lower compression members 208 , 210 by the next adjacent clip 10 B. As forward-most clip 100 A is pushed forward, the lateral sides of wire loops 102 , 104 slide along rails 220 , 222 of clip carrier 216 in a semi-open position owing to the biasing force towards the closed position of clip 100 A against each rail. Continued forward movement of clip 100 along the length of the clip applier brings the lateral sides of wire loops 102 , 104 up a ramped portion of rails 220 , 222 , over a ramp portion 268 of pins 234 , 236 , and onto rail extension 230 within upper and lower compression members 208 , 210 (shown in FIG. 10 ). As wire loops 102 , 104 come into registry with releasing openings 232 , 233 , support member 106 and clamping arm 108 of clip 100 A snap shut toward each other, thus clamping vessel V therebetween as clip 100 A is released from upper and lower compression members 208 , 210 , as shown in FIGS. 9A-9C . The surgeon can view the discharge of the clip through windows 270 , 272 in upper and lower compression members 208 , 210 , respectively.
After trigger 256 has been squeezed to close compression members 208 , 210 and advance clip 100 A into the compression members where it is released, subsequent release of trigger 256 will pull back push rod 212 . The column of clips 100 will stay in place within clip carrier 216 due to the gripping of rails 220 , 222 by clips 100 . Prongs 214 will slip back past the clips and engage the next rearward clip on the next squeeze of trigger 256 .
When upper and lower compression members 208 , 210 are closed together, a generally uniform vertical force is applied across the width of vessel V to occlude the vessel. The closing motion of compression members 208 , 210 may be described as pre-clamping vessel V by movement of clamping surfaces 224 toward one another.
It is noted that the step of pre-clamping vessel V between upper and lower compression members 208 , 210 typically occurs prior to the step of pushing spring clip 100 A from clip carrier 216 into upper and lower compression members 208 , 210 . As spring clip 100 A is moved into upper and lower compression members 208 , 210 , it subsequently is released from those compression members when the wire loops move into registry with the releasing openings 232 , 233 .
It is further noted that the methods of operating clip applier 200 includes steps of loading in a plurality of spring clips 100 into clip carrier 216 such that the wire loops 102 , 104 are received within channels with the clips thus held in an open position by rails 220 , 222 . Then, each time that trigger 256 is compressed, each clip 100 is advanced forward in clip carrier 216 . Clips 100 are arranged in clip carrier 216 head to tail with a small space between adjacent clips so that the clips are pushed through clip carrier 216 by prongs 214 of pusher rod 212 .
During this procedure rotation of spring clip 100 is prevented by containing wire loops 102 , 104 in the partially closed channels of clip carrier 216 .
In summary, compression members 208 , 210 are substantially parallel and are fixedly attached to the applier at slidable pins 234 , 236 . Slidable pins 234 , 236 engage clip magazine 216 in slot 238 . Magazine 216 is fixedly attached to the handle of the applier. Tubular shaft 206 is distally movable during the trigger stroke. As tubular shaft 206 moves distally under the control of the trigger stroke, crimp features 258 , 260 cause guide 262 to move distally. Protrusions 264 , 266 move up ramps 244 , 246 that are fixedly attached to upper and lower compression members 208 , 210 . This force has a downward component that compresses spring 240 and moves upper and lower compression members 208 , 210 toward each other, compressing tissue therebetween. Pins 234 , 236 ride in slot 238 keeping upper and lower compression members 208 , 210 registered with each other and substantially parallel, as shown in FIGS. 8B and 9B . In the second part of the trigger stroke, the spring clip, which has control features mating with rails 220 , 222 , rides up onto pins 234 , 236 and onto upper and lower compression members 208 , 210 . Ejection and tissue ligation then occurs.
With this invention there is thus no jaw pivot to damage tissue. In addition, since the compression members are substantially parallel to one another, visibility is enhanced.
It will be appreciated by those skilled in the art that the embodiment described above is only exemplary and that the clip applier of the present invention may be modified without going beyond the scope of the present invention. For example, although two springs are shown on each side of the proximal end of the compression members, a single spring or other mechanical equivalents may be used to bias the compression members if it is desired that the compression members be biased relative to one another. Movement of the upper and lower compression members toward one another may be accomplished in other ways such as with a vertical turn screw and gear arrangement. The compression members may be directly attached to the shaft of the clip applier rather than the clip carrier as would be appreciated by those skilled in the art.
Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
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A ligation clip applicator design is provided that is particularly applicable to placement of a surgical ligation clip during a laparoscopic surgical procedure. The applicator has a magazine including first and second longitudinally extending partially closed channels within which enlarged portions of a ligation clip are received and held in an open position. First and second substantially parallel compression members are attached to the magazine and have first and second channel extensions therein aligned with the first and second channels of the magazine for receiving the first and second enlarged portions of the clip. The channel extensions include first and second releasing openings. The compression members close about a vessel, remaining substantially parallel as they close. The clip is pushed forward into the compression members to a position where the enlarged portions of the clip are aligned with the releasing openings, permitting the clip to be released to close and ligate the vessel.
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BACKGROUND OF THE INVENTION
In making composite structures by building up a stack of tapes, each tape is comprised of a layer of collimated fibers held against a metallic foil backing for holding the fibers in position during stacking. The fibers are held against the foil backing in several ways, such as by a plasma metal spray that forms a coating to hold the fibers in position. These tapes are limited in practical length, costly, and the fiber properties may be adversely affected by the matrix when applied by plasma-spraying.
Tapes have been made with organic binders holding the fibers in position and the tape consists of two metal sheets with the binder and fibers sandwiched in between. If the binder is volatile, the final bonding of the composite cannot be done until the volatile binder is all disposed of and thus the process requires much time as well as the necessary vacuum chambers and associated pumps. Further, the fibers may become misaligned between the vaporization of the binder and the application of full densification pressure.
SUMMARY OF THE INVENTION
One feature of this invention is a tape that requires no temporary binder of any type. Another feature is the full compaction of the tape in selected areas only during manufacture of the tape to hold the foils in position on opposite sides of the layer of fibers. Another feature is a partial compaction of the tape with full compaction only in selected areas, the size and spacing of these areas being dependent upon fiber size and spacing and the material and thickness of the foil.
According to the invention, a tape is made up of a single layer of collimated fibers positioned between metallic foil covering sheets and the tape is then fully compacted in selected spaced areas to establish a good bond between the opposing foil sheets and the fibers in these areas. This makes a unitary tape that can be handled in shaping, cutting and assembling in a stack without loss or misalignment of the fibers. In most cases the entire tape is also partially compacted between the areas of full compaction to make a thinner tape that gives better stacking characteristics and handleability.
The foregoing and other objects, features, and advantages of the present invention will become more apparent in the light of the following detailed description of preferred embodiments thereof as illustrated in the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a tape embodying the invention.
FIG. 2 is a perspective view of a modification.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The tape of the invention is used in making composite structures by stacking the tapes to the desired configuration and then densifying and bonding all the tapes together under heat and pressure to form the completed structure. The tapes must be such as to retain their integrity with the fibers therein remaining in position during the necessary handling in stacking. The present invention meets this requirement.
As shown in FIG. 1, the tape is made up of facing foil sheets 2 and 4 on opposite sides of a monolayer of collimated fibers 6. The assembled fibers and covering foils are partially compacted to produce the result shown at 8, the area marked "Partial Compaction." In this partial compaction, the foil sheets are forced together to some extent and the material of the foils is extruded somewhat over each fiber to form, in each foil, grooves 10 to receive the fibers and ridges 12 between the grooves and extending between the fibers. These ridges on either of the opposed foil sheets do not extend far enough to touch the ridges on the other sheet as shown.
For securely holding the sheets and fibers in assembled relation in the tape, selected areas 14 of the tape are fully compacted, this being shown by the designation "Fully Compacted" on the drawing. These areas are not necessarily contiguous as shown and are so spaced that they will function to hold the two sheets securely enough so that the tape can be handled without affecting the integrity of the tape. In these fully compacted areas the foils are forced together enough, more than in the partially compacted area, to deepen the grooves 10' holding the fibers to complete semicircles so that the opposed grooves fully enclose the fibers. In so doing, this increases the heights of the intervening ridges 14' so that opposed ridges are in contact and are securely bonded together. This tape is now ready for use and may be cut, shaped, and stacked without loss of the parallel relation and spacing of the fibers in the tape.
This tape is a complete structure without the need for plasma spray or organic resins for holding the elements of the tape together and there is no foreign matter that must be removed as by volatilization in making the composite structure.
As described, the tape is first partially compacted over its entire area and then fully compacted in selected areas. However, it is conceivable that suitable devices could perform the partial and full compaction in a single step. The important feature is the full compaction in selected areas only. A tape of this type is advantageous for several reasons. There is no binder so the binder cost, and the time and expense of application and subsequent necessary removal of the binder is avoided. The tape, partially compacted is thinner and therefore has reduced stiffness and has improved lay-up ability as well as reduced accumulated thickness in the stack. The partially bonded areas permit matrix deformation during final densification and bonding to break up any oxides or other undesirable materials on the tape surfaces, thereby to provide a virgin matrix bond between the foils, between the foils and the fibers, and between adjacent tapes. This process is applicable to continuous tape fabrication so that the dimension of the tape is not limited as before.
The tape as shown in FIG. 1 was made with boron fibers 0.0056 inch in diameter and the foils were 0.0015 inch thick aluminum. For compaction a pressure of 5000 psi was used for full compaction and of less than 2500 psi for the partial compaction. The pressure is applied for less than two minutes and at a temperature of 900° F.
Tapes of this type may be made by the well-known step-by-step pressing of a long strip of tape. This is produced by feeding a number of filaments through a collimator and thence between sheets of foil into a press where the compaction occurs between molds in a step-by-step process. Pull rolls that mantain the tape under tension draw the completed tape from the press and thus maintain a tension on the fibers to keep the desired spacing and parallelism of the fibers.
In the production of large sized sheets, it is expected that the fibers would be wound under tension on a foil clad mandrel after which a covering foil is applied and the partial and complete compaction carried out on the mandrel before removing the assembled foil and fibers from the mandrel. Both the flat assembly of foil and fibers prior to compaction and the winding of the fibers on a foil covered mandrel are well-known and are used in the art as described in U.S. Pat. No. 3,606,667 in aligning the fibers in readiness for a plasma spray or other coating for holding the fibers in parallel relation on a backing sheet. No claim is made to these techniques. The novelty in the present invention is the complete compaction of the assembled foil and fibers in selected noncontiguous areas and the partial compaction in the remaining areas. The technique for such partial and complete compaction when the foil sheets are applied and while the fibers are still held in parallel relation will be obvious to one skilled in this art once the concept of such partial and total compaction is known.
Although this has been described as applicable to a monolayer tape it will be apparent that it is also applicable to a multilayer tape where the several layers of foil would be fully compacted only in selected areas. The same benefits would be obtained as in the monolayer tape.
A modified form of tape is shown in FIG. 2 in which the layer of collimated fibers 22 are positioned between foil sheets 24 and 26. The assembly is partially compacted in the areas 28 and fully compacted in the areas 30. In this arrangement, the fully compacted areas, instead of being discrete spots, are parallel strips preferably at an angle to the fibers so that all of the fibers, in selected portions only, are necessarily within the full compaction areas. The same results are obtained as in the structure of FIG. 1. In this modification the fibers shown are Borsic™ fibers 0.0057 inch in diameter and the foils are titanium alloy (6A1-4V) 0.002 inch thick. For compaction, the full compaction is done under 15,000 psi and the partial compaction under 7500 psi for two minutes at 1600° F. When the tape is completely formed, as shown, the thickness in the fully compacted area is 0.007 inch and in the partially compacted areas is 0.0085 inch. It will be apparent that the areas of partial and complete compaction blend gradually with one another as shown. Obviously, other fibers and foils may be used in practicing the invention.
Although the invention has been shown and described with respect to a preferred embodiment thereof, it should be understood by those skilled in the art that other various changes and omissions in the form and detail thereof may be made therein without departing from the spirit and the scope of the invention.
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A partially compacted fiber-reinforced metallic tape has a layer of collimated fibers between two layers of metal foil, the foil being partially compacted around the fibers, somewhat deforming the foil around the fibers and, in selected areas only, the foil being fully compacted around the fibers forming complete bonds between the metal foil layers and the fibers in these areas.
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RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/813,766, filed Jun. 14, 2006, the entire teachings of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to securing message traffic in a data network using a protocol such as IPsec, and relates more particularly to how security policies are distributed in the network.
BACKGROUND OF THE INVENTION
[0000] The following definitions are used in this document:
[0000]
“Securing” implies both encryption of data in transit as well as authenticating that the data has not been manipulated in transit.
A “secure tunnel” between two devices ensures that data passing between the devices is secure.
A “key” for a secure tunnel is the secret information used to encrypt and decrypt (or authenticate and verify) the data in one direction of traffic in the secure tunnel.
A “Policy Enforcement Point” (PEP) is a device that secures the data based on the policy.
Existing Network Security Technology
[0007] According to the most commonly used computer networking protocols, network traffic is normally sent unsecured without encryption or strong authentication of the sender and receiver. This allows the traffic to be intercepted, inspected, modified, or redirected. As a result, either the sender or receiver can falsify their identity. In order to allow private traffic to be sent in a secure manner, a number of security schemes have been proposed and are in use. Some are application dependent, as with a specific program performing password authentication. Others, such as Transport Layer Security (TLS), are designed to provide comprehensive transport layer security such as the HTTP (web) and FTP (File Transfer Protocol) level.
[0008] Internet Security (IPsec) was developed to address a broader security need. As the majority of network traffic today is over Internet Protocol (IP), IPsec was designed to provide encryption and authentication services to this traffic regardless of the application or transport layer protocol. This is done, in IPsec tunnel mode, by encrypting a data packet (if encryption is required), performing a secure hash (authentication) on the packet, then wrapping the resulting packet in a new IP packet indicating it has been secured using IPsec.
[0009] The secret keys and other configuration data required for this secure tunnel must be exchanged by the parties involved to allow IPsec to work. This is typically done using Internet Key Exchange, IKE. IKE key exchange is done in two phases.
[0010] In a first phase (IKE Phase 1 ), a connection between two parties is started in the clear. Using public key cryptographic mechanisms, where two parties can agree on a secret key by exchanging public data without a third party being able to determine the key, each party can determine a secret for use in the negotiation. Public key cryptography requires each party either share secret information (pre-shared key) or exchange public keys for which they retain a private, matching, key. This is normally done with certificates (Public Key Infrastructure or PKI). Either of these methods authenticates the identity of the peer to some degree.
[0011] Once a secret has been agreed upon in IKE Phase 1 , a second phase (IKE Phase 2 ) can begin where the specific secret and cryptographic parameters of a specific tunnel are developed. All traffic in phase 2 negotiations are encrypted by the secret from phase 1 . When these negotiations are complete, a set of secrets and parameters for security have been agreed upon by the two parties and IPsec secured traffic can commence.
[0012] When a packet is detected at a Security Gateway (SGW) with a source/destination pair that requires IPsec protection, the secret and other security association (SA) information are determined based on the Security Policy Database (SPD) and IPsec encryption and authentication is performed. The packet is then directed to an SGW that can perform decryption. At the receiving SGW, the IPsec packet is detected, and its security parameters are determined by a Security Packet Index (SPI) in the outer header. This is associated with the SA, and the secrets are found for decryption and authentication. If the resulting packet matches the policy, it is forwarded to the original recipient.
[0000] General Limitations of IPsec
[0013] Although IPsec tunnel mode has been used effectively in securing direct data links and small collections of gateways into networks, a number of practical limitations have acted as a barrier to more complete acceptance of IPsec as a primary security solution throughout industry.
[0014] Configuration of Policies—Each SGW must be configured with each pair of source and destination IP addresses or subnets that must be secured (or allowed in the clear or dropped). If there are 11 SGW units fully meshed, each protecting 10 subnets, this requires 1000 policies in the SPD. This is a challenge in terms of the user setting up the policies, the time required to load the policies, the memory and speed difficulties in implementing the policies, and the increase in network time spent performing negotiations and rekey. The time for initial IKE negotiations in this example might be 10 minutes or more.
[0015] In addition, even for smaller networks, it requires the user to have a complete knowledge of all protected subnets and their security requirements. Any additions or modifications must be implemented at each gateway.
[0016] Certificate/PKI Management—PKI can become complex and difficult to manage. At minimum, it is intimidating to many network managers. However, strong PKI implementation is at the heart of effective security using IPsec (or TLS for that matter). The SGW should make this aspect as easy as possible for the network manager.
[0017] Multicast/Broadcast Traffic—IPsec in its present configuration cannot secure multicast or broadcast traffic. This is because keys are established between two entities and multicast or broadcast involves sending traffic from one source to many destinations at once.
[0018] The Internet Engineering Task Force (IETF) has a couple of Requests for Comments (RFCs) in place or in process to address group domain of interpretation (GDOI), or group secure association key management protocol (GSAKMP). GDOI is generally available, for example, on Cisco devices.
[0019] Load Balancing—Many large network implementations require load balancing or other Quality of Service (QOS) techniques where traffic to a particular address may take one of a number of paths. If a set of SGW units must be placed along these parallel paths, there might be no way to assure which SGW traffic sees. As IKE provides secrets only between a pair of SGW units (remote and local), traffic to the second SGW would require a different set of secrets. In the existing IPsec implementations, this is impossible. The result is a limitation in the placement of SGW units in the network which may not be possible in certain situations.
[0020] Network Address Translation (NAT)—There are various forms of NAT, all of which cause problems for IPsec.
[0021] With Static NAT, a source IP address on an outgoing packet is replaced with an assigned replacement IP address. If the SGW exists before the static NAT device, the original source IP address will still exist in the encrypted packet and will be exposed on decryption. This would likely create problems on the receiving network or on the return packet. Dynamic NAT (which is rarely used) is similar except that the replacement IP address comes from an available pool. In either case, the SGW must be placed outside the NAT device.
[0022] In masquerading dynamic NAT (NAPT), the source IP address of a packet is replaced with a new source IP address and the port number is changed to identify the original source IP address and port. This might be done to provide a single IP address to the wide area network (WAN) for a large number of IP addresses in the local area network (LAN).
[0023] Unfortunately, if the SGW is behind the NAT device, IPsec hides the port and IP address on the original packet and does not provide a port on the outer header. The NAPT protocol is broken without a port to modify. A mechanism called NAT-Traversal (NAT-T) had been added to IPsec to address this problem. This can also be addressed by placing the SGW outside the NAT devices. Normally this cannot be done in cases of remote access by a home user running the IPsec gateway on their computer.
[0024] Further variations of NAT can be combined with load balancing, creating virtual servers, or providing QOS which combines the problems of NAT with the load balancing problem described above.
[0025] Firewalls/Intrusion Detection Systems (IDS)—A firewall or IDS can create conflict with IPsec as they may require inspection of the packet beyond the outer header (Layer 3). Firewall rules are often set to manage connections based on port or protocol, but this information is stored in the encrypted packet under IPsec. An IDS normally does deep packet inspection for viruses, worms, and other intrusion threats. Again, this information is encrypted under IPsec. Many firewall functions can be implemented using well written IPsec policies, although this can complicate the SPD entries. If the SGW is on the WAN side of the firewall and IDS, this problem is eliminated.
[0026] Path Maximum Transfer Unit (PMTU) and Fragmentation—The PMTU specifies the maximum IP packet size that can be sent. Above that size, packets must be fragmented to be sent in smaller sizes. A protocol for PMTU discovery permits a device to send larger and larger packets with a Do Not Fragment bit set. This continues until a device with a path limitation sends back a message that the packet is too large. Other networks simply set the PMTU to a specific value.
[0027] In IPsec, however, the packet is made larger by the IPsec header information. If the devices behind the SGW uses the largest packet size, the SGW must either fragment the packet, which can be slow and certainly reduces network efficiency, or ignore the PMTU. To avoid this problem, networks must employ PMTU discovery or set the PMTU for devices behind the SGW smaller than for the main network.
[0028] Resilient Network Traffic—If the network is implementing resiliency, it will likely require the secure solution be resilient as well. This can be accomplished with a virtual router redundancy protocol (VRRP), but a switchover would result in the need to rekey all traffic. In a fully meshed situation, this could be a significant interruption. If fast switchover is required, a resilient gateway with shared state may be needed.
[0029] In addition, one of the most significant barriers to general acceptance of IPsec as a security solution is the challenge of securing the data as it leaves on computer to where it enters the remote computer. This level of security, combined with authentication and authorization on each side, would extend security from just covering the WAN (e.g., the internet) to protecting data from unauthorized internal access. Some of the general limitations of IPsec are exacerbated by end-to-end deployment. For example, the IPsec implementation cannot be place on the WAN side of the firewall, IDS, NAT device, or any load balancing between virtual servers. There are a number of hurdles to true end-to-end security in addition to the general limitations described above:
[0030] Installation of an IPsec/IKE Stack on Individual PCs—With the variety of available operating systems (Windows XP, XP Service Pack 1 and 2, Linux and all it's kernel releases, etc.) and hardware platforms, a software implementation of the IPsec stack, which is dependent on both of these, must be designed, compiled, tested, and supported for each implementation.
[0031] Hardware solutions, such as IPsec on a NIC, provide some separation from these issues, but preclude automated remote installation of the IPsec stack. In addition, the computer with the installation must be configured with the user certificate and the policy configuration. Ideally, the user would be identified in some way other than a machine based certificate. Unfortunately, all existing implementations require the computer to be configured directly, normally by a network security manager. IKE offers methods for remote access using certificate based authentication combined with RADIUS and XAUTH for the user ID as well as mode configuration to supply the user with a local network identification.
[0032] Limitation in Ability to Provide High-Speed, Low Latency, and High Number of SAs and Policies—A software solution on a computer (or mobile device) would be unable to provide high speed encryption or latency as low as on the existing SGW. In some cases this doesn't matter, but in situations with a high speed connection or involving streaming data, this may be significant. A hardware solution may suffer this limitation as well due to heat, space, or power considerations.
[0033] Either solution may be limited in the number of SAs or policies that are supported. This could be critical in a large, meshed security situation.
SUMMARY OF THE INVENTION
[0000] A. Division of Security Policy Definition, Key Definition, and Their Distribution
[0034] Implementation of a SGW requires policy management, IKE key generation and exchange, and IPsec policy enforcement. By dividing these functions into separate components and combining them in new ways, one can solve some of the limitations of existing IPsec approaches and offer approaches to resolving some others. One approach used by the present invention herein is the logical separation of IKE and IPsec functionality, with distribution of policies over secure tunnels. The functions provided are by modules of the system of the present invention as the following: Policy Enforcement Point (PEP), Key Generation Layer, Local and Remote Policy Definitions, Policy Linkage, Policy Distribution, and other relevant modules. Detailed description of the functions of these modules are to follow.
[0035] It should be noted that, in general, all traffic between the modules described above should either be local (within a single device) or protected by a secure tunnel. Management of each device should also be done via a secure tunnel and with secure user authentication. Also, if a highly resilient implementation is required, each module must be resilient and, if state is stored, a method for exchanging state and performing switch over implemented.
[0000] B. Problem Solution Using Distributed Policy and Key Generation, Shared Keying, and Secure Policy Dissemination
[0036] The present invention is a method for securing message traffic in a data network by distributing security policies. A security policy is identified to a first key generation and distribution point (KGDP) located at a first location. The security policy is a policy to be applied to a network connection, and include at least an identification of a first security group and a network device that is assigned to the first security group at the first location.
[0037] The communication network includes, in different embodiments, an Ethernet, an asynchronous transfer mode (ATM), one or more inter-networking devices (i.e. a router or a switch), or a wireless communication network.
[0038] The security policy is forwarded from the first KGDP to a first security policy manager (SPM) device. The first SPM is also located at the first location. The first SPM device stores an association between the first security policy and an identifier for the KGDP at the first location.
[0039] The first SPM then sends a message to a central security policy manager (cSPM) indicating that the first SPM has information pertaining to a security group that pertains to the first KGDP.
[0040] The cSPM, then stores a representation of the first SPM that sent the message and the first security group, optionally including an identifier for the first KGDP.
[0041] Upon receiving similar messages from other SPMs, the cSPM can then make and report associations between devices and security groups. This is done without the cSPM actually having to know network device configurations or keys.
[0042] The present invention relates novel ways to secure IP traffic using IPsec where the security policies, which define traffic to be secured and the security parameters for that traffic, and the keys, the secret information used to encrypt and authenticate traffic, are generated in a distributed manner. This distribution can be done in either by central control or in a hierarchical manner. In addition, the keys are shared over a number of devices, and dissemination of the security policies and keys is sent and received via secure tunnels. Finally, because of the shared keying and distributed security policies, the non-secure part of the packet, the outer header, can use the original IP source and destination address.
[0043] One embodiment of the present invention is a system for securing Internet Protocol (IP) traffic. The system includes a first location. The first location includes a communication network with which the components of the system interface. The components includes a first group of end nodes, of which at least some end nodes of the first group are defined as a security group. Furthermore, the components include a first that is configured to apply a security policy to a network connection, and a first distribution point that is configured to store the security policy and to forward the security policy to a first managing module. The first managing module is configured to receive the security policy from the distribution point and to record an association between the security policy and an identifier for the for the first distribution point, and to perform a policy linkage when the definition of the security group is updated. The security policy includes at least the definition of the security group.
[0044] In a first preferred embodiment, the communication network includes, in different embodiments, an Ethernet, an asynchronous transfer mode (ATM), one or more inter-networking devices (i.e. a router or a switch), or a wireless communication network.
[0045] In a second preferred embodiment, the first managing module is further configured to send first information to a central managing module, which is configured to generate a security group database entry based on the first information. Furthermore, the first information indicates that the first managing module has stored the definition of the security group associated with the first distribution point. In a more preferred embodiment to the second preferred embodiment, the first managing module and the central managing module are in a hierarchy. The hierarchy comprises at least a second managing module, which is located in a second location and configured to send a message to the central managing module that indicates the second managing module has additional information associated with the definition of the security group.
[0046] Another embodiment of the present invention is a method for securing message traffic in a data network by distributing security policies. The method comprises the steps at a first distributing point of a first location of determining a security policy to be applied to a network connection, and forwarding the security policy from the first distribution point to a first controlling module. The security policy include the steps at a first managing module including least a definition of a security group and a network device that is assigned to the security group. The method further comprises the steps at a first managing module of receiving the security policy from the first distribution point, recording a first association between the first security policy and an identifier for the first distribution point, and sending a message to a central managing module indicating that the first managing module has stored the definition of the security group associated with the first distribution point. The method yet further comprises the steps at the central managing module of receiving the first message and generating a security group database entry based on the first message. In a preferred embodiment, the method further includes the step at the central managing module of receiving additional messages associated with definitions of additional security groups from two or more additional managing modules, and generating additional security group databases entry based on the additional information. In a more preferred embodiment, the method further include the step at a second managing module in a second location of recording a second association between the security policy and an identifier for a second distribution point. The second location includes a second distribution point.
[0047] One embodiment is a computer readable medium having computer readable program codes embodied therein for securing message traffic in a data network by distributing security policies. The computer readable medium program codes performing functions comprises a routine for determining a security policy to be applied to a network connection at a first distributing point located at a first location, a routine for forwarding the security policy from the first distribution point to a first controlling module, a routine for receiving at a first managing module the security policy from the first distribution point, a routine for recording at the first managing module a first association between the first security policy and an identifier for the first distribution point, a routine for sending a message from the first managing module to a central managing module indicating that the first managing module has stored the definition of the security group associated with the first distribution point, a routine for receiving the first message at the central managing module; and a routine for generating a security group database entry based on the first message at the central managing module. The security policy includes at least a definition of a security group and a network device that is assigned to the security group.
[0048] While a considerable amount of work has been done in the area of data security in general, particularly in IP security, the disclosed methods and apparatus are unique and useful to solve specific network needs that are lacking in the limitations and problems described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0050] FIG. 1 is a system level diagram illustrating of a distributed policy scenario using Key Generation and Distribution Points (KGDP's), Policy Enforcement Points (PEPs), Security Managers (SM), and Security Policy Managers (SPMs), and Central SPMs (cSPMs).
[0051] FIG. 2 is a block diagram of a SGW that may be used with the present invention.
[0052] FIG. 3 is a flow chart of steps performed by the system of FIG. 1 .
[0053] FIG. 4 is a system level diagram illustrating key exchange between two KGDPs.
[0054] FIG. 5 illustrates a hierarchy of SPMs and cSPMs.
DETAILED DESCRIPTION OF THE INVENTION
[0055] A description of a preferred embodiment of the invention follows. An environment as shown in FIG. 1 , in which the invention may be implemented generally has a number of data processors and functions including end nodes 10 , a managing module (i.e. Security Manager (SM) 12 ), a distribution point (i.e. a Key Generation and Distribution Point (KGDP) 14 ), and a security module (i.e. Secure Gateways (SGWs) 22 ), connected by interfacing a communication network such as at least two inter-networking devices 16 (i.e. such as routers/switches). One or more of the SGWs 22 has an associated Policy Enforcement Point (PEP) function 20 . PEP is a software module that executes in a SGW on the data path that performs packet encryption and decryption as well as IPsec header generation on packets requiring security. It also passes or drops packets, and may be configured to perform additional functionality such as Static NAT or fragmentation. It is typically configured with security policies and SAs with security parameter indices (SPIs), and keys for encrypting and decrypting inbound and outbound packets.
[0056] The end nodes 10 can be typical client computers such as personal computers (PCs), workstations, Personal Digital Assistants (PDAs), digital mobile telephones, wireless network enabled devices and the like. The nodes 10 can also be file servers, video set top boxes, other data processing machines, or indeed any other networkable device from which messages originate and to which message are sent. The message traffic typically takes the form of data packets in the well known Internet Protocol (IP) packet format. As is well known in the art, an IP packet may typically be encapsulated by other networking protocols such as Transmission Control Protocol (TCP), User Datagram Protocol (UDP), or other lower level and higher level networking protocols.
[0057] The security manager (SM) 11 is a data processing device, typically a PC or workstation, through which an administrative user can input and configure security policies 12 . The SM 11 also acts as a secure server to store and provide access to such policies 12 by other elements of the system. As will be explained more fully below, the Key Generation and Distribution Points (KGDP) 14 and Policy Enforcement Points (PEPs) 20 cooperate to secure message traffic between the end nodes 10 according to policies 12 .
[0058] More particularly, a KGDP 14 is responsible for generating and distributing “secret data” known as encryption keys upon request. The keys are then used as a basis to derive other keys that actually secure transmission of traffic from one end node 10 -A- 1 to another end node 10 -B- 1 , to perform authentication, and other functions.
[0059] The PEPs 20 are located on the data path, and can typically be instantiated as a process running on a Secure Gateway (SGW) 22 . The PEPs 20 have a packet traffic or “fast path” interface on which they receive and transmit the packet traffic they are responsible for handling. They also have a management interface over which they receive configuration information, and other information such as policies 12 and encryption keys.
[0060] In general, traffic between the modules described above is either local (within a single device) or protected by a secure tunnel in network 24 . Management of each device is also via a secure tunnel and with a secure user authentication. Also, and for highly resilient implementation is required, each module must itself be resilient and if a state is stored, a method for exchanging state and performing switch over must be implemented.
[0061] The PEPs 20 are responsible for a number of tasks. They are principally responsible for performing encryption of outbound packets and decryption of inbound packets received on the fast path interface. The PEPs 20 can thus identify packets that need to be secured according to configured policies 12 . The PEPs 20 can also typically be programmed to pass through or drop such packets according to such policies 12 .
[0062] The PEPs 20 are also configured to perform IPsec tasks such as handling Security Association (SA) information as instructed by the SM 12 , to store and process Security Packet Index (SPI) data associated with the IPsec packets, and the like. The PEPs 20 thus perform many (if not all) of the IPsec security gateway functions as specified in IPsec standards such as Internet Request for Comments (RFCs) 2401-2412.
[0063] The SGW 22 in which the PEPs 20 run can be configured to perform additional functions typically of IP network gateways such as Network Address Translation (NAT), packet fragmentation handling, and the like. It should be understood that the PEPs 20 may also be installed on other internetworking devices, and that the choice of an SGW 22 in the illustrated embodiment is but one example.
[0064] FIG. 2 is a high-level block diagram of an SGW 200 that may be used with the present invention. SGW 200 comprises one or more network interfaces 210 , a processor 230 , a policy content-addressable memory (CAM) 500 and a memory 220 . The network interfaces 210 are conventional network interfaces configured to interface the SGW 200 with the network 100 and enable data (packets) to be transferred between the SGW 200 and the network 100 . To that end, the network interfaces 210 comprise conventional circuitry that incorporates signal, electrical, and mechanical characteristics and interchange circuits, needed to interface with the physical media of the network 100 and the protocols running over that media.
[0065] The processor 230 is a conventional processor which is configured to execute computer-executable instructions and manipulate data in the memory 220 and the policy CAM 500 . The processor 230 may be a network processing unit (NPU) or may comprise a collection of interconnected processors configured as a mesh or series of processors. The policy CAM 500 is a conventional CAM device that is configurable by processor 230 and, as will be described further below, contains information that the processor uses to process packets received by the SGW 200 in accordance with aspects of the present invention.
[0066] The memory 220 is a conventional random access memory (RAM) comprising, e.g., dynamic RAM (DRAM) devices. The memory 220 includes an operating system (OS) 222 , security services 224 , a security association table (SAT) 300 , a security association database (SAD) 400 and a security policy database (SPD) 600 . The operating system 222 is a conventional operating system that comprises computer-executable instructions and data configured to implement various conventional operating system functions that support the execution of processes, such as security services 224 , on processor 230 . These functions may include functions that, e.g., enable the processes to be scheduled for execution on the processor 230 as well as provide controlled access to various services, such as memory 220 . The security services 224 is illustratively a process comprising computer-executable instructions configured to enable processor 230 to implement various functions associated with PEP's as well as perform functions that enable the processing of packets in accordance with aspects of the present invention.
[0067] The SAT 300 is a data structure that contains information that may be used to locate security associations associated with packets processed by the SGW 200 . A security association, as used herein, relates to security information that describes a particular kind of secure connection between one device and another. This security information may include information that specifies particular security mechanisms that are used for secure communications between the two devices, such as encryption algorithms, type of authentication and the like. The operation of SGW is illustrate in a copending patent application entitled S ECURING N ETWORK T RAFFIC B Y D ISTRIBUTING P OLICIES I N A H EIRARCHY O VER S ECURE T UNNELS, U.S. Provisional Patent Application No. 60/813,766, filed Jun. 14, 2006, assigned to CipherOptics, Inc., and which is hereby incorporated by reference.
[0068] Returning to FIG. 1 , the SM 11 , the PEP 20 and KDP 14 perform and/or participate in several security related functions including:
[0069] key generation
[0070] key distribution
[0071] policy generation
[0072] local and remote policy definition
[0073] policy distribution (local and remote)
[0074] policy linkage
[0075] These functions are now discussed briefly, before continuing with detailed examples of how policy distribution is implemented according to the present invention.
[0076] Key Generation. This module creates keys to secure a given tunnel. As in IKE this is done in coordination with a single peer as each side agrees on outbound and inbound keys. However, in the embodiment of the present invention, this might also be a single unit that generates keys for traffic between a number of units. It may also be embodied in a single PEP generating a key for outbound traffic on a given tunnel.
[0077] Key Distribution. This module ensures that all connections to the tunnel have keys necessary to decrypt and encrypt data between the end points. As mentioned previously, this is done in standard IKE as part of the “Phase 2” key exchange between two peers. However, in the present invention, as will be described in several detailed examples shortly, this is performed by the PEPs exchanging keys in other ways. With these techniques, key distribution is still securely protected to prevent eavesdropping, tampering, and to ensure that the exchange occurs with an authorized party.
[0078] The Key Generation and/or Key Distribution modules may be located on individual stand alone machines, or may be incorporated together within a Key Generation and Distribution Point (KGDP). In addition, Key Distribution may be co-located with the PEP 20 in other architectures.
[0079] Local Policy Definition (also called “Policy Generation” herein). This module maintains information on IP addresses, subnets, ports or protocols protected by the PEP. This may be part of a complete security policy definition 12 for many different nodes 10 in the network as specified by the SM 11 . The policy definition can also be limited to a collection of subnets protected by a certain PEP. Or it can simply relate to and be stored at a single IP address, such within the network software on a remote access client 10 (for example, Microsoft Windows and other operating systems provide certain tools for specifying security policies). The policy definition can also occur via a discovery process performed by a PEP. If a complete security policy definition is not present, it should also include information to link the protected local traffic to its secure destinations.
[0080] Local Policy Definition—This module maintains information on IP addresses, subnets, ports or protocols protected by the SGW. This might be part of a complete policy definition, as provided to the system. It might be a single IP address on a remote access client. It could be a discovery process done by a SGW. It might be a collection of subnets protected by the SGW. If the complete policy definition is nor present, it must also include information to link the protected local traffic to its secure destinations.
[0081] Remote Policy Definition—This module maintains information on IP addresses, subnets, ports or protocols that are remote to the protected region which require protection of traffic with the local region. Definitions are as with the local policy definition. This function may be locally defined or distributed throughout the network.
[0000] Policy Distribution
[0082] The present invention relates more particularly to policy distribution. Note that in the illustrated system, a number of data processing machines are associated with a first location 20 - a including first host 10 - a - 1 , second host 10 - a - 2 , a first security manager (SM) 11 - a , a first Key Generation and Distribution Point (KGDP) 14 - a , one or more internetworking devices 16 - a , and a first Policy Enforcement Point (PEP) 20 - a.
[0083] In addition, a first Security Policy Manager, (SPM) 30 - 1 , which may or may not be physically located within the confines of location 20 - a , is responsible for distributing policies 12 to and from location 20 - a in a manner that will be described below.
[0084] Similarly, a second location 20 - b has other data processing machines such as a first server 10 - b - 1 , second server 10 - b - 2 , an associated Security Manager (SM) 11 - b , KGDP 14 - b , and internetworking devices 16 - b . Location 20 - b may, for example, be a high availability web and/or storage server and thus has multiple PEPs 20 - b - 1 and 20 - b - 2 . As with location 20 - a , a second Security Policy Manager (SPM) 30 - 2 is associated with and responsible for policies distributed to and from location 20 - b.
[0085] Locations 20 - a and 20 - b may be subnets, physical LAN segments or other network architectures. What is important is that the network locations 20 - a and 20 - b are logically separate from one another and from other locations 20 . For example, a location 20 may be a single office of an enterprise that may have only several computers, or a location 20 may be a large building, complex or campus that has many, many different machines installed therein. For example, location 20 - a may be in a west coast headquarters office in Los Angeles and location 20 - b may be an east coast sales office in New York.
[0086] The policy managers 30 , including first SPM 30 - 1 and second SPM 30 - 2 communicate with a central SPM (cSPM) 32 through network 24 .
[0000] Policy Linkage
[0087] This module provides linkage of the Local and Remote Policy Definitions for a specific gateway. This may be automatic as in the complete policy definition currently used or it may be distributed across a network. The PEP could establish a secure tunnel with a Policy Distribution Point (PDP, not shown) with authorization performed in both directions. The PEP could either have the policy distribution done as the various units are configured and come on line or upon receiving a packet at the PEP for which no policy definition exists at the PEP. Policy distribution could be done in one of various ways.
[0088] For example, the local policy definition could be defined on the PEP along with a security group (SG) identification. The PEP could send the policy and SG to the PDP. The PDP could establish a secure tunnel with a SPM with authorization performed in both directions. The PDP would then send the policy and SG information to the SGC. The SGC would perform policy linkage with information from other SPM or PDP units. Policy linkage would be performed on matching SG identities. The corresponding remote portions of the policy would be sent to the PDP which would then forward the complete policy to all appropriate PEP units. There could either be a single SPM unit over the entire secure network, an SPM unit associated with various domains that communicate with each other and their domain's PDP units over secure tunnels, or a hierarchy of SGC units with domain SGCs communicating over secure tunnels to regional SGC units. Alternately, the PDP could communicate directly with peer PDP units that have been configured and could exchange local and remote policy information based on the security group.
[0089] The above approach could be taken with the local policy definition loaded on either the PDP or the SGC. Furthermore, the PDP could be configured with the complete policy definition. This could then be communicated to the PEP via a secure tunnel when required.
[0090] The reader will recall that “security policies” 12 can define traffic to be secured by source and destination, IP address, port and/or protocol. A security policy 12 also defines the type of security to be applied to a particular connection. The SPMs 30 define policies 12 by a function module known as local policy definition module. This module maintains information on IP addresses, subnet supports or protocols to be protected by a specific SPM 30 . Each policy definition 12 can, in a preferred embodiment, be limited to a certain collection of subnets such as those at first location 20 - a that are under control of a local administrator there.
[0091] The policy definitions 12 can be created by a user entering the pair of IP addresses via an administrative user command interface. However, policies 12 can also be defined using certain features of Microsoft Windows and similar operating systems that provide certain tools for specifying security policies for each node 10 .
[0092] As the PEP's must carry out policies 12 in handling the traffic they see, the PEP's need to have access to policies in some manner, including not only policies for their respective local traffic, but also remote traffic. The present invention provides a scheme for distributing policy information not only to a local PEP 20 - a that is local to a corresponding SPM 30 - a , but also to distribute policy information to remote PEPs 20 - b - 1 and 20 - b - 2 . The invention accomplishes this with limited or no involvement of the local security manager 11 in maintaining information about remote location policies, thus freeing each local security manager 11 from having to be updated with the same.
[0093] The specific process for doing so is shown in FIG. 3 . In a first step 300 , an SM 11 - a assigns a first (local) policy 12 . For example, policy 12 may specify that a host 10 - a - 1 is assigned to a first security group SG 1 . It may also define another policy 12 - 2 that specifies host 10 - a - 2 is assigned to a second security group SG 2 .
[0094] This assignment of hosts to security groups is then communicated from SM 11 - a to its local KGDP 14 - a ; this communication may take place via a secure tunnel over a management interface, such as provided through local internetworking equipment 16 - a.
[0095] In a next step 302 , KGDP 14 - a then eventually establishes a secure connection to a SPM 30 - 1 . Over this secure connection (which may also be a secure tunnel) KGDP 14 - a sends a request to add host 10 -A- 1 to security group 1 (SG 1 ) and host 10 -A- 2 to security group 2 (SG 2 ). At this point, SPM 30 - 1 enters the two security group entries in its database. However, these security group definitions will at this point only have host Al associated with them and thus will be incomplete.
[0096] In a next step 304 , SPM 30 - 1 will eventually establish a secure connection to a central SPM 30 - 2 . (Connections are attempted according to a schedule, so that the SPMs and cSPM 30 , 32 remain updated). This connection is then used to distribute information about the new security groups (not necessarily the policies themselves), allowing central cSPM 32 to update its own database with a definition for a new security group. However the new security group definition will not necessarily include any specific details for any particular policies 12 , and will not contain specific detailed information such as the nodes or addresses that participate in the security group(s). The security group database entry at cSPM 32 need only identify that the location SPM 30 - 1 has a policy called SG 1 and, that policy SG 1 can be or is controlled by KGDP 14 - a . Therefore, KGPD 14 - a , for example, can regulated, altered or updated the policy SG 1 as the definition of SG 1 is changed, supplemented or subtracted. Similarly, an entry is made in cSPM 32 that SPM 30 - 1 has defined a security group policy SG 2 using KGDP 14 - a.
[0097] At this point at step 306 , central SPM 32 will check its existing database, seeing that no peers have yet been associated with SPM 30 - 1 or KGDP 14 - a , it will thus reply to KGDP 14 - a that there are no peers to report at the present time.
[0098] After a period of time, in step 308 the security manager for the second location (SM 11 - b ) receives a security policy 12 input assigning server 10 -B- 1 and server 10 -B- 2 to security group SG 1 . This information is then passed to KGDP 14 - b via a secure tunnel between SM 11 - b and KGDP 14 - b.
[0099] In step 310 , KGDP 14 - b establishes a secure connection to its local (the second) SPM 30 - 2 and with a request to add subnet B to SG 1 . Thus, it should be understood that participants in secure connection normally can be identified by particular end node identifiers, but also by their subnet identification as well.
[0100] In step 312 , SPM 30 - 2 then establishes a secure connection to central SPM 32 . SPM 30 - 2 will then send a message that SPM 2 has a security group 1 policy using KGDP 14 -B. Again, the details of that policy are not communicated to the central SPM —merely information that SPM 30 - 2 has a security policy associated with KGDP 14 - b.
[0101] At this point, checking its database, central SPM 32 will note that there has already been a SG 1 policy defined. Thus, in step 314 central SPM 32 will reply to SPM 30 - 2 that there is another SPM (namely the first SPM 30 - 1 ) that also has policy, and that that SG 1 policy is using KGDP 14 - a . Note, however, that the details of the configuration of the policy (for example which end nodes are associated with it) need not be shared between SPM and central SPM 32 .
[0102] In step 316 SPM 30 - 2 may then contact its own local KGDP 14 - b instructing it to add KGDP 14 -A to its SG 1 list. The central SPM in step 318 will similarly send a message to SPM 1 30 - 1 informing it that SPM 2 has a security group policy in KGDP 14 -B.
[0103] In step 320 , upon receipt of such a message, SPM 30 - 1 will check its database noting that it has a complete security group policy for SG 1 . Thus it will inform KGDP A to add KGDP 14 -B to its own SG 1 list.
[0104] Again, after the expiration of some time, as shown in FIG. 4 , in step 322 KGDP 14 -B may establish a secure tunnel with KGDP 14 - a and request if it can trade keys for SG 1 . If the answer is affirmative, then KGDP 14 - a in step 324 will reply with key KA 1 that is associated with host 10 - a - 1 . In step 326 , KGDP 14 -B will reply with its keys KB associated with outbound transmissions for subnet B.
[0105] The key exchange between KGDPs still requires distribution of keys to the respective PEPs 20 that will be handling the traffic. This can be done in a number of different ways as described in a copending patent application entitled SECURING NETWORK TRAFFIC USING DISTRIBUTED KEY GENERATION AND DISSEMINATION OVER SECURE TUNNELS, U.S. Provisional Patent Application No. 60/756,765, filed Jan. 6, 2006, assigned to CipherOptics, Inc., and which is hereby incorporated by reference.
[0106] However, in one preferred embodiment as shown in step 328 , KGDP 14 - a establishes a secure connection with its local nodes 10 - a - 1 and sends its keys to be used. Namely to use key KA 1 as an outbound key when communicating with subnet B, and to use key KB when communicating as an inbound key with messages received from subnet B.
[0107] KGDP 14 -B in step 330 similarly establishes a secure tunnel with its local server B 1 , telling it to use key KB as an outbound key when communicating with host 10 -A- 1 .
[0108] In step 334 , traffic can now flow in an encrypted fashion from host 10 -A- 1 to server 10 -B- 1 and/or server 10 -B- 2 , being secured using key KA 1 as well as from server 10 -B- 1 or 10 -B- 2 to host 10 -A- 1 secured using key KB.
[0109] It should be understood now that the SPMs 30 and central SPM 32 form a hierarchy. As shown in FIG. 5 , instead of there being a single central SPM 32 there may also be a hierarchy thereof which will in turn communicate requests up and down the chain. The hierarchy of SPMs may also communicate with their neighbor in the hierarchy, such that a change in policies and identifiers for machines to which requests to establish the policies should be directed.
[0110] The invention provides several advantages over prior art policy distribution schemes. It avoids polling that would otherwise be necessary for KGDPs 14 to themselves discover peers in the network and/or PEPs 20 . It is also more secure, in that not every device needs to know everything about security. Thus, SPM devices are essentially associated with distributing policy information in KGDPs 14 are associated with their local subnets, but not necessarily associated with actually applying keys or encrypting or decrypting traffic.
[0111] SPMs 30 and 32 also need not be aware of local security policies—only how to identify where such definitions can be found by peers in the hierarchy.
[0112] It should be understood that the association between security groups and hosts could take place in ways other than just the SM sending the information to the KGDP. In particular, the SM might send the association to any SPM in the hierarchy and the KGDP could make an inquiry via the SPM. Alternately, the KGDP and/or SPM could access this data from an independent database interface, such as Active Directory, to perform authentication and obtain group association.
[0113] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
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A technique for securing message traffic in a data network using a protocol such as IPsec, and more particularly various methods for distributing security policies among peer entities in a network while minimizing the passing and storage of detailed policy or key information except at the lowest levels of a hierarchy.
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STATEMENT OF INCORPORATION BY REFERENCE
This non-provisional U.S. patent application claims the benefit of and priority to provisional U.S. patent application No. 61/411,694 filed 9 Nov. 2010 (the '694 application), and relates to U.S. patent application Ser. No. 12/760,337 filed 14 Apr. 2010 (the '337 application). The entire contents of the '694 and the '337 applications are hereby incorporated as if fully set forth herein.
BACKGROUND OF THE INVENTION
a. Field of the Invention
The disclosure relates to electrophysiology (EP) catheters for use in medical procedures. In particular, the disclosure relates to a family of catheters for use in diagnostic and therapeutic procedures at or near an annular region of a patient's anatomy, such as the ostium of a pulmonary vein.
b. Background Art
Catheters are used for an ever-growing number of procedures. For example, catheters are used for diagnostic, therapeutic, and ablative procedures, to name just a few examples. Typically, the catheter is manipulated through the patient's vasculature and to the intended site, for example a site within the patient's heart.
A typical EP catheter includes an elongate shaft and one or more electrodes on the distal end of the shaft. The electrodes can be used for ablation, diagnosis, or the like. Oftentimes, these electrodes are ring electrodes that extend about the entire circumference of the catheter shaft.
One specific use of an EP catheter is to map the atrial regions of the heart, and in particular the pulmonary veins, which are often origination points or foci of atrial fibrillation. Such EP mapping catheters typically have at least a partial loop shape at their distal end in order to surround the pulmonary vein ostia. Because of varying patient anatomies, however, it can be challenging to properly place the looped section of the catheter precisely in the pulmonary vein ostia.
BRIEF SUMMARY OF THE INVENTION
Accordingly, it is the present disclosure relates to a family of EP catheters having enhanced ability to rapidly collect EP diagnostic data from said subject with a distal portion with a wholly in-plane dual loop relative to other portions of said dual loop.
Another embodiment described and depicted herein relates to EP catheters that allow the in-plane dual loop distal portion to deflect relative to the remainder of the catheter body, thereby permitting the angle of the loop to be fine tuned. In an embodiment, the in-plane dual loop distal portion has an outer-loop diameter of between about 20 mm and about 35 mm, although other dimensions are not excluded. The outer diameter of the catheter body (expressed in units known as French abbreviated as 4 F, for example, each unit of which equals ⅓ of a millimeter, or mm) can vary. For example a majority of the catheter body, the proximal portion, can be on the order of about 7 F and an adjacent neck region can include structure, including an anchoring location for an activation wire, transitions the outer diameter to about 4 F such that the in-plane dual loop distal portion is 4 F or other uniform outer diameter throughout.
In some embodiments, the in-plane dual loop distal portion includes 20 electrodes, including a relatively longer distal tip electrode (e.g., 19 discrete 1 mm wide ring-type electrodes and a single 2 mm long distal tip electrode). In one form, 20 electrodes are distributed in a paired bi-polar mapping configuration wherein each pair is equally separated from each other pair (e.g., 2.5 mm to 7 mm, more or less if desired, apart) and each individual pair is closely situated (e.g., 1 mm apart—including the tip electrode to the most-distal ring-type electrode). Such closely spaced bi-polar pairs tend to reduce so-called far field effects in an in-chamber electrocardiogram (EGM) signal. In another form, 10 discrete electrodes (9 ring-type electrodes and one tip electrode) couple to the in-plane dual loop distal portion to sense EGM signals and are typically evenly-spaced (e.g., 3 mm, 4 mm, 5 mm, 7 mm, or the like) although that is not a requirement as they may be paired in bi-polar pairs as described above. That is, a 1 mm spacing could be following by a 7 mm spacing (in what can be referred to as a 1-7-1 arrangement). In this form the initial spacing between a tip electrode and the next ring-type electrode might be a different value, for example, 2 mm or some other value.
Accordingly, this disclosure describes EP catheters including: a tubular catheter body having a proximal region, a neck region, and a distal portion predisposed into a fixed-diameter loop portion; a plurality of electrodes disposed on the distal portion (e.g., as noted above, 10 or 20—or more or less—also known as deca- and duo-deca pole or polar electrode arrangement—with unipolar and bipolar pairing provided via suitable switching, as desired); a handle joined to the proximal region (for deflecting the distal part of the shaft portion); and a first activation wire extending through at least a portion of the proximal region of the catheter body.
The activation wire deflects the catheter body in a common plane. In general, the activation wire couples to a first element s (e.g., a round or flat wire, a thread of fiber such as Kevlar, or the like) such that forces are transferred to the shaft proximal of the loop (and the neck portion) via a deflection mechanism such as a rotary knob or a push-pull handle as is known in the EP art.
In yet another aspect, the present invention provides a method of manufacturing an EP catheter. The method generally includes the steps of: joining a proximal portion of a shaft portion of an EP catheter to a deflection mechanism and a distal portion to a proximal region of a distal in-plane dual loop region having a plurality of electrodes disposed thereon; joining a manual deflection mechanism including a wire coupled to a distal portion of a segment of flat wire near the neck region and passing through a lubricious tube fastened to the segment of flat wire (thus the flat wire serving as an anchor structure adapted to deflect the proximal portion near the neck region of the EP catheter). A method of delivering therapy via a catheter manufactured according to the foregoing includes: introducing the EP catheter into a patient's body proximate an ostium of interest (in a compressed state); actuating the deflection mechanism to deflect the proximal region of the catheter in order to deflect the catheter, and advancing or otherwise deploying the in-plane dual loop portion relative to the ostium of interest.
An advantage of EP catheters designed, built, and implemented according to the present disclosure is that the distal portion thereof (the in-plane dual loop portion) can be deflected relative to the remainder of the catheter body and thus can efficiently map various surfaces of a heart via the 10 or 20 (or other number) of electrodes.
Thus, an EP catheter according to this disclosure includes a tubular catheter body having a proximal region, a neck region, and a distal portion predisposed into an in-plane dual loop (or greater) configuration and including mapping electrodes arranged in diverse spacings therebetween. In deflectable embodiments, at least one activation wire extends through at least a portion of the proximal region of the catheter body and is adapted to deflect the distal portion (e.g., approximately 180 degrees) relative to the proximal region. The catheter can be operated manually by a clinician or via a clinician-surrogate such as a computer processor-controlled surgical system. In addition, a variety of localization, visualization, and/or orientation-specific elements can be incorporated into the proximal region, neck region, and proximal portion (e.g., metallic coil members, active impedance emitting or receiving electrodes, fluoroscopically opaque materials, and the like) for use in conjunction with an electroanatomical system, for example.
The foregoing and other aspects, features, details, utilities, and advantages of the present invention will be apparent from reading the following description and claims, and from reviewing the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a plan view including a partially exploded depiction of an exemplary EP catheter having a distal in-plane dual loop cardiac mapping portion with closely-spaced, or high-definition, EP electrodes, with the partially exploded depiction illustrating the catheter in both a deflected and an undeflected configuration.
FIG. 1B is a plan view of the exemplary EP catheter illustrated in FIG. 1A in an undeflected configuration.
FIG. 1C is an enlarged view of the distal in-plane dual loop cardiac mapping portion of the exemplary EP catheter of FIG. 1A ; namely, an illustration of a pair of electrodes residing a segment of the dual loop cardiac mapping portion.
FIG. 1D is an elevational side view in partial cross section of a neck portion formed just proximal of the distal in-plane dual loop cardiac mapping portion of the exemplary EP catheter depicted in FIGS. 1A and 1B .
FIG. 2A is a close up isometric view of the distal in-plane dual loop cardiac mapping portion of the exemplary EP catheter of FIGS. 1A and 1B (with a perspective view of connecting elements within interior portions of the catheter body, or shaft, illustrated) according to some embodiments of the present invention.
FIG. 2B is an enlarged isometric fragmented view of the interior details of the ends of the connecting elements within the interior of the catheter body shown in FIG. 2A .
FIG. 2C is an enlarged fragmented plan view of the interior details of the ends of the connecting elements within the interior of the catheter body shown in FIG. 2A .
FIG. 3 is an elevational view showing exemplary dimensions of the distal in-plane dual loop cardiac mapping portion of the exemplary EP catheter of FIGS. 1A and 1B according to an embodiment of the present disclosure.
FIG. 4A depicts the distal in-plane dual loop cardiac mapping portion of the exemplary EP catheter of FIGS. 1A and 1B (with cross references to details shown in FIGS. 4B and 4C ).
FIG. 4B is an enlarged fragmentary view in partial cross section and partial cut-away of the distal tip electrode and two ring electrodes and flat wire subassembly connection within the catheter body, respectively, shown in FIG. 4A .
FIG. 4C is an enlarged fragmentary view in partial cross section of the catheter body near the neck region shown in FIG. 4A
FIG. 5 is a cross-sectional view of the EP catheter illustrated in FIG. 4C taken along line A-A as shown in FIG. 4C .
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described with reference to an EP catheter utilized in cardiac EP studies, such as the AFocus II DL (or dual loop) diagnostic catheter of St. Jude Medical, Atrial Fibrillation Division, Inc., which can provide relatively faster cardiac activity data collection having the necessary detail to efficiently diagnose complex cardiac arrhythmias. It should be understood, however, that the present teachings can be applied to good advantage in other contexts as well, such as radiofrequency (RF) ablation catheters or other diagnostic cardiac catheters.
Referring now to the drawings, FIGS. 1A and 1B depict an EP catheter 10 according to a first aspect of the present invention.
FIG. 1A is a plan view including a partially exploded depiction of an exemplary EP catheter 10 having a distal in-plane dual loop cardiac mapping portion 16 with EP diagnostic, or mapping, electrodes 20 (as depicted herein arranged in an exemplary duodecapolar configuration), with the partially exploded depiction illustrating the catheter 10 in both a undeflected and a deflected configuration (denoted as “C” and “D” respectively).
FIG. 1B is a plan view of the exemplary EP catheter 10 illustrated in FIG. 1A in an undeflected configuration (i.e., configuration “C” of FIG. 1A ).
FIG. 1C is an enlarged view of the distal in-plane dual loop cardiac mapping portion 16 of the exemplary EP catheter 10 of FIG. 1A ; namely, an illustration of a pair of electrodes 20 residing on a segment 16 ′ of the dual loop cardiac mapping portion 16 . The lateral edges 20 ′ of electrodes 20 are bonded to the adjacent relatively smaller (e.g., 4 F) diameter biocompatible tubing (e.g., PTFE or the like) of portion 16 with a biocompatible material such as a polyurethane matrix composed of Polycin 936 and Vorite 689 (mixed 52:48 percent, as an example) produced by CasChem Inc. of Bayonne, N.J.
FIG. 1D is an elevational side view in partial cross section of a neck portion 18 formed just proximal of the distal in-plane dual loop cardiac mapping portion 16 of the exemplary EP catheter 10 depicted in FIGS. 1A and 1B . As shown, an extended braid tube/spring assembly 50 surrounds a variety of subcomponents of catheter 10 and is itself wrapped by a relatively smaller diameter biocompatible tubing 18 that covers the neck region and transitions the outer diameter to the about 4 F distal in-plane dual loop cardiac mapping portion 16 . Where the extended braid tube/spring assembly 50 terminates at its distal edge a small amount of medical grade adhesive polymer 20 ″ (e.g., like the polymer 20 ′ used at the edges of electrodes 20 ) can be applied. A polyimide tube 56 ′ passes through the extended braid tube/spring assembly 50 (and neck region 18 ) and into the distal in-plane dual loop cardiac mapping portion 16 and isolates a plurality of elongate conductive strands 70 ′ (shown in FIG. 4B ) that couple the electrodes 20 , 46 to remote circuitry via a handle ( 22 as shown in FIGS. 1A and 1B ) having a mass termination where the conductors 70 pass through the handle to couple to an EP recording system or other diagnostic equipment, for example. A flat wire subassembly 52 , which includes segment of flat wire 59 , is coupled to an activation wire 54 and is adapted to impart and release tension to deflect the proximal end 16 in a plane defined by the flat wire subassembly 52 (via manipulation of the handle, such as by rotation or linear actuation members, and the like). A short segment of polyimide tubing 56 ′ surrounds a junction of several components; namely, a lubricous tubing member 58 (e.g., PEEK tubing) that receives a proximal end of an elongate shape memory member 30 (formed of nitinol, for example) that is preformed into a desired dimension and configuration for distal portion 16 . In one embodiment, the distal portion 16 has an overall outer diameter of 20 mm (i.e., for the outermost loop) with a 4 F dimension for portion 16 ′ and 1 mm (wide) platinum electrodes 20 and a 2 mm (long) tip electrode 46 . In this embodiment, the electrodes 20 can be spaced apart in bipolar pairs or evenly (e.g., about 1 or 2-4 mm or other nominal spacing between them). In a bipolar pair configuration the electrode spacing can vary, of course, although in on embodiment the spacing for 1 mm (wide) ring-type electrodes is 1 mm per bipolar pair with 2.5 mm between pairs. In this embodiment the spacing between the tip electrode 46 to the most distal ring-type electrode 20 can also be 1 mm. In the embodiments depicted herein the diameter of the outer loop of the distal portion 16 is fixed (e.g., at about 20 mm or less to about 33 mm or more, if desired) although using reasonably well-known techniques the diameter can be manually varied with one or more tension elements for imparting and releasing tension. Such element(s) couple to structure within one or more locations with a distal looped portion (e.g., using KEVLAR fibers, metallic or composite wires or axially rigid elements, thin so-called pull wires and the like). At the junction of the flat wire subassembly 52 with the nitinol wire 30 wrapped in, for example, PEEK tubing urethane adhesive (denoted by reference numeral 26 in FIG. 2B ) can be applied between, above, and around the components within the polyimide tubing 56 ′ to encapsulate same. Similarly, urethane adhesive 26 can be impregnated into the interstices of the neck region 18 and distal portion 16 to reduce or eliminate any migration of the nitinol wire 30 or PEEK tubing 58 or polyimide tube 60 (surrounding conductor 70 ′) during use.
In general, EP catheter 10 can include an elongate catheter body 12 , which, in some embodiments, is tubular (e.g., it defines at least one lumen therethrough). Catheter body 12 includes a proximal region 14 , a distal portion 16 , and a neck region 18 between proximal region 14 and distal portion 16 . One of ordinary skill in the art will appreciate that the relative lengths of proximal region 14 , distal portion 16 , and neck region 18 depicted in FIGS. 1A and 1B are merely illustrative and can vary without departing from the spirit and scope of the present invention but likely should not have a magnitude of less than about 110 cm. Of course, the overall length of catheter body 12 should be long enough to reach the intended destination within the patient's body.
Catheter body 12 will typically be made of a biocompatible polymeric material, such as polytetrafluoroethylene (PTFE) tubing (e.g., TEFLON® brand tubing). Of course, other polymeric materials, such as fluorinated ethylene-propylene copolymer (FEP), perfluoroalkoxyethylene (PFA), poly(vinylidene fluoride), poly(ethylene-co-tetrafluoroethylene), and other fluoropolymers, can be utilized. Additional suitable materials for catheter body 12 include, without limitation, polyimide-based thermoplastic elastomers (namely poly(ether-block-amide), such as PEBAX®), polyester-based thermoplastic elastomers (e.g., HYTREL®), thermoplastic polyurethanes (e.g., PELLETHANE®, ESTANE®), ionic thermoplastic elastomers, functionalized thermoplastic olefins, and any combinations thereof. In general, suitable materials for catheter body 12 can also be selected from various thermoplastics, including, without limitation, polyamides, polyurethanes, polyesters, functionalized polyolefins, polycarbonate, polysulfones, polyimides, polyketones, liquid crystal polymers and any combination thereof. It is also contemplated that the durometer of catheter body 12 can vary along its length. In general, the basic construction of catheter body 12 will be familiar to those of ordinary skill in the art, and thus will not be discussed in further detail herein.
Referring now to FIG. 2A which is a close up isometric view of the distal in-plane dual loop cardiac mapping portion 16 of the exemplary EP catheter 10 of FIGS. 1A and 1B (with a perspective view of connecting elements within interior portions of the catheter body, or shaft, illustrated) according to some embodiments of the present invention. As illustrated, the proximal and distal ends of the flat wire subassembly 52 (e.g., implemented to promote planarity during deflection) are emphasized.
FIG. 2B is an enlarged isometric fragmented view of the interior details of the ends of the various connecting elements within the interior of the catheter body 14 , 18 of FIG. 2A . As depicted, the proximal end of a flattened PEEK tube 58 that contains the nitinol wire 30 is adhered with urethane adhesive 26 (or other suitable medical grade adhesive) to segment of flat wire 59 of the flat wire subassembly 52 and wrapped in polyimide tubing 56 ′ for containment. The proximal end of the flat wire subassembly 52 couples via a segment of polyimide tubing 56 filled with urethane adhesive 26 that also encapsulates the smaller diameter polyimide tubing 61 where the activation wire 54 resides. A gap of about 1-2 mm between the tubing 56 and the distal end of extended braid/spring subassembly 50 should be optionally maintained (as depicted) and the activation wire 54 and conductor wires 70 (within polyimide tube 60 ) are conveyed through subassembly 50 to a handle or other remote location.
FIG. 2C is an enlarged fragmented plan view of the interior details of the ends of the connecting elements within the interior of the catheter body shown in FIG. 2A . As depicted, the flattened section of the PEEK tubing 58 disposed within the polyimide tubing 56 ′ can comprise a 1 mm segment to promote adhesion to the urethane adhesive 26 impregnated therein and thus to the flat wire subassembly 52 , including segment of flat wire 59 . Similarly, the proximal end of the flat wire subassembly 52 can be surrounded by polyimide tubing 56 and impregnated with urethane adhesive ( 70 not shown) to promote mechanical coupling to the adjacent extended braid/spring subassembly 50 . A suitable biocompatible compound 20 ″ (e.g., such as polymer 20 ′) can be applied to the junction between the outer covering for distal portion 16 ′ and the neck region 18 .
FIG. 3 is an elevational view showing exemplary dimensions of the distal in-plane dual loop cardiac mapping portion 16 of the exemplary EP catheter 10 of FIGS. 1A and 1B according to an embodiment of the present disclosure. For example, the plane of the distal portion 16 can be on the order of 10 mm to the neck region 18 , although other dimensions can be used if desired. Whatever dimension is used the wire support length therefrom should be a reasonable length (e.g., 2.5 mm as depicted).
FIG. 4A depicts the distal in-plane dual loop cardiac mapping portion 16 of the exemplary EP catheter 10 of FIGS. 1A and 1B (with cross references to details shown in FIGS. 4B and 4C ). In the illustrated embodiment the distal portion 16 includes paired twenty pole electrodes 20 with a nominal separation of about 1 mm between each pair of electrodes 20 and 2.5 mm between adjacent pairs of electrodes 20 . Of course, other dimensions can be used for the electrodes 20 and the spacing therebetween. At the proximal end of the catheter body 12 a plurality of individually electrically insulated elongate conductors 70 emerge and are adapted to be individually coupled to a mass termination terminal within a handle 72 for ultimate electrical communication with an EP recording system, an electroanatomical localization and visualization system (e.g., such as the ENSITE system of St. Jude Medical, Inc. operating the ONEMAP facility or other similar systems for monitoring cardiac activity and providing one or more visual representations of same).
FIG. 4B is an enlarged fragmentary view in partial cross section and partial cut-away of the distal tip electrode 46 and two ring electrodes 20 and flat wire subassembly 52 connection within the catheter body 12 , respectively, shown in FIG. 4A . Each electrode 20 , 46 couples via an elongate conductor 70 ′ in FIG. 4B to remote EP recording and/or localization and visualization equipment. A biocompatible adhesive 21 (e.g., LOCTITE adhesive) can be applied to the junction of the biocompatible tubing 16 of the distal portion 16 and the electrode 46 to eliminate body fluid ingress therein. A so-called safety wire (or element) 71 can couple to the electrode 46 and a proximal location to reduce or eliminate the chance that the electrode 46 might separate from the catheter assembly 10 .
FIG. 4C is an enlarged fragmentary view in partial cross section of the catheter body near the neck region shown in FIG. 4A and indicates a cross sectional view along lines A-A therein which is reflected in FIG. 5 hereinbelow described. The dimensions indicated on FIG. 4C are merely exemplary and illustrative and not intended as limiting in any way.
FIG. 5 is a cross-sectional view of the EP catheter 10 illustrated in FIG. 4C taken along line A-A as shown in FIG. 4C . The biocompatible tubing overlaying next region 18 includes (electrode 20 ) conductor wires, denoted by reference numeral 34 in FIG. 5 , surrounded by polyimide tubing 60 and nominally spaced from nitinol wire 30 by a space impregnated with urethane adhesive 26 .
One of ordinary skill in the art will appreciate that electrodes 20 can be ring-type electrodes or any other electrodes suitable for a particular application of EP catheter 10 . For example, where EP catheter 10 is intended for use in a contactless EP study, electrodes 20 can be configured as described in U.S. application Ser. No. 12/496,855, filed 2 Jul. 2009, which is hereby incorporated by reference as though fully set forth herein. Of course, in addition to serving sensing purposes (e.g., cardiac mapping and/or diagnosis), electrodes 20 can be employed for therapeutic purposes (e.g., cardiac ablation and/or pacing).
Referring again to the present disclosure in general, various handles and their associated actuators for use in connection with deflecting EP catheters are known, and thus handle 22 will not be described in further detail herein.
In use, EP catheter 10 is introduced into a patient's body proximate an area of interest, such as a pulmonary vein ostium. Of course, EP catheter can be introduced surgically (e.g., via an incision in the patient's chest) or non-surgically (e.g., navigated through the patient's vasculature to a desired site). Activation wire 54 can be actuated in order to deflect proximal region 14 of catheter body 12 such that distal portion 16 is oriented generally towards the ostium of interest. Electrodes 20 can then be employed for diagnostic or therapeutic purposes.
All directional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present invention, and do not create limitations, particularly as to the position, orientation, or use of the invention. Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and can include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily infer that two elements are directly connected and in fixed relation to each other.
It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure can be made without departing from the invention as defined in the appended claims.
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An EP catheter includes a tubular body having a proximal region, a neck region, and a distal portion predisposed into an in-plane dual loop (at least, approximately, more or less) configuration and including a plurality of diagnostic electrodes. In deflectable catheter forms, at least one activation wire extends through at least a portion of the proximal region of the catheter body and is adapted to deflect the distal portion up to approximately 180 degrees relative to the proximal region. The catheter can be operated manually by a clinician or via a clinician-surrogate such as a computer processor-controlled surgical system. In addition, a variety of localization, visualization, and/or orientation-specific elements can be incorporated into the devices described, depicted, and claimed herein (e.g., metallic coil members, active impedance emitting or receiving electrodes, fluoroscopically opaque materials, and the like).
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. §119 of German Patent Application DE 10 2013 211 390.0 filed Jun. 18, 2013, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention pertains to an air gap-insulated exhaust manifold for a supercharged internal combustion engine, preferably of a motor vehicle. The present invention pertains, in addition, to an exhaust system equipped with such an exhaust manifold for an internal combustion engine, preferably of a motor vehicle.
BACKGROUND OF THE INVENTION
[0003] An exhaust manifold is used as the inlet area of an exhaust system and merges the separate exhaust gas streams usually coming from a plurality of combustion chambers of the internal combustion engine. An exhaust manifold usually comprises for this an engine flange, with which the exhaust manifold can be fastened to an engine block of the internal combustion engine. Separate inlet openings, which are associated with the individual combustion chambers of the internal combustion engine, are, in turn, provided in the area of the engine flange. The exhaust manifold is usually connected permanently with a turbine flange on the discharge side in a supercharged internal combustion engine in order to feed the exhaust gases arriving from the internal combustion engine to the turbine as close to the engine as possible. Double-flow turbines, so-called twin-scroll turbines, may be used in internal combustion engines that have two cylinder banks or two groups of cylinders. To prevent the two cylinder groups from mutually interacting with one another, the exhaust gas is likewise routed in two flows up to the double-flow turbine, so that the exhaust manifold has separate manifolds for the two cylinder groups, which said manifolds lead each from a plurality of inlet openings to an outlet opening, and the two outlet openings of the separate manifolds feed the separate exhaust gas streams to separate inlet openings of the turbine in the turbine flange.
[0004] It is known that such an exhaust manifold can be equipped with an air gap insulation for improved heat insulation. This is achieved by an exhaust gas-carrying inner pipe being enveloped by an outer pipe, forming a gap, and this gap between the inner pipe and the outer pipe forms the desired air gap insulation. The outer pipe and inner pipe may also be called outer shell and inner shell, respectively.
[0005] For a supercharged internal combustion engine with twin-scroll turbine, an air gap-insulated exhaust manifold thus comprises an engine flange for fastening the exhaust manifold to the engine block of the internal combustion engine, a turbine flange for fastening the exhaust manifold to the turbine of the exhaust gas turbocharger, two separate inner pipes, which lead each from at least one inlet opening for exhaust gas arranged in the area of the engine flange to an outlet opening for exhaust gas arranged in the area of the turbine flange, as well as an outer pipe, which envelops the two inner pipes, forming an air gap insulation and extends essentially from the engine flange to the turbine flange.
[0006] The inner pipes may have a multipart design in order to make it possible to merge a plurality of inlet openings into a common outlet opening in a simpler manner. The individual members of the respective inner pipe may be inserted one into another to make relative motions caused by thermal effects possible. Leaks may develop due to these plug-type connections, as a result of which exhaust gas can escape from the respective inner pipe and enter the interior space of the outer pipe, which said interior space is enveloped by the outer pipe. Such tolerable leaks occur in a pulsed manner, corresponding to the working rhythm of the internal combustion engine. To prevent these pressure pulsations of the two cylinder groups within the exhaust manifold from mutually affecting each other, a partition, which divides the interior space of the outer pipe into two interior spaces, in which one of the two inner pipes each is arranged, may be arranged in the outer pipe. This partition advantageously extends from the turbine flange to the engine flange.
[0007] It was found that such a partition is subject to very high thermal loads because of it being positioned between the two inner pipes. In particular, the partition is subject to strong thermal expansion effects. Undesired wear may develop as a result.
SUMMARY OF THE INVENTION
[0008] The present invention pertains to the object of providing an improved embodiment, which is characterized especially by reduced wear, for an exhaust manifold of the type described in the introduction or for an exhaust system equipped therewith.
[0009] According to the invention, an air gap-insulated exhaust manifold is provided for a supercharged internal combustion engine. The exhaust manifold comprises an engine flange for fastening the exhaust manifold to an engine block of the internal combustion engine and a turbine flange for fastening the exhaust manifold to a turbine of an exhaust gas turbocharger. Two separate inner pipes lead each from at least one inlet opening for exhaust gas arranged in the area of the engine flange to an outlet opening for exhaust gas arranged in the area of the turbine flange. An outer pipe envelopes the two inner pipes, forming an air gap insulation. The outer pipe extends between the engine flange and the turbine flange. A separate partition separates two interior spaces, in which one each of the two inner pipes is arranged, from each other in the interior space of the outer pipe. The partition is arranged loosely at the turbine flange.
[0010] The present invention is based on the general idea of designing the partition as a separate component and arranging it movably, i.e., loosely, at least in relation to the turbine flange. The partition can move relative to the turbine flange, at least in the area of a front side facing the turbine flange, due to this design. As a consequence, the partition can expand based on thermal stress and move relative to the turbine flange in the process without a risk of excessive wear occurring. Furthermore, the risk of mechanical damage to the turbine flange due to the partition possibly supported thereon can be reduced due to the loose arrangement of the partition in relation to the turbine flange.
[0011] Corresponding to another advantageous embodiment, the partition may be guided at the turbine flange by guide contours in a positive-locking manner. A guiding is defined hereby for the motions of the partition relative to the turbine flange, which simplifies these relative motions and reduces the risk of wear. A positive-locking guiding can be achieved in an especially simple manner without additional components, because the partition is guided directly at the turbine flange if the guide contours are formed integrally on the turbine flange.
[0012] According to a preferred variant, the respective guide contour may be formed by a guide support, which is formed in the turbine flange and with which a lateral edge area of the partition meshes (engages) in a positive-locking manner. Such a guide support can be formed as an integral component at the turbine flange in an especially simple manner. In the area of a front side facing the turbine flange, the partition can simply mesh with lateral edge areas facing away from one another with the diametrically opposite guide supports, as a result of which a secure guiding is achieved for the partition.
[0013] The partition may also be arranged loosely at the outer pipe in another embodiment. This means that the partition is also arranged movably in relation to the outer pipe, i.e., it can, in particular, expand thermally without blocking with the outer pipe.
[0014] According to a preferred variant, the partition may be positioned at the outer pipe in positioning contours in a positive-locking manner. Such positioning contours can be integrated in the outer pipe in an especially simple manner. For example, the outer pipe may be manufactured as a shell construction, wherein the individual shells can be manufactured by means of the deep-drawing technique or blow-molding technique. Such positioning contours can thus be formed integrally with the outer pipe in an especially simple manner, without additional effort.
[0015] According to a preferred variant, the positioning contour may be formed by a positioning support, which is formed in the outer pipe and with which support a lateral edge area of the partition meshes. Permanent positioning is achieved by means of the respective positive-locking connection in this case as well, without additional fastening measures being necessary.
[0016] The respective positioning contour may extend, in principle, from the engine flange to the turbine flange on the outer pipe. However, an embodiment in which the respective positioning contour is located at a spaced location from the engine block and at a spaced location from the turbine flange is preferred. As a consequence, the positioning contour extends only over part of the respective lateral edge of the partition. For example, the respective positioning contour extends only over a maximum of 50% of the respective lateral edge of the partition. The respective positioning contour preferably extends over about 25% of the respective lateral edge. If the positioning contour does not extend over the entire respective lateral edge of the partition, the edge area of the partition, which cooperates with the positioning contour and consequently meshes with same, is preferably formed by a projection, which projects from the rest of the lateral edge and meshes with the respective positioning support.
[0017] The partition may also be arranged loosely at the engine flange in another embodiment. In other words, the partition can also move relative to the engine flange, as a result of which motions caused by thermal effects are possible here as well and stresses caused by thermal effects can be reduced.
[0018] According to an advantageous variant, the partition may be held at the engine flange in at least one holding contour in a positive-locking manner. The need for separate holding means are eliminated due to the use of a positive-locking connection in this case as well, as a result of which the holding contour can be embodied in an especially simple manner.
[0019] According to an advantageous variant, the respective holding contour may be formed by a holding support, which is formed in the engine flange and with which a front-side edge area of the partition meshes. Such a holding support can be manufactured integrally with the engine flange in an especially simple manner, for example, by taking it into account in an injection mold, which is used to manufacture the engine flange.
[0020] The turbine flange may have an open design in another advantageous embodiment. This means that an open connection is present within the turbine flange to the air gap insulation, i.e., to the intermediate space between the inner pipes and the outer pipe. As a result, the turbine flange will have a considerably simplified design, and, in particular, it is possible to eliminate a middle web, which extends between the two inner parts, in the area of the respective outlet opening. In addition, the risk of collision of the partition with the middle web can be efficiently avoided in the absence of a middle web.
[0021] The turbine flange may preferably have a single flange opening, which surrounds the two inner pipes in the area of the respective outlet opening and in which the partition ends in a detached manner on the front side. Due to the partition ending in a detached manner, the partition can move quasi as desired within the flange opening in the direction of the turbine, without colliding with an obstacle. The wear on the partition and turbine flange can be reduced in this manner.
[0022] The turbine flange may have a closed design in another embodiment. This means that the air gap insulation is also closed in the turbine flange. Leaks, which could lead to an undesired interaction between the two interior spaces separated from each other by the partition, can be avoided as a result in the area of the turbine flange as well.
[0023] The turbine flange may advantageously have two separate flange openings, which enclose each one of the inner pipes in the area of the respective outlet opening. Each inner pipe is thus enclosed in itself, preferably extensively tightly, for example, in the manner of a plug-type connection with sliding fit. The partition may be supported now on the front side at a support area of the turbine flange. Due to the front-side support of the partition at the turbine flange, efficient sealing can be achieved between the two interior spaces in this area as well. The support area is formed in this case at a middle web of the turbine flange, which separates the two flange openings from one another and which thus passes through between the two inner pipes.
[0024] Corresponding to an advantageous variant, the support area may have at least one elastic support element, via which the partition is supported on the turbine flange on the front side. Such an elastic support element thus makes relative motions possible between the partition and the aforementioned middle web of the turbine flange, without excessive mechanical stress developing in the process. Such an elastic support element may be formed, for example, by a wire mesh element. Such wire mesh elements are characterized by high thermal loadability as well as high elasticity.
[0025] The partition may be arranged in a detached or contactless manner, i.e., without contact, in relation to the two inner pipes. This measure also reduces the risk of wear.
[0026] Further, the partition may preferably be flat, so that it extends in a partition plane. As a result, the partition can be manufactured at an especially low cost. For example, the partition may be formed by a sheet metal body, which can be manufactured in an especially simple manner, for example, by means of a punching operation. In case of a flat partition, the partition may mesh with the respective guide support preferably in parallel to the plane of the partition. Further, the partition may mesh with the respective positioning support in parallel to the plane of the partition. Finally, the partition may mesh with the respective holding support in parallel to the plane of the partition. Furthermore, provisions may be made for the partition to be arranged movably in the respective guide support in parallel to the plane of the partition, in which case the direction of motion is oriented in parallel to the direction of a gap between the engine flange and the turbine flange. Furthermore, the partition may be arranged movably in the respective positioning support in parallel to the plane of the partition, in which case the direction of motion is oriented at right angles to the direction of the gap between the engine flange and the turbine flange. Finally, the partition may be arranged movably in the respective holding support in parallel to the plane of the partition. The direction of motion is again oriented in parallel to the direction of the gap between the engine flange and the turbine flange in this case.
[0027] It is also possible, as an alternative, to make the partition uneven and to provide it, for example, with a curvature or crown. Such a curvature can help avoid unintended deformations during heating up and cooling. Such an uneven partition may also be flat or straight in the area of the respective guide contour in order to bring about linear guiding. This also applies analogously to the area of the respective positioning contour and/or of the holding contour.
[0028] It is also possible, according to another alternative, to provide the partition with a bent rim in the area of the respective positioning contour. The respective positioning contour is designed in this case to receive the rim. Further, it is possible, in principle, to provide the respective positioning contour with a mounting contour, which makes possible a positive-locking connection with the respective rim.
[0029] Two positioning contours, which are located diametrically opposite at the outer pipe, may be provided in another embodiment. Furthermore, the two positioning contours may be advantageously arranged approximately centrally between the engine flange and the turbine flange. A variant in which the positioning contours are used as fixed mounts for expansion motions of the partition oriented in parallel to the direction of the gap between the engine flange and the turbine flange, while the guide contours and at least one holding contour are used each as movable mounts, in which the relative motions between the partition and turbine flange, on the one hand, as well as between the partition and engine flange, on the other hand, take place.
[0030] Furthermore, provisions may be made for the partition, which is preferably flat, to extend essentially at right angles to a plane of the turbine flange. Simple kinematics is achieved hereby for the thermal expansion effects, as a result of which it is possible, in particular, to avoid warping and the like.
[0031] An exhaust system according to the present invention, which is intended for a supercharged internal combustion engine, especially in a motor vehicle, comprises a turbine of an exhaust gas turbocharger as well as an exhaust manifold of the above-described type, via which the exhaust system can be fastened to the internal combustion engine. The engine flange is fixed for this to the engine block of the internal combustion engine, while the turbine flange is fixed to the turbine of the exhaust gas turbocharger.
[0032] Further important features and advantages of the present invention appear from the subclaims, from the drawings, and from the corresponding description of the figures on the basis of the drawings.
[0033] It is obvious that the above-mentioned features, which will also be explained below, can be used not only in the particular combination indicated, but also in other combinations or alone, without going beyond the scope of the present invention.
[0034] Preferred exemplary embodiments of the present invention are shown in the drawings and will be explained in more detail in the following description, in which identical reference numbers designate identical or similar or functionally identical components.
[0035] 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 preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a highly simplified, diagram-like general view of an internal combustion engine with an exhaust system, which has an exhaust manifold shown in section;
[0037] FIG. 2 is an axial view of the exhaust manifold in the area of a turbine flange;
[0038] FIG. 3 is an axial sectional view of the exhaust manifold through the turbine flange;
[0039] FIG. 4 is an axial view of the exhaust manifold in the area of the turbine flange in another embodiment;
[0040] FIG. 5 is an axial view of the exhaust manifold through the turbine flange in the embodiment shown in FIG. 4 ; and
[0041] FIG. 6 is a longitudinal sectional view of the exhaust manifold in the area of the turbine flange.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] Referring to the drawings in particular, corresponding to FIG. 1 , an internal combustion engine 1 comprises an engine block 2 with a plurality of combustion chambers 3 , which are formed by a cylinder 4 each in the usual manner, in which a piston each, not shown here, is arranged in such a manner that its stroke is adjustable. The internal combustion engine 1 has a fresh air feed unit 5 for supplying the combustion chambers 3 with fresh air. Further, an exhaust system 6 is provided, which removes exhaust gas from the combustion chambers 3 during the operation of the internal combustion engine 1 . The internal combustion engine 1 is designed as a supercharged internal combustion engine 1 . It is correspondingly equipped here with an exhaust gas turbocharger 7 , which has a turbine 8 and a compressor 9 in the usual manner. The compressor 9 is integrated into the fresh air feed unit 5 and is drive-connected with the turbine 8 , which is integrated into the exhaust system 6 . The exhaust system 6 has an exhaust manifold 10 , which connects the block 2 with the turbine 8 .
[0043] Corresponding to FIGS. 1 through 6 , the exhaust manifold 10 has an engine flange 11 , which is used to fasten the exhaust manifold 10 to the engine block 12 . The exhaust manifold 10 has, in addition, a turbine flange 12 , which is used to fasten the exhaust manifold 10 to the turbine 8 . Further, the exhaust manifold 10 comprises two separate inner pipes 13 , 14 , an outer pipe 15 as well as a partition 16 . The respective inner pipe 13 , 14 extends from at least one inlet opening 17 arranged in the area of the engine flange 11 to an outlet opening 18 arranged in the area of the turbine flange 12 . In the example shown in FIG. 1 , the engine block 2 has six cylinders 4 , which are combined in two cylinder groups 19 , 20 , so that each cylinder group 19 , 20 has exactly three cylinders 4 . The two inner pipes 13 , 14 are separately associated with these two cylinder groups 19 , 20 . Each inner pipe 13 correspondingly has three inlet openings 17 and one outlet opening 18 . Consequently, two such outlet openings 18 are merged at the turbine flange 12 . The turbine 8 is preferably designed as a twin-scroll turbine, i.e., as a double-flow turbine 8 , so that the two outlet openings 18 of the exhaust manifold 10 are led in separate exhaust gas paths in the turbine 8 . The two inner pipes 13 , 14 may also be called inner shells 13 , 14 .
[0044] The outer pipe 15 , which may also be called outer shell 15 , envelops the two inner pipes 13 , 14 , such that an air gap insulation 21 is formed now. The outer pipe 15 extends here essentially from the engine flange 11 to the turbine flange 12 . The outer pipe 15 is connected permanently directly with the engine flange 11 and with the turbine flange 12 in the examples being shown. It is likewise conceivable to fasten the outer pipe 15 indirectly to the engine flange 11 and/or to the turbine flange 12 , namely, via the respective inner pipe 13 , 14 , which is permanently connected at least in this case with the engine flange 11 and with the turbine flange 12 , respectively.
[0045] The partition 16 forms a separate component in relation to the inner pipe 13 , 14 , outer pipe 15 , engine flange 11 and turbine flange 12 . The partition 16 is arranged in an interior space 22 of the outer pipe 15 , such that it separates two interior spaces 23 , 24 from one another in the interior space 22 . One of the two inner pipes 13 , 14 each is arranged in each interior space 23 , 24 .
[0046] Corresponding to FIGS. 2 through 6 , the partition 16 is arranged loosely at the turbine flange 12 , i.e., it is not fixed to it directly, so that the partition 16 is movable relative to the turbine flange 12 . According to FIGS. 2 , 3 and 5 , guide contours 25 , which guide the partition 16 in a positive-locking manner, are formed on the turbine flange 12 . The respective guide contour 25 is formed here by a guide support 26 , which is formed directly in the turbine flange 12 and with which meshes a lateral edge area 27 of the partition 16 in a positive-locking manner.
[0047] The partition 16 may be arranged, in addition, loosely at the outer pipe 15 . According to FIGS. 3 and 5 , the outer pipe 15 may have two positioning contours 28 for this, which bring about a positive-locking positioning of the partition 16 . The respective contour 28 is formed here by a positioning support 29 , which is formed in the outer pipe 15 and with which a lateral edge area 30 of the partition 16 meshes. The positioning contours 28 are arranged diametrically opposite each other in the example. Further, the two positioning contours 28 are arranged each approximately centrally between the engine flange 11 and the turbine flange 12 . The positioning contours 28 are designed such that the partition 16 is fixed relative to the outer pipe 15 in relation to a direction 31 of the gap between the engine flange 11 and the turbine flange 12 , whereas the partition 16 is arranged movably in the positioning contours 28 at right angles to the direction 31 of the gap. The positioning contours 28 form fixed mounts here, so that the partition 16 can expand thermally starting from the positioning contours 28 .
[0048] According to FIGS. 3 , 5 and 6 , the partition 16 is advantageously also arranged loosely at the engine flange 11 , i.e., it is not fixed to it directly. The engine flange 11 may have for this at least one holding contour 32 according to FIG. 6 , which brings about positive-locking holding of the partition 16 . The respective holding contour 32 is formed in the example by a holding support 33 , which is formed directly on the engine flange 11 and with which a front-side edge area 34 of the partition 16 meshes in a positive-locking manner.
[0049] As can be seen especially in FIG. 6 , the inner pipes 13 , 14 are of a multipart design, so that they are consequently composed of a plurality of individual pipes.
[0050] The turbine flange 12 is designed as an open flange in the embodiment shown in FIGS. 2 and 3 , as a result of which the air gap insulation 21 is visible especially in the axial view according to FIG. 2 . The turbine flange 12 has a single flange opening 35 in this case, through which both inner pipes 13 , 14 are led. This common flange opening 35 thus encloses both inner pipes 13 , 14 each in the area of the respective outlet opening 18 . An inner edge of the flange opening 35 , not designated specifically, is flatly and sealingly in contact with the respective inner pipe 13 , 14 in a circumferential section facing away from the partition 16 . Contrary to this, the partition 16 ends in a detached manner in the flange opening 35 . As can be recognized, the partition 16 is located now at a spaced location from both inner pipes 13 , 14 . It can be recognized especially from FIG. 3 that the partition 16 has no axial obstacle at the flange 12 and is consequently movable within the guide contours 25 .
[0051] Contrary to FIGS. 2 and 3 , FIGS. 4 and 5 show an embodiment in which the turbine flange 12 has a closed design. The air gap insulation 21 is not consequently visible here. The turbine flange 12 has two separate flange openings 36 , 37 in this case, through which one each of the inner pipes 13 , 14 is passed. Thus, each flange opening 36 , 37 encloses one of the two inner pipes 13 , 14 in the area of the corresponding outlet opening 18 . An inner wall of the respective flange opening 36 , 37 , not designated more specifically, is flatly in contact with the respective inner pipe 13 , 14 , extending circularly in a closed pattern in the circumferential direction. The turbine flange 12 has in this embodiment a middle web 38 , which passes through between the two inner pipes 13 , 14 and which separates the two flange openings 36 , 37 from each other.
[0052] According to FIG. 5 , the partition 16 is supported in this embodiment at a support area 39 of the turbine flange 12 , namely, via a front side 40 facing the turbine flange 12 . This support area 39 may have at least one elastic support element 41 , which may be especially a wire mesh element, which will likewise be designated by 41 hereafter.
[0053] As can be determined especially from FIGS. 2 and 6 , the partition 16 is arranged in a detached manner in relation to the inner pipes 13 , 14 . Further, the partition 16 is preferably of a flat design, so that it extends in the partition plane 42 suggested in FIG. 6 . The partition 16 advantageously meshes with the guide supports 25 , positioning supports 28 and holding support 32 in parallel to the partition plane 42 . Further, the partition 16 is arranged movably in the guide contours 25 , in the positioning contours 28 and in the holding contour 32 in parallel to the partition plane 42 . This mobility is oriented in parallel to the direction 31 of the gap in the guide contours 25 and in the holding contour 32 and at right angles to the direction 31 of the gap in the positioning contours 28 . Further, the partition plane 42 extends essentially at right angles to a flange plane 43 of the turbine flange 12 shown in FIGS. 3 and 5 , in which plane the turbine flange 12 extends.
[0054] Finally, a ring groove 44 can be recognized in FIGS. 2 through 6 , wherein said groove 44 is milled into the turbine flange 12 and a seal can be inserted into it in order to seal the connection between the turbine flange 12 and a flange of the turbine 8 , which latter flange is complementary thereto.
[0055] As can be seen especially in FIGS. 3 and 5 , the positioning contour 28 is positioned in the embodiments shown here at a spaced location from the engine flange 11 and at a spaced location from the turbine flange 12 , so that it does not extend over the respective entire side wall 45 of the partition 16 . A projection 46 , which projects from the respective side wall 45 outwardly and forms the edge area 30 of the partition 16 meshing with the positioning support 29 , is correspondingly formed at the respective side wall 45 .
[0056] 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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An air gap-insulated exhaust manifold ( 10 ) for a supercharged internal combustion engine ( 1 ), preferably of a motor vehicle has an engine flange ( 11 ) fastening the exhaust manifold to an engine block ( 2 ) and a turbine flange ( 12 ) fastening the exhaust manifold to a turbine ( 8 ) of an exhaust gas turbocharger ( 7 ). Two inner pipes ( 13, 14 ) lead from an inlet opening, for exhaust gas, adjacent to the engine flange to an outlet opening ( 18 ), for exhaust gas, adjacent to the turbine flange. An outer pipe ( 15 ) envelopes the two inner pipes, forming an air gap insulation ( 21 ), and extends from the engine flange to the turbine flange. A separation partition ( 16 ) separates, in the interior space ( 22 ) of the outer pipe, two interior spaces ( 23, 24 ), in which one each of the two inner pipes is arranged. Reduced wear is achieved with the partition arranged loosely at the turbine flange.
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RELATED APPLICATIONS
This application is a continuation of and claims the benefit under 35 U.S.C. §120 of U.S. patent application Ser. No. 12/238,308, filed Sep. 25, 2008, which is herein incorporated by reference in its entirety. U.S. patent application Ser. No. 12/238,308 claims the benefit under 35 U.S.C. §119(e) of provisional U.S. Patent Application Ser. No. 60/975,467, filed Sep. 26, 2007, having the same title as the present application, provisional U.S. Patent Application Ser. No. 61/022,968, filed Jan. 23, 2008, entitled “Regenerative Building Block and Diode Bridge Rectifier,” and provisional U.S. Patent Application Ser. No. 61/048,336, filed Apr. 28, 2008, entitled “MOSFET with Integrated Field Effect Rectifier,” all of which have the same inventors as the present application and are incorporated herein by reference in full for all purposes.
FIELD OF THE INVENTION
The present invention relates generally to rectifiers, and more particularly relates to rectifiers using a Field Effect structure.
BACKGROUND OF THE INVENTION
A rectifier is a two terminal device that is commonly used in electric circuits to conduct current in one direction and block current in the opposite direction. The main element of a rectifier is a potential barrier that controls current carrier flow depending on the sign of the potential applied to the external electrodes. Until recently only two major technologies were used to make rectifiers. In Schottky Barrier Diodes (SBD's), the potential barrier is created at the interface between a metal and a semiconductor. Such a barrier is defined by the difference between the work functions of the metal and the semiconductor that make the contact. SBD's provide very good low forward voltage drop (up to 0.4V), which is the major performance characteristic of a diode, but are known to have reliability problems. Due to the lack of carrier modulation they cannot withstand high forward current surges. Additional reliability problem arise due to the spiking during metallization process, which reduces the breakdown voltage and reduces overall yield. Even with the trench Schottky technology, which allows obtain higher breakdown voltage, practical SBD's are limited to breakdown voltages below 250V. The PN-junction technology is typically used for higher voltages. They provide usually higher V F (above 0.7V) and thus lower efficiency, but higher reliability. However, due to carrier density modulation they can withstand large current surges. Also since the maximum electric field is at the PN junction and not at the surface as in a SBD, the metallization spikes do not cause the early breakdown problem.
Other approaches, based on the field effect under an MOS gate, have been proposed in order to combine the high efficiency of a SBD with the high reliability of PN junction diodes. For example, in Pseudo-Schottky Barrier diodes and super barrier rectifiers, the potential barrier is created in the bulk of the semiconductor under the gate via processing (e.g. implantation, diffusion, oxidation etc.). The channel under the MOS gate is only weakly inverted and can be viewed as a barrier for majority carriers. The height of this barrier can be controlled by the gate thickness and the doping concentration under the gate. The presence of the barrier results in rectifying behavior similar to the SBD. SBD's can have a fixed barrier height, corresponding to the metals that make good contact with silicon, while in other prior art devices, the barrier height can be continuously changed. Short channel length and good control of the doping in the channel region are essential to making practical devices. The low voltage (breakdown below 100V) super barrier rectifiers have been shown to combine high reliability (similar to PN-junction diodes) and high efficiency.
However, many high voltage versions of such prior art devices (rated above 150V) exhibit negative differential resistance. Any negative resistance region can be useful to make oscillators, but in rectifiers this is undesirable behavior and needs to be avoided. Thus these prior art devices suffer from significant limitations at high voltages.
To overcome the inability of the prior art to operate reliably at high voltages, it is important to control the negative resistance region, which can involve either an increase or a decrease, depending upon other factors. The source of the negative resistance is the rapid reduction of the drift region resistivity due to the injected carriers. As shown in FIG. 1 , which depicts a model of a typical prior art field effect barrier rectifier, the total drift region resistance is typically modeled as being divided into two parts, R 1 and R 2 . The top resistance, R 1 , typically controls the voltage on the P-N junction, and bottom R 2 . Once the sum of voltage drops on the resistor R 1 and the channel is above the knee voltage V* of the P-N junction, the holes can be injected from P-N junction to the drift region. To maintain quasineutrality the electrons are injected from the substrate. This rapidly growing carrier concentration reduces the resistivity of the drift region and the voltage drop on resistor R 2 . This voltage drop on the drift region can lead to the negative resistance. The negative resistance can be effectively controlled by varying resistor R 1 because it changes the critical current when the injection starts (I*), and because the slope of negative resistance depends on the ratio of R 2 /R 1 . Thus the R 1 reduction increases the negative resistance region and the R 1 increase reduces the negative resistance region.
R
2
R
1
=
N
D
1
A
1
W
2
N
D
2
A
2
W
1
,
where A 2 is the total area of the drain region and A 1 is smaller since current cannot flow through the P region. W 1 is close to the thickness of the P region and W 2 is the distance between the P region and substrate. The required breakdown voltage sets the donor concentration in the bottom epitaxial region (N D2 ), but the donor concentration in the top region (N D1 ) can be adjusted.
One of the ways to control negative resistance in Field Effect Rectifiers is to adjust the donor concentration in the top layer, which was analyzed in Rodov V., Ankoudinov A. L., Ghosh P., Solid State Electronics 2007; 51:714-718. There a reduction of N D1 twice, by the use of a double layer epitaxial structure, was enough to remove negative resistance from the I-V curve. However, this solution of the negative resistance problem may be not the best practical approach, since it is more difficult to manufacture double layer epitaxial structures.
Another major concern is how fast the diode can be switched from forward current conduction to reverse current blocking. One of the major concerns in reverse recovery is the storage time which depends at least in part on how much charge is present in the barrier region. It takes some time to remove this charge, before the depletion layer can be developed to support reverse voltage. The total stored charge still largely determines the total reverse recovery, however some reasonable amount of storage charge is useful since it can provide soft recovery and reduce electro-magnetic interference problems. Thus the softness of reverse recovery is affected by the total stored charge and junction capacitance. To optimize diode reverse recovery it is helpful to be able to quickly deplete the channel region and to be able to trade off between speed of reverse recovery and electromagnetic emissions.
A brief overview of the prior art leads to following conclusions:
Field Effect Diodes provide a good combination of performance and reliability which cannot be achieved by conventional Schottky or PN-junction technologies.
To avoid negative resistance, prior art Field Effect Diodes typically need special means to adjust the top layer resistance.
The ability to rapidly deplete the channel region and operate at high frequency without large electromagnetic interference is desirable in at least some embodiments.
SUMMARY OF THE INVENTION
The present invention comprises an Adjustable Field Effect Rectifier (sometimes “AFER” hereinafter) device having an adjustment pocket or region which permits the device to function reliably and efficiently at high voltages without the negative resistance of prior art devices, while also permitting fast recovery and operation at high frequency without large electromagnetic interference. The process for fabricating a device according to the invention comprises opening the gate oxide followed by ion implantation to create a dopant concentration below that opening. The opening can be covered by oxide, if contact between the doped region and the metal is not desired.
The introduction of the adjustment pocket of the present invention gives a much more flexible device design because it allows modification of the top layer resistance during processing. In some embodiments, it is desirable to increase the top layer resistance, which can be accomplished by a P+ implantation into the pocket. Alternatively, an N+ implantation is used to decrease the top layer resistance. For high voltage devices, the P+ implant is useful to remove negative resistance and thus correct Field Effect rectifier performance. The N+ implant is useful to improve the performance of low voltage diodes. Additional advantages of the adjustment pocket structure are to allow the reduction of the junction capacitance and of the charge stored in the channel area, thus improving the reverse recovery characteristics of the diode.
The present invention can be better understood from the following Detailed Description of the Invention, taken in combination with the appended Figures, as described below.
THE FIGURES
FIG. 1 illustrates a prior art structure of the Field Effect barrier rectifier. Oxide on the top is a remnant of the self-alignment process and represents a problem for metal adhesion and thermal heat removal. Resistance R 1 needs to be reduced to address negative resistance problem.
FIG. 2 illustrates an embodiment of the Adjustable Field Effect Rectifier (AFER) in accordance with the invention. Resistance R 1 is reduced by the geometry and resolves the negative resistance problem. The embodiment also promotes better thermal and electrical contact.
FIG. 3 is a schematic representation of an embodiment of an AFER as a MOSFET with gate electrode shorted to the source. Polarity of the diode is the same as that of the MOSFET intrinsic body diode. Such shorted MOSFET will not always function as an efficient diode, and structural parameters (gate oxide thickness, channel length, etc.) need to be chosen carefully.
FIG. 4 illustrates the operation of the AFER. During forward bias the depletion layers from various P-regions do not overlap (shown by dashes) and electrons can easily flow from the channel region to the drain. During reverse bias depletion layers grow in size and after pinch-off start to overlap (see dash-dots). This pinch-off effect helps to reduce the leakage of the device.
FIG. 5 illustrates in graphical form forward current density versus applied voltage for an embodiment of a 600 V AFER. The structure without adjustment area exhibits negative resistance (leftmost curve at V axis). Introduction of the adjustment area 0.25 um (middle curve at V axis) or 0.35 um (rightmost curve at V axis) wide fixes the problem. The width and doping concentration in the adjustment area can be used also to improve device performance at low current density.
FIGS. 6-16 illustrate processing steps for fabricating an embodiment of the invention. In particular, FIG. 6 shows an intermediate structure after vertical etching through the polysilicon gate and gate oxide (can leave some of gate oxide to reduce the channeling) using the Gate mask.
FIG. 7 illustrates a cover mask placed on the Gate mask to cover the adjustment area opening.
FIG. 8 illustrates the structure of an embodiment after a P+ well boron implant and contact arsenic implant are performed.
FIG. 9 illustrates a trench etched in silicon to provide ohmic contact to the P-well. Notice that only small portion of implanted As is left.
FIG. 10 illustrates an embodiment after both masks are isotropically etched. This self-aligning step provides uniform barrier height throughout the device.
FIG. 11 illustrates an embodiment after channel boron is implanted. The Implantation dose determines the potential barrier height inside the channel. It is desirable to use a self-aligning process in at least some embodiments to help ensure having the same barrier height throughout the chip.
FIG. 12 shows an embodiment after the Gate and Cover masks are removed. Contact boron is implanted. If the dose is high, the barrier height in the adjustment area is higher than in the channel region. In this case it can be a final structure. Otherwise, oxide or oxide walls can be put in the adjustment area, as shown below.
FIG. 13 shows an embodiment after the insulating oxide layer is deposited. The Cover mask is placed to keep oxide in the adjustment area.
FIG. 14 shows an embodiment after the oxide is etched.
FIG. 15 shows an embodiment after the cover mask is removed. It can used as a final structure in some implementations, which prevents any current through the adjustment area. This is the structure if adjustment area implant type was the same as EPI type in order to reduce resistor (in this case contact implant can be done before Cover mask is placed for the first time—see FIG. 1 ).
FIG. 16 shows an embodiment where the oxide is vertically etched to leave just the oxide sidewalls, and can be the final structure for some embodiments. This final structure is preferred when the contact implant is of the opposite type than the EPI type. Without an oxide side wall the potential barrier under the gate in the adjustment area can be too small in some implementations.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 2 , en embodiment of an Adjustable Field Effect Rectifier (sometimes abbreviated as “AFER” hereinafter for simplicity) in accordance with the invention is shown generally at 200 , and in the illustrated arrangement includes an adjustment area, or pocket, discussed in greater detail hereinafter. The barrier for the carrier transport is created under the MOS gate 205 due to the field effect. The barrier height is controlled by the gate material, the gate oxide thickness and the doping concentration in the semiconductor under the gate. A pocket 210 is etched in the middle of the gate, and a shallow P+ implant is created under that opening, which can be insulated from the source 215 via oxide layer 220 or directly connected to the source electrode (for faster performance). The described arrangement is depicted in FIG. 2 . For clarity the connection between the source, gate and pocket area is omitted from FIG. 2 , but is included in FIG. 4 . The connection is typically implemented by a conductive layer, such as a metal layer, for example The shallow P+ implant 225 restricts the current flow of majority carriers, thus increasing the top layer resistance R 1 . Those skilled in the art will appreciate that the device of the present invention can be either N-type or P-type, depending upon the substrate and related processing. For purposes of clarity, an N-type substrate is described hereinafter, but is not to be considered limiting.
The adjustment pocket 210 comprises an opening 225 in the gate 205 , into which a dopant is implanted. In some embodiments, the adjustment pocket can also comprise an oxide over the opening 220 to assist in ensuring that no significant current can pass through adjustment area. In at least some embodiments, it is desirable to have substantially identical resistors from both sides of the gate opening, to prevent one side from becoming less active during operation. Such an imbalance can cause deterioration in device performance. To facilitate creating substantially equal resistance on both sides of the gate, a self-aligning processing is used in an embodiment
The small N+ contact 230 provide the ohmic contact to the metal for electrons flow. In some embodiments, the N+ contact can be avoided if the Schottky barrier height at the contact is smaller than the barrier height under the gate. In such an embodiment the rectifying behavior is determined by the channel barrier and not the Schottky barrier height. The N++ substrate 235 provides ohmic contact on the backside of the structure and provides as many electrons as holes generated by the P-well 240 , thereby maintaining quasineutrality.
In a simplified view, the AFER structure of the present invention resembles the structure of a MOSFET, with the gate shorted to the source. Thus a MOSFET's electric circuit symbol can be modified to represent the AFER device, as shown in FIG. 3 . However, in order to function as an efficient rectifier in accordance with the present invention, the structural parameters (gate oxide thickness, channel length, distance between channels, etc.) are significantly modified, including substantial removal of a layer of oxide that, in the prior art, would insulate the gate and source. In addition, the adjustment area is added, and is also shorted to the gate and the source. The result is that the structure of the present invention behaves as a high performance diode which does not exhibit negative resistance. The polarity of that resulting diode is the same as that of the intrinsic body diode. Thus for an N-type device the source electrode will become anode of the diode, and for a P-type device the source will be cathode of the diode.
Referring next to FIG. 4 , in forward bias, the current flows from the top source electrode 410 horizontally under the gate 405 to get over the channel barrier for carrier transport. Then the current spreads through the N-epitaxial layer 420 , changes to a mostly vertical direction, and flows toward the drain electrode 425 . The depletion layers of the P-well 430 and shallow P implant 440 (dashed lines 430 A and 440 A on FIG. 4 ) do not overlap, but restrict current flow to a narrow region and determine resistance R 1 . The vertical intrinsic PN diode 430 does not play any role until the combined voltage drop on the channel and resistance R 1 reaches the “knee” voltage (about 0.6V). Above that voltage the P-well 430 injects holes into the N-epitaxial layer 420 , which leads to conductivity modulation and provides the field effect rectifier of the present invention with the ability to handle large forward surge current.
During reverse bias, and because of the connection 445 shown between the source, gate and pocket area, the depletion layers 430 A and 440 A around the P-well 430 and P-pocket 440 grow in size and eventually start to overlap as shown at dotted dashed curve 450 on FIG. 4 . It will be appreciated by those skilled in the art that the curve 450 can be thought of as an equipotential line that serves to describe the growth of the depletion layer during reverse bias. This determines a leakage current of the device. For the higher applied reverse bias the depletion layer behavior is similar to that of the PN junction diode. Note that P-pocket promotes the earlier pinch-off and lower leakage current of the device.
In at least several embodiments, the adjustment pocket provides several important improvements to device performance during the switching between forward and reverse bias. Since part of the gate is removed, junction capacitance is automatically reduced. This also means that fewer carriers will be accumulated under the gate when the device is forward biased. This further reduces the storage time that has to elapse before the depletion layer starts to develop during reverse recovery. Thus, in an embodiment, the traditional methods for controlling carrier lifetime (e.g. electron irradiation), together with the adjustment pocket, allows optimization for reverse recovery, which in turn permits operation at maximum frequency with minimum electromagnetic interference.
As illustrated in FIG. 5 , in at least some embodiments the adjustment region also provides adjustment of the top resistor to avoid negative resistance in high voltage AFERs. The leftmost curve at the V axis shows the I-V characteristic of the diode without the adjustment area of the present invention, and exhibits negative resistance. The middle curve at the V axis shows the I-V curve for the same device parameters with an adjustment area of 0.25 μm added in accordance with the present invention, and shows no trace of the negative resistance. The rightmost curve at the V axis shows the I-V curve for a device with 0.35 μm, and also shows elimination of the negative resistance. This method of controlling negative resistance has the advantage that uniform dopant concentration can be used, which is simpler to manufacture.
Low voltage devices, with a breakdown voltage below 100 volts, typically do not have the negative resistance problem. To optimize these structures, it is desirable to minimize the forward voltage of the device while keeping leakage at acceptable level. In some embodiments, the adjustment region also helps such optimization by including an N+ pocket implant to reduce the resistance modeled as resistor R 1 in FIG. 2 . In these embodiments a thick oxide is preferably deposited in the adjustment pocket, to prevent the current flow through the pocket. This step is included within the process flow discussed below, although it is not required in all embodiments.
Those skilled in the art will appreciate that the AFER structure described above provides improvements in reverse recovery as well as controlling the value of the top resistance R 1 . As discussed above, an increased value of R 1 is useful for high voltage devices to solve the negative resistance problem, while a reduced value of R 1 can be used to improve efficiency of the low voltage devices.
Referring next to FIGS. 6-16 , generally, one embodiment of a process for manufacturing AFER devices can be better appreciated. It is assumed that an epitaxial layer has been grown on a substrate, together with the following steps that are typical of production of semiconductor devices and so are not shown in detail. The breakdown voltage can be adjusted by varying the doping concentration (N-type) and the thickness of this epitaxial layer. A guard ring (GR) structure, on the order of 0.5 to 5 μm in at least some embodiments, is built using one of the standard methods, and a field oxide is formed by either thermal oxidation, CVD of silicon oxide, a combination of the two, or any other suitable method. The guard ring mask is used to open a window in the field oxide, through which a P-well implant is introduced, followed by thermal diffusion. The field mask is then used to open a window in the field oxide for fabrication of the active area of the device.
Referring particularly to FIG. 6 , a gate oxide 600 is grown to on the order of 30-200 Å, following by growing a layer of polysilicon 605 on the order of 600-1200 Å. A gate mask 610 is then developed, after which the polysilicon 605 is vertically etched, resulting in the structure shown in FIG. 6 with openings 615 and 620 . If a reduction of the resistance shown as R 1 in FIG. 2 is desired for the particular embodiment, a contact arsenic (As) implantation can be done at this stage through the openings 615 and 620 .
Referring next to FIG. 7 , a second cover mask 700 is made on top of the gate mask 710 to cover the adjustment pocket 705 . In some embodiments, it is desirable to adhesively affix the gate mask to the wafer, or, alternatively, to fabricate the gate mask from silicon nitride or other suitable material. This masking arrangement facilitates use of self-aligning process with uniform barrier heights and R 1 values throughout the entire area of the device.
Referring next to FIG. 8 , the contact arsenic implant 805 and P-well boron are implanted, resulting in P-wells 810 . In some embodiments, the dose of P-well boron is selected to be high enough to restrict the main current flow through the channel area.
Referring next to FIG. 9 , a contact well 900 is vertically etched into the silicon to provide contact to the P-well. In the absence of such a contact, the charge in the P-well can be affected by the hole current that flows to the anode through the P-wells of the guard ring structure. In some instances, this may slow down device operation. The contact wells help to optimize the use of the active device area and allow holes from P-well to flow directly to the source electrode. In addition, sufficient ohmic contact is preserved to allow for the flow of electrons, since most of the electron current is flowing through the narrow channel under the gate. It will be appreciated by those skilled in the art that, in some embodiments, only a small portion of the implanted As remains after formation of the contact wells.
Referring next to FIG. 10 , the gate mask 710 and the cover mask 700 are isotropically etched, which provides a self-aligned mask for a channel boron 1100 implantation shown in FIG. 11 , thus helping to assure uniform barrier height throughout the relevant portion of the device. The cover mask is also etched at this stage, while still covering the adjustment area.
Referring to FIG. 12 , the gate and cover masks are removed, followed by a P-type pocket 1200 implant to increase the resistance R 1 of the top region, to restrict current flow. In some embodiments, and particularly those where the doping concentration under the gate in the adjustment pocket is larger than that in the channel region, the structure shown in FIG. 12 is the final structure. This can make further processing steps unnecessary.
However, in some embodiments, it is desirable to further develop the adjustment pocket by adding oxide sidewalls or a layer of oxide. This is shown beginning with FIG. 13 , where a layer of oxide (identified by numeral 1300 ) on the order of 50-500 Å thick is deposited, followed by placement of a cover mask 1305 . Then, referring to FIG. 14 , the oxide is vertically etched, followed by removing the cover mask 1305 , shown in FIG. 15 . FIG. 15 depicts the final structure for those embodiments where the resistance shown as R 1 in FIG. 2 is to be reduced, and an N-type implantation was made in the adjustment area. This approach permits reduction of R 1 while also preventing electrons from flowing to the source through the opening of the adjustment area.
Next, as shown in FIG. 16 , the oxide is vertically etched until only the oxide sidewalls are left. This structure depicts the final structure if the value of R 1 is to be increased, together with the use of P-type implantation in the adjustment area. This structure permits holes from the P-contact in the adjustment area to flow to the source electrode, thus allowing for fast operation, while at the same time limiting electron flow to the source only through the channel region.
Having fully described an embodiment of the invention, together with numerous alternatives and equivalents, those skilled in the art will appreciate that numerous alternatives and equivalents exist which do not depart from the invention and are intended to be included within its scope. As a result, the invention is not to be limited by the foregoing description.
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An Adjustable Field Effect Rectifier uses aspects of MOSFET structure together with an adjustment pocket or region to result in a device that functions reliably and efficiently at high voltages without significant negative resistance, while also permitting fast recovery and operation at high frequency without large electromagnetic interference.
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Priority is claimed to Swiss Patent Application No. CH 00428/06, filed on Mar. 20, 2006, the entire disclosure of which is incorporated by reference herein.
The present invention relates to the field of thermal machines. It concerns a measuring device for measuring the temperature of a thermally loaded metallic base element, provided with a protective surface coating, according to the precharacterizing clause of claim 1 and a method for producing such a measuring device.
BACKGROUND
Such a measuring device is known for example from the printed document U.S. Pat. No. B2-6,838,157.
The use of integrated thermocouples for temperature measurement on gas turbine blades without a surface coating has long been known (see for example U.S. Pat. No. 3,592,061).
The blades in the first stages of modern gas turbines, which are exposed to increasingly higher hot-gas temperatures to increase efficiency, are provided on the surface with a special protective surface coating (heat insulating layer or Thermal Barrier Coating TBC), which is intended to protect the underlying metal of the base element from excessively high temperatures. For normal operation (base load), the influence of the thermal barrier coating in the heat transfer models is well understood. In the part-load range, however, the effect of the thermal barrier coating decreases, since the boundary conditions for heat transfer change. Together with the lower pressures in the cooling air supply in the case of part-load, this can lead to a restriction of the service life of the blading.
The existing instrumentation with thermocouples relates to blades without a thermal barrier coating, in order to eliminate the influence of the thickness and the thermal conductivity of the thermal barrier coating in the validation of the cooling in base-load operation. In order to permit validation also in part-load operation, technology with which temperature measurement under the thermal barrier coating can be realized (by means of thermocouples) is necessary.
In the document mentioned at the beginning, it has already been proposed to arrange temperature sensors “buried” in gas turbine components provided with thermal barrier coatings (see for example the sensor 78 in FIG. 2 of U.S. Pat. No. B2-6,838,157), in that a trench is first made in the ready-coated component, the trench is then lined with an insulation, a conducting layer is subsequently deposited on the bottom of the trench, an insulating layer is applied thereover, and finally the trench is filled again to the surface of the thermal barrier coating ( FIG. 3 ).
SUMMARY OF THE INVENTION
This known type of buried temperature sensor has various disadvantages:
It is not suitable for thermocouples.
When the trenches are created, the thermal barrier coating and the bond coat lying thereunder are locally broken through and are also not completely restored. This produces weak points, which impair the heat resistance and service life of the component.
A comparatively great effort is required to make the trench penetrate through the surface coating to the metallic base element.
It is an object of the invention to provide a temperature measuring device for thermally loaded components of gas turbines or the like that are provided with a thermal barrier coating which avoids one or more of the disadvantages of known forms of instrumentation and is distinguished by suitability for the use of thermocouples, simplified construction and installation, and improved long-term properties, and also to provide a method for its production.
The arrangement according to the invention, in which the sensor is preferably a thermocouple, is characterized in particular in that the protective surface coating is formed continuously over the sensor located in the recess.
A refinement of the invention is distinguished by the fact that the thermocouple in the recess is embedded in braze or modified wettable powder, and in that the braze or modified wettable powder fills the recess in such a way that the base element has a continuously planar surface in the region of the recess. This produces a uniform base for the surface coating lying thereover.
Another refinement of the invention is characterized in that the protective surface coating comprises a metallic bond coat, preferably of MCrAlY, and in that the metallic bond coat is formed continuously over the sensor located in the recess. In particular, the metallic bond coat has a uniform thickness over the sensor located in the recess.
According to a further refinement, the metallic bond coat comprises two partial layers lying one on top of the other, only the upper partial layer having a uniform thickness over the sensor located in the recess.
The protective surface coating also preferably comprises a ceramic thermal barrier coating, which is arranged over the metallic bond coat and is formed continuously over the sensor located in the recess.
A refinement of the one method according to the invention is characterized in that the recess is filled with braze or modified wettable powder, in that first a metallic bond coat, preferably of MCrAlY, and then a ceramic thermal barrier coating are applied as the protective surface coating. The metallic bond coat may in this case be applied in two partial layers one after the other.
The metallic bond coat is preferably applied by means of atmospheric plasma spraying (APS) or low-vacuum plasma spraying (LVPS) or high-velocity oxyfuel spraying (HVOF), and the ceramic thermal barrier coating is applied by means of thermal spraying or electron-beam physical vapor deposition (EB-PVD).
A refinement of the other method according to the invention is characterized in that the recess is filled with braze or modified wettable powder, and in that first a second metallic partial layer, preferably of MCrAlY, and then a ceramic thermal barrier coating are applied as the protective surface coating.
The second metallic bond coat is preferably applied by means of atmospheric plasma spraying (APS) or low-vacuum plasma spraying (LVPS) or high-velocity oxyfuel spraying (HVOF), and the ceramic thermal barrier coating is preferably applied by means of thermal spraying or electron-beam physical vapor deposition (EB-PVD).
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is to be explained in more detail below on the basis of exemplary embodiments in conjunction with the drawings, in which:
FIG. 1 shows a first exemplary embodiment of a measuring device according to the present invention in section;
FIG. 2 shows a second exemplary embodiment of a measuring device according to the present invention in section;
FIG. 3 shows a third exemplary embodiment of a measuring device according to the present invention in section; and
FIG. 4 shows various steps in the production of a measuring device as shown in FIG. 1 in several part- FIGS. 4( a ) to 4 ( d ).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 , a first exemplary embodiment of a measuring device according to the invention is reproduced in section. The measuring device 10 is integrated in a metallic base element 11 , a detail of which is represented in the figure, and which may for example be the blade of a gas turbine. Set into the base element 11 from the outer surface is a recess 16 , which is adapted in depth and cross section to the sensor to be received, especially a thermocouple. Located in the recess 16 as the temperature sensor is a thermocouple 13 , which is surrounded on all sides by braze or modified wettable powder 12 . The braze or modified wettable powder 12 has the effect that the thermocouple 13 is thermally coupled closely to the base element 11 and at the same time fixed in the recess 16 . The braze or modified wettable powder 12 fills the recess 16 in such a way that the base element 11 has a continuously planar surface ( 17 FIG. 4 c ) in the region of the recess 16 . The planar surface of the base element is covered by a continuous metallic bond coat 14 , which preferably has the composition MCrAlY (M=Fe, Co or Ni). This bond coat 14 is suitable for imparting to a ceramic thermal barrier coating lying thereover the necessary bonding strength on the surface of the base element 11 .
The production of such a measuring device 10 is performed in several steps according to FIGS. 4 a - d. This starts with the uncoated base element 11 ( FIG. 4 a ), into which a recess 16 is introduced ( FIG. 4 b ) from the surface (from the outside). The sensor or the thermocouple 13 is introduced into the recess 16 . The recess 16 with the sensor 13 located in it is then filled (with braze or modified wettable powder 12 ) in such a way that the base element 11 has a continuous surface 17 in the region of the recess 16 ( FIG. 4 c ). Finally, the metallic bond coat 14 is applied to the base element 11 in such a way that the region with the sensor 13 is covered ( FIG. 4 d ). The metallic bond coat 14 is in this case preferably applied by means of atmospheric plasma spraying (APS) or low-vacuum plasma spraying (LVPS) or high-velocity oxyfuel spraying (HVOF).
A further exemplary embodiment of the measuring device according to the invention is reproduced in FIG. 2 . The base element 11 , the recess 16 , its filling with braze or modified wettable powder 12 , and the thermocouple 13 of the measuring device 20 are the same as in FIG. 1 . As a difference from FIG. 1 , however, here a ceramic thermal barrier coating 15 is applied over the metallic bond coat 14 as a further layer. In order to permit improved bonding, the bond coat 14 is subdivided into two partial layers 14 a and 14 b, lying one on top of the other, the partial layer 14 a being made smooth and the partial layer 14 b being made rough. The production of this device can be performed in a way analogous to FIG. 4 , the application of the thermal barrier coating 15 , preferably by means of thermal spraying or electron-beam physical vapor deposition (EB-PVD), being provided downstream as an additional step.
A variant of the exemplary embodiment of FIG. 2 is represented in FIG. 3 . In the case of this measuring device 20 ′, the partial layer 14 a is first applied to the uncoated base element 11 , before the recess 16 is then created (through the partial layer 14 a ). The filling of the recess 16 with braze or modified wettable powder 12 takes place up to the surface of the partial layer 14 a. Then, the partial layer 14 b is applied, and the thermal barrier coating 15 is applied thereover.
Altogether, the invention provides a measuring device and a method for producing it that are comparatively simple, are suitable for thermocouples, and lead to an improved surface finish of the component. Furthermore, the actual temperature of the metal is sensed and there is no impairment of the service life of the component with respect to oxidation.
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A measuring device for measuring the temperature of a thermally loaded metallic base element, especially a gas turbine component, provided with a protective surface coating includes a sensor integrated in the base element. The sensor is arranged in a recess introduced into the base element from the outside. The protective surface coating is formed continuously over the sensor disposed in the recess.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to a device for introducing an elastically bendable indwelling cannula together with an essentially rigid puncture cannula located therein into a blood vessel of a human or animal body.
[0002] The introduction of cannulas into blood vessels is one of the most common actions of every physician. Although this is carried out daily many, many times, with this there often occur problems, and specifically on piercing in the cannulas which are to be considered as essentially rigid, as they are for example provided with syringes, as well as in particular with large-lumen indwelling cannulas which consist of a rigid part for puncturing and a bending-elastic part for the subsequent dwelling in the vessel. The manual methods common up to now are to a great extent dependent on the subjective assessment and the skill of the operating physician of locating and hitting the blood vessel. Often particular anatomical situations, adipositis or pathological conditions such as for example edemas create problems. On account of the prevailing size conditions and tissue characteristics, the introduction of indwelling cannulas is particularly difficult with babies and infants. One may only approximate the course of the veins. Although devices have been suggested which are to simplify the location and introduction of a syringe cannula, they have not succeeded in practice and are not so suitable for applying indwelling cannulas.
[0003] From U.S. Pat. No. 5,311,871 there is known a document with which an ultrasound producer is arranged in the plunger base of a syringe. The oscillations produced here are transmitted to the cannula via the fluid located in the syringe cylinder, wherein the emitter is simultaneously the receiver of the reflected sound waves and Doppler sonography is applied in order to locate a blood vessel. A similar arrangement is known from U.S. Pat. No. 5,080,103. These locating aids have however not succeeded in practice, since the locating principle only functions when the cannula has intimate contact with the body, i.e. has already penetrated through the surface of the body. They are accordingly unsuitable for vessels running close under the skin.
[0004] From U.S. Pat. No. 5,427,108 there is known a device with which a blood vessel may likewise be located using ultrasound Doppler sonography, wherein the device at the same time is aligned at a direction to the vessel such that the cannula may be manually introduced through a guide of the device into the vessel. A device known from U.S. Pat. No. 4,527,569 is even more mechanised and with this a holder for the cannula to be introduced is largely positioned automatically with regard to the located blood vessel and the introduction of the cannula into the vessel may then be effected in a manually controlled manner. The two last-mentioned devices are technically complicated and have likewise not been successful in practice. Although the location of vessels may be simplified with such devices, the introduction of the cannulas themselves is however hardly simplified at all since the physician must estimate the course of the vessel and therefore himself must estimate the penetration depth.
[0005] From DE 41 42 795 C1 there is known a device for injecting or puncturing joint cavities with which a puncture syringe is mounted in a syringe holder which is electromotorically traversable on a carrier. The motor control is effected dependent on the signal of a sonar measuring device in a manner such that the correct penetration depth of the cannula arranged on the syringe is always ensured. Notwithstanding the fact that this device is provided for puncturing joint cavities, it is not suitable for introducing cannulas and even less suitable for introducing indwelling cannulas into vessels, since they introduce the needle essentially perpendicular to the body surface, and only the penetration depth is determined. Furthermore the ultrasound measurement head surrounding the cannula is not so suitable for vessel puncture since it completely covers the penetration location on the skin and thus prevents a visible control which usefully should be carried out continuously.
[0006] From DE 42 06 065 C2 there is known an auxiliary device for introducing a canulla of a syringe with which there are provided two sound heads so that the position and course of the vessel to be punctured may be determined quite reliably. Here it is the case however of a pure location device, a mechanisation of the puncture procedure is not provided with this device so that the actual puncture procedure is not reproducible and as before is subject to the manual skill of the physician.
[0007] The device known from DE 94 14 727 U1 serves for biopsy, thus for removing tissue samples and is therefore not applicable to the field of application being discussed here.
[0008] Common to all previously mentioned devices is the fact that they merely represent auxiliary devices on introducing a cannula into a vessel and therefore do not yield any reproducible results or are only provided for the mechanised introduction of simple cannulas, thus are not suitable for introducing indwelling cannulas in which two cannulas are to be introduced and then are to be moved relative to one another in a designated manner.
BRIEF SUMMARY OF THE INVENTION
[0009] Against this state of the art it is the object of the invention to provide a device for introducing an elastically bendable indwelling cannula with an essentially rigid puncture cannula, which largely mechanises and automises the laying of an indwelling cannula.
[0010] This object according to the invention is achieved by the features specified in claim 1. Advantageous embodiments of the invention are specified in the dependent claims, and explained in the subsequent description and drawings.
[0011] In order to make the reliability and reproducibility of the introduction procedure as independent as possible of the manual skill and the prevailing anatomical particularities, the invention not only envisages the provision of a location means as an aid for locating a vessel and a holder for the cannulas to be introduced, but also envisages mechanising the complete introduction procedure in that for the indwelling cannula and for the puncture cannula in each case there is provided a separate holder, which are traversable along a guide independently of one another in the direction of introduction as well as in the counter direction. The control is effected dependent on the exit signal of the location means which is designed for locating the vessel as well as for determining the course of the vessel, and specifically in front of and behind the puncture location or the expected puncture location of the puncture cannula. Since the holders are traversable independently of one another, not only may the indwelling cannulas with the puncture cannula located therein be introduced into the vessel, but furthermore the puncture cannula may be retracted and at the same time the indwelling cannula where appropriate may be advanced further, as is usual also with the manual laying of such indwelling cannula.
[0012] Basically with the device according to the invention simple cannulas may also be introduced into a vessel in a secure and reproducible manner, however the application for laying indwelling cannulas is particularly advantageous. Indwelling cannulas in comparison to syringe cannulas have a considerably larger lumen so that it is even more important for this cannula to be brought into the designated position precisely and quickly, since pain, dangers of injury and their consequences are significantly greater on introducing indwelling cannulas than with other cannulas. Apart from the complete mechanisation of the introduction procedure the device according to the invention further offers the advantage that on account of the technological control of the connection between the exit signal of the location means and the drive means for introducing the cannulas, one may securely reach blood vessels lying even deeper. At the same time by way of a suitable coordination of the introduction speed as well as by way of the fact that one effects the introduction always at a favorable angle, the patient does not feel so much pain. Furthermore by way of the secure and very exact introduction, the danger of injury to the wall of the vessel and the consequences of this such as bleeding, haematoma or inflammation of the vessel is considerably reduced. Finally by way of machanising the introduction procedure the risk of infection to the operating person is reduced since the manual introduction of the sharp cannulas during puncture is avoided and the distance to the patient is increased so that the operating person does get into contact with spurting blood so easily.
[0013] Preferably the device has two locating devices, which are designated such that the vessel to be punctured is located in a manner such that the puncture location and a region in the puncture direction behind the puncture location is detected so that the complete introduction procedure may be effected according to the course of the vessel with location control. The locating means however also determine the region in front of the puncture location so that the course of the vessel is detected in the direct vicinity of the puncture location or the puncture location to be expected is detected and also monitored during the introduction procedure.
[0014] As a location means there serves an ultrasound emitter and receiver which preferably functions Doppler-sonographically, since then on account of the flow within the vessels this may then be particularly differentiated from other organs and furthermore on account of the flow direction one may without further ado ascertain whether with the vessel which has just been located, it is the case of a vein or an artery. Such ultrasound locating systems have been known for a long time, and function either continuously (CW Doppler sonography) or also in a pulsed manner (PW Doppler sonography). They are available on the market and therefore are not described individually here. In this context one refers to Schaeberle, Wilhelm, Ultrasound in vessel diagnosis, Springer publishing house, Berlin, Heidelberg 1998 (ISBN 3-540-631148-8).
[0015] In order to ensure that the introduction of the cannula is only effected when the device is located in the designated position with respect to the vessel to be punctured, the control is designed such that the drive moving the cannulas in the introduction direction is only switched when the evaluation of the signals emitted by the locating means by way of the control results in the fact that the device is located in a position to the vessel to be punctured which is suitable for the puncture procedure. In order to provide the physician with an aiding position on aligning the device to the patient, there is provided an optical or acoustic display which emits a signal when the device is located in the designated position for puncture of the located vessel. Such a display may for example be formed by light diodes which by way of an optical signal in a program-controlled manner indicate when the optimal position of the device to the vessel is reached for introducing the cannula. For this the device is moved manually over the skin until the display lights up.
[0016] In order to simply a course orientation of the device on application, it is useful for the distal end of the device to be equipped with a contact surface which is set obliquely to the direction of the traversing direction of the guides, thus to the movement direction of the cannula holders. The angle of this oblique position is usefully between 30° and 45°, thus in the region in which an optimal alignment of the cannulas with regard to the vessel to be punctured is to be expected when this contact surface is brought to rest on the skin of a patient, for example in the region of the extremities. It is to be understood that this angle may be adapted to the shape of the distal end of the cannula. In order however to provide the user with the possibility of aligning the device with regard to the located vessel in spite of the two dimensional contact, it is useful not to form the contact surface completely flat, but to form it crowned so that at least in the borders to be expected the device may be pivoted forward, backwards or also to the one or other side. The crowned design also simplifies the sliding over the skin for locating the vessel. In particular with the application of ultrasound locating means it is necessary for there to exist a good coupling between the emitter and the object to be located or between the receiver and the object to be located, i.e., a connection conducting sound waves well. In order to achieve this it is useful to arrange the emitter-receiver arrangement on the rear side of the contact surface.
[0017] It is useful to provide two linear guides, specifically one for the puncture cannula and a further one arranged parallel thereto for the indwelling cannula. With this the drives may be activated separately in order also to be able to carry out the procedure of the retraction of the puncture cannula as well as the advancing of the indwelling cannula in a largely mechanised manner.
[0018] Commercially available indwelling cannulas for puncturing as a rule have a rigid, sharply ground puncture cannula which is surrounded by the actual blunt, elastically bendable indwelling cannula which together with the puncture cannula is introduced into the vessel. After puncture the indwelling cannula is advanced further in the introduction direction and the puncture cannula is retracted and finally is removed manually.
[0019] The device may have different shapes according to the application purpose. An approximately pistol-shaped design of the device has shown to be particularly advantageous, with which the release button is provided in the front part of the grip piece and the control and evaluation electronics are preferably likewise integrated in the grip piece. The electrical energy required for the operation of the device is preferably made available by a battery arranged in the grip piece or another suitable location, wherein as is usual with such apparatus one may provide a charging holder or also an external charging station for the battery. Such an arrangement is particularly useful when the device is to be held and guided with one hand. The pistol-like configuration is selected in order to be able to puncture as flexibly as possible every vessel reachable on the torso or extremities. The actuation with only one hand gives the user the possibility at any time of holding the extremity of the patient with the other hand and where appropriate of intervening to correct or support. After applying the indwelling cannula the free hand is required to release the holders from the indwelling cannula and to remove the puncture cannula and to set up suitable conduit connections for example for an infusion.
[0020] The holders for the puncture cannula, which are provided on the guides, and for the indwelling cannula must be provided with drive means. With this it is to be seen as particularly advantageous to arrange the guides to lie outside the housing and to set the actual drive inwards in the pistol grip and to merely let one lug via a longitudinal recess engage in the piston-like body for the purpose of the drive connection. This is useful already for reasons of hygiene since all components which come into contact with the cannulas are accessible and removable for the purpose of cleaning and disinfection. The drive at the same time is effected preferably by way of electric motors which for example drive a worm into which a lug connected to the holder engages, so that the holder is traversable in a defined manner along the guide by way of selecting the rotational direction and number of rotations of the motor. In place of a worm drive one may also employ a telescopic drive. Such drives are known for example for extending and retracting telescopic car antennas.
[0021] In order to ensure that the cannulas are introduced in a designated manner, according to their constructional type and size, it is useful to provide suitable sensorics on the device for detecting the cannula type and/or size. Since the cannulas usually with a lumen increasing in size may also increase in their constructional length, the cannula size used in each case may be determined by a row of photo-diodes which are attached on the upper side and which function in the manner of a reflective light barrier, and this transmitted to the control. Alternatively there may also be provided a scanner which detects a bar code attached on the side of the cannula, in which the cannula type and the cannula size are specified in a coded manner. A mechanical detection is also conceivable, either for the case that a device is designed only for the application of a certain cannula type or that the size differences are mechanically sensed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention is hereinafter explained by way of an embodiment example shown in the drawings. There are shown in:
[0023] [0023]FIG. 1 in a schematic representation, a lateral view of a device according to the invention,
[0024] [0024]FIG. 2 a plan view of the device according to FIG. 1,
[0025] [0025]FIG. 3 a view of a common indwelling cannula with a puncture cannula,
[0026] [0026]FIG. 4 a view, displaced by 90° with respect to the cannula axis, of the puncture cannula according to FIG. 3,
[0027] [0027]FIG. 5 the indwelling cannula in a representation according to FIG. 4,
[0028] [0028]FIG. 6 the arrangement of the distal end of the device with the location means in relation to a vessel which is to be punctured,
[0029] [0029]FIG. 7 a schematic, perspective representation of the device on application on an arm,
[0030] [0030]FIG. 8 the arrangement of the distal end of the device at the beginning of the introduction procedure and
[0031] [0031]FIG. 9 the arrangement according to FIG. 8 during the advance of the indwelling cannula over the puncture cannula into the vessel.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The introduction device shown in the Figures comprises a pistol-shaped housing 1 , with a grip part 2 for handling the device. The housing 1 at the top blends into a gun-barrel-shaped part 3 , whose distal end 4 comprises a contact surface 5 .
[0033] On the upper side of the gun-barrel-like part 3 there is provided a telescope-like guide 6 which accommodates two rods 7 which are arranged at a distance and parallel to one another and which are traversable in the axis direction of the rods 7 by way of an electromagnetic drive which is not shown in detail. At the distal end of the rods 7 there is provided a holder 8 for the releasable accommodation of a puncture cannula 9 .
[0034] Parallel to the guide 6 on the upper side of the gun-barrel-like part 3 there is provided a further guide whose likewise telescopic rods 11 are arranged parallel to one another and parallel to the rods 7 . The rods 11 , as indicated in FIG. 1, comprise lugs 12 which by way of longitudinal reliefs are connected to an electromotoric drive likewise arranged within the grip part. At the distal ends of the rods 11 there are provided -like holders 13 with which the fins 14 of an indwelling cannular 15 are held.
[0035] With the cannulas 9 , 15 shown in the figures it is the case of common indwelling cannulas, as are on the market under the trademark VENFLON of the company VIGGO AG, Sweden and are shown by way of FIGS. 3 to 5 in detail. Such a cannula arrangement consists of an essentially rigid puncture cannula 9 as is shown in FIG. 4, and of an elastically bendable plastic indwelling cannula 15 as is shown in FIG. 5. The puncture cannula consists of a common metal tube 16 ground off obliquely on the distal side, whose proximal end is held in a plastic part 17 which on the proximal side is designed as a Luer connection and is closed off by way of a closure plug 18 . On the plastic part 17 there upwardly projects a guide part 19 , it serves the manual removal of the puncture cannula from the indwelling cannula after the puncture of the vessel has been effected.
[0036] The bending-elastic indwelling cannula 15 consists of a flexible plastic tube 20 which on the proximal side likewise opens into a plastic part 21 , whose proximal end is also designed as a Luer connection. Furthermore the plastic part 21 further comprises a transverse access 22 which may be closed off by way of a closure plug 23 . The cannulas 9 and 15 are dimensioned such that in the assembled form they form the arrangement shown in FIG. 3, in which the distal, ground-off free end of the metal tube 16 projects beyond the distal free end of the plastic tube 20 .
[0037] The cannulas 9 and 15 in the arrangement shown in FIG. 3 are fastened in a clamped manner in the device, as this is represented by way of FIGS. 1 and 2. With this the guide 19 of the cannula 9 is fastened in the holder 8 and the fins 14 are fastened in the holders 13 . The rods 7 and 11 when they are completely retracted in the initial situation, as this is shown in the FIGS. 1 and 2, are designed such that the distal end of the metal tube 16 ends in front of the contact surface 5 , thus in front of the distal end of the device. The cannulas 9 and 15 are at the same time only fastened in the holders 8 and 13 , otherwise however they are arranged at a distance to the housing in order to ensure sterility.
[0038] Directly behind the contact surface 5 there are arranged two ultrasound locating means 24 and 25 within the housing 1 , as this is schematically shown in FIG. 6. The locating means consist either, as in the embodiment shown, in each case of an ultrasound emitter S and an ultrasound receiver E, or of a combination of emitter and receiver (pulse operation). With this the received reflection signal of the ultrasound waves are not only evaluated with regard to temporal intervals of the returning signals as with the usual ultrasound location, but furthermore also with regard to the frequency shifting which results according to the Doppler effect when ultrasound waves are reflected on moved bodies, in particular the blood cells of a blood vessel. This is schematically shown in FIG. 6, with this the surface of the skin is indicated at 26 , the vessel to be located at 27 and the blood cells flowing therein at 28 . The ultrasound locating means 24 and 25 are aligned such that they not only detect the expected puncture location of the puncture cannula 9 with the vessel 27 , but also the region directly in front of and behind this location, so that the course of the vessel may be represented. The evaluation of the signals of the ultrasound locating means 24 and 25 is effected via a control which is not shown in the figures and which is arranged within the housing 1 . The voltage supply of the apparatus is effected via a mains cable 29 or an incorporated energy storer (e.g. batteries). Within the pistol-shaped housing there are furthermore located the electrical drive required for traversing the rods 7 and 11 , with where appropriate mechanical gears connected intermediately.
[0039] The distal end of the gun-barrel-like part 3 is closed of by the contact surface 5 which as is shown in FIG. 6, is formed slightly crowned in order on the one hand to permit an easy alignment of the housing 1 with regard to the surface of the skin 26 . On the other hand however the contact surface 5 is formed flattened such that on applying this on the surface of the skin 26 there is provided a secure hold at an angular position which roughly corresponds to the expected optimal angular position. This angle α (angle between traversing direction of the cannulas 9 , 15 and the contact surface) is 35° in the embodiment example, and usually lies between 30° and 45°, according to application.
[0040] Before the beginning of the introduction procedure the apparatus is equipped with a cannula arrangement according to FIG. 3 so that there results the initial situation previously described and shown by way of the FIGS. 1 and 2. The apparatus detects by way of a bar code reader arranged on its upper side (not shown in the figures), where the fins 14 of the indwelling cannula 15 are arranged after application into the associated holder, detects a bar code located on the fins 14 . On account of information coded in this bar code, the type and the size of the applied cannula is transmitted to- the control.
[0041] For the introduction of the cannula, the operating person grips the grip part 2 of the housing with the hand and places the distal end 4 with the contact surface onto the skin surface 16 where thereunder there is to be expected a course of a vessel. On account of the Doppler evaluation the location means 24 and 25 may locate blood vessels. As soon as a blood vessel has been detected by one of the two locating means 24 or 25 a first light diode 30 lights up on the upper side of the housing. As long as this diode 30 does not light up one must traverse the contact surface 5 on the skin surface 2 until a suitable vessel 27 has been located. If the light diode 30 lights up, the apparatus 1 must merely be brought into the angular position and direction envisaged for introducing the needle. This is the case when both locating means 24 and 25 detect the same vessel and the apparatus is located at designated angles to the vessel 27 . A second light diode 31 then lights up, simultaneously a release button 32 is switched free so that the programm-controlled introduction of the cannulas may be activated.
[0042] Thus if the operating person by way of the signal of the light diodes 30 and 31 recognises that the designated position with regard to the vessel 27 to be punctured has been reached, the release button 32 is actuated. Thereafter firstly the rods 7 and 11 are simultaneously extended out, by which means the surface of the skin is pierced. The rods 7 and 11 under the control of the locating means 24 and 25 are extended until the distal end of the puncture cannula 9 as well as the distal end of the indwelling cannula 15 have reached the inside of the vessel 27 . Then the rods 11 are further extended out, the rods 7 however are simultaneously or subsequently retracted (see FIG. 9). The puncture cannnula 9 by way of the rods is retracted so far that it just closes off the indwelling cannula 15 on the proximal side.
[0043] The further removal of the puncture cannula 9 is effected manually, since then the indwelling cannula on the proximal side must anyway be provided with a closure plug or connected. It is to be understood that the holders 8 and 13 are likewise to be released in order to separate the apparatus from the cannulas. In a further embodiment this may likewise be part of the program control. In the embodiment shown the holders however are designed as clamping holders so that they may be released with the free hand with a slight force effort.
[0044] It is to be understood that with the previously described device not only indwelling cannulas, but also puncture cannulas such as are for example directly connected to syringes, may be brought into a vessel. Basically an empirical evaluation of the exit signals of the locating means 24 and 25 is sufficient in order to permit a secure control of the device and to achieve the designated puncture of the vessel. Here also apart from the described simple signal transmitters 30 and 31 one may provide acoustic signal transmitters as locating aids as well as complex optical aids, for example in the form of a co-ordinate cross with four light diodes at the ends for a simplified positioning. For particularly complicated operations in deeper-lying vessels an additional monitor control may also be provided, as is known for locating means of the previously described type.
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The device ( 1 ) is provided for introducing an elastic indwelling cannula ( 15 ) with a rigid puncture cannula located therein, into a blood vessel of a human or animal body. It comprises holders ( 8, 13 ) for the cannulas ( 9, 15 ) to be introduced as well as a locating means for locating the vessel and for aligning the cannulas ( 9, 15 ) to the vessel. The holders ( 8, 13 ) are in each case fastened on the device by way of a guide ( 10 ) and displaceably mounted in the introduction direction as well as in the counter direction. They may be traversed electromotorically independently of one another along the guides. The control of the electromotors is effected in dependence on the signals of the locating means so that the complete introduction procedure may be automatically controlled up to the retraction of the puncture cannula.
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[0001] This application is a continuation of application Ser. No. 10/965,305 filed on Oct. 14, 2004 (pending) which is a continuation of application Ser. No. 10/391,830 filed on Mar. 19, 2003 (now U.S. Pat. No. 6,813,917) which is a continuation of application Ser. No. 09/985,975 filed Nov. 7, 2001 (now U.S. Pat. No. 6,546,769) which is a continuation of application Ser. No. 09/409,760 filed Sep. 30, 1999 (now U.S. Pat. No. 6,314,773) which is a continuation of application Ser. No. 08/985,901 filed Dec. 5, 1997 (now U.S. Pat. No. 5,960,655) which is a continuation of application Ser. No. 08/593,725 filed Jan. 29, 1996 (now U.S. Pat. No. 5,720,194), which is a division of application Ser. No. 08/371,319 filed Jan. 11, 1995 (now U.S. Pat. No. 5,487,290), which is a continuation of application Ser. No. 07/819,216 filed Jan. 13, 1992 (abandoned).
TECHNICAL FIELD OF THE INVENTION
[0002] This invention relates to a high security lock mechanism and, more particularly, to an electronically controlled combination lock and lock-bolt operable by a very small amount of self-generated electrical power.
BACKGROUND OF THE PRIOR ART
[0003] Items of extremely sensitive nature or very high proprietary value often must be stored securely in a safe or other containment device, with access to the items restricted to selected individuals given a predetermined combination code necessary to enable authorized unlocking thereof. It is essential to ensure against unauthorized unlocking of such safe containers by persons employing conventional safe-cracking techniques or sophisticated equipment for applying electrical or magnetic fields, high mechanical forces, or accelerations intended to manipulate elements of the locking mechanism to thereby open it.
[0004] Numerous locking mechanisms are known which employ various combinations of mechanical, electrical and magnetic elements both to ensure against unauthorized operation and to effect cooperative movements among the elements for authorized locking and unlocking operations.
[0005] One example of such recently-developed devices is disclosed in U.S. Pat. No. 4,684,945, to Sanderford, Jr., which relates to an electronic lock actuated by a predetermined input through a keyboard outside a safe to a programmable control unit within a housing of the safe. The device has an electric motor for driving a lock-bolt for locking a safe door to the safe housing, and means for displaying codes entered by the user, with a facility for selectively changing the necessary code. The device also has a battery-powered backup circuit maintained in a dormant state to conserve energy until an actuation key is operated. A microprocessor of the unit is programmed to activate a relatively high frequency of power output pulses at the start of movement of a locking bolt by the electric motor, to overcome inertia and any sticking forces on the bolt, and a lower frequency of power pulses to complete the movement of the bolt.
[0006] Another example is provided in U.S. Pat. No. 4,674,781, to Reece et al., which discloses an electric door lock actuator and mechanism having manual and electrically driven locking means. This device utilizes a combination of a lost motion coupling and resilient springs for driving a motive means to a neutral position, to thereby isolate an electric motor and gearing from the locking means so that the locking means may be operated manually without back-driving of the electric motor and intermediate gearing.
[0007] A major problem with such devices is that they require substantial amounts of electric power to perform their locking and unlocking functions. For securely storing and accessing highly sensitive or valuable items, it is important to avoid depending on the ready availability of sufficient electrical power for driving the locking mechanism. In fact, for many applications, the use of long-life batteries, even to power a small microprocessor, may also be deemed unacceptable.
[0008] The stringency of relevant U.S. government specifications is readily appreciated from Federal Specification FF-L2740, dated Oct. 12, 1989, titled “FEDERAL SPECIFICATION: LOCKS, COMBINATION” for the use of all federal agencies. Section 3.4.7, “Combination Redial”, for example, requires that once the lock-bolt has been extended to its locked position “it shall not be possible to reopen the lock without completely redialing the locked combination”, and defines the locked position as one in which the bolt has been fully extended. Section 3.6.1.3, “Emanation Analysis”, requires that the lock shall not emit any sounds or other signals which may be used to surreptitiously open the lock within a specified period. Section 4.5.2.2.4, “Surreptitious Entry”, requires that for any lock to be deemed acceptable, attempts shall be made to unlock the lock through manipulation, radiological analysis and emanations analysis, further including the use of computer enhancement techniques for signals or emanations. Even further, Section 6.3.2 defines surreptitious entry as a method of entry such as manipulation or radiological attack which would not be detectable during normal use or during inspection by a qualified person.
[0009] In short, for high security storage of sensitive or valuable material, in light of the availability of sophisticated computer-assisted means and methods for unauthorized operation of locking mechanisms, there exists a need for an autonomous locking mechanism that does not require batteries or external sources of power for any purpose, receives and recognizes only specific user-selected combination code information for access, emanates no information useful to persons attempting unauthorized operation, and is made to resist unauthorized operation even when subjected to strong externally imposed electrical, magnetic or mechanical forces, and satisfies other U.S. government specifications. Most important, once the mechanism is put in its locked position it loses all “memory” of the input combination code and requires a totally new and correct provision of the complete combination code to be unlocked again.
[0010] The present invention, as more fully disclosed hereinbelow, meets these perceived needs at reasonable cost with a geometrically compact, electrically autonomous, locking mechanism.
SUMMARY OF THE DISCLOSURE
[0011] It is an object of this invention to provide a locking mechanism which remains securely in a locked state until, following receipt of a predetermined combination code, a very small amount of electrical power is employed to put it in condition to be manually unlocked thereafter.
[0012] It is another object of this invention to provide a locking mechanism actuated by the input of a selected combination code followed by the delivery of a very small amount of electrical power generated during input of a user-selected combination code to a low friction engagement means to put the same in a position to enable purely manual unlocking of the mechanism thereafter.
[0013] Yet another object of this invention is to provide a locking mechanism which upon being put into a locked state remains in that state immune to electrical, magnetic, thermal or mechanical inputs accompanying attempts at unauthorized unlocking thereof.
[0014] It is an even further object of this invention to provide a secure locking mechanism which is unlocked by the provision of a preselected combination code within a specified time followed by the provision of a very small amount of electrical power to move an engagement element to a position to enable solely manual unlocking of the mechanism thereafter.
[0015] It is an even further object of this invention to provide a locking mechanism which utilizes a very small amount of electrical power, generated during input of a user-provided combination code, to be put into condition for manual unlocking, the mechanism, upon being manually put into a locked state, remaining in such a locked state until a predetermined combination code is entered.
[0016] These and other related objects are realized, according to a preferred embodiment of the invention, by providing a locking mechanism which comprises a first means for moving an engagement element from a disengaged position to an engageable position thereof solely upon receipt of a controlled predetermined electrical power output, a manually operated second means for engaging the engagement element when the latter is in its engageable position for thereby manually moving the first means further in a first direction and back in a second direction, and third means for driving a lock-bolt engaged by the further movement of the first means to drive the lock-bolt to locking and unlocking positions thereof in correspondence with movements of the first means in the first and second directions respectively. Movement of the first means in the second direction restores security by returning the engagement element to its disengaged position when the lock-bolt reaches its locked position.
[0017] In still another aspect of the invention, the first means comprises an electrical stepper motor having a rotor supporting the engagement element and having stable positions determined by magnetic detents which correspond to the disengaged and engageable positions of the engagement element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of an exemplary safe having a generally rectangular casing and a hinged door, with a lock mechanism according to this invention mounted to the door of the safe.
[0019] FIG. 2 is a horizontal cross-sectional view of the door and the lock mechanism at line II-II in FIG. 1 .
[0020] FIG. 3 is an exploded perspective view of a lock mechanism according to a preferred embodiment of this invention as viewed from a location behind a casing of the lock mechanism.
[0021] FIG. 4 is a vertical elevation view of elements of the lock mechanism which are mounted to a rear cover of a casing of a lock mechanism according to FIG. 3 .
[0022] FIG. 5 is a plan view of the elements illustrated in FIG. 4 in the direction of arrow V therein.
[0023] FIGS. 6A, 6B and 6 C are elevation views of elements of the lock mechanism operationally supported to and within the casing of the lock mechanism of FIG. 3 to explain coaction of the elements at various stages as the lock-bolt is moved to an unlocked disposition thereof.
[0024] FIGS. 7A, 7B and 7 C are vertical elevation views illustrating, for a second embodiment of this invention, how various elements of the invention coact at various stages as the lock-bolt is moved from its locked position to its unlocked position.
[0025] FIGS. 8A, 8B and 8 C are elevation views, according to a third embodiment of this invention, illustrating various stages in the movement of the lock-bolt thereof from its locked to its unlocked position.
[0026] FIG. 9 is a partial vertical cross-sectional view of one embodiment of another aspect of this invention, in which a voice coil is employed to ensure against unauthorized magnetically induced unlocking of the mechanism.
[0027] FIG. 10 is a partial vertical cross-sectional view of another embodiment of the aspect shown in FIG. 9 .
[0028] FIG. 10A is a vertical cross-sectional view at section XI-XI in FIG. 10 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] A typical safe for securely storing valuable items, e.g., sensitive documents, precious jewelry or cash, hazardous materials such as radioactive or biologically dangerous substances, and the like, conveniently has a generally cubical form, with an opening closable by a single hinged door. Such a safe also typically has a multi-walled construction, both for the principal sides and for the door. As best seen in FIG. 1 , such a safe 100 generally has a principal side wall 102 to which a door 104 is locked by operation of a lock mechanism 200 .
[0030] As best seen in FIG. 2 , a lock mechanism 200 according to a preferred embodiment of this invention has an external user-accessible hub 202 conveniently provided with an easily viewable combination code input display window 204 and a manually rotatable combination input knob or dial 206 . Hub 202 is attached to the outer surface 106 of door 104 in any known manner. Similarly, a casing 208 is securely attached to an inside surface 108 of door 104 in known manner. Door 104 may be kept hollow or may have an inner space filled with a thermally insulating material (not shown) to protect the contents of the safe in the event of a local fire.
[0031] A shaft 210 , rotatable by knob 206 , extends through the thickness of door 104 and into casing 208 to cooperate thereat with a combination of important elements of the present invention as described more fully hereinbelow. A lock-bolt 212 is slidably supported by casing 208 to be projected outwardly into a locking position, or to be retracted substantially within casing 208 to an unlocking position, upon appropriate manual operation of combination-input knob 206 by a user. Casing 208 is provided with a detachable cover 272 which also serves to provide support to various components of the lock mechanism according to this invention.
[0032] FIG. 3 is an exploded view of a lock mechanism according to a preferred embodiment of this invention, as viewed in looking toward the inside surface 108 of door 104 . Persons of ordinary skill in the art can be expected to appreciate that it is not critical to the utility of the present invention that lock mechanism 200 be mounted to a door since, without difficulty, the lock mechanism can be easily mounted to a wall of safe 100 in such a manner that lock-bolt 21 2 projects in its locking position into the safe door to lock it to the body of the safe. Details of such an alternative construction are simple and easy to visualize, hence illustrations thereof are not included. Such structurally obvious variations are contemplated as being within the scope of this invention.
[0033] Referring again to FIG. 3 , an aperture 110 extends through the entire thickness of door 104 to closely accommodate therein shaft 210 extending from combination-input knob 206 into a space 214 defined inside casing 208 . Located in correspondence with aperture 11 0 in door 104 , in casing 208 there is provided an annular journal bearing 216 to closely receive and rotatably support shaft 210 via 266 projecting therethrough into space 214 .
[0034] Casing 208 is conveniently formed, e.g., by machining, molding or otherwise in known manner, to provide a pair of guide slots 218 , 218 which are shaped, sized and disposed to closely accommodate lock-bolt 212 in a sliding motion between its locked and unlocked positions. While an important object of this invention is to provide its locking function in a highly compact manner, which inherently necessitates the selection of strong materials for forming the casing 208 and lock-bolt 212 , guides 218 , 218 and lock-bolt 212 must be shaped and sized to provide the necessary strength to resist any foreseeable brute-force to open door 104 . Persons of ordinary skill in the art are expected to know of suitable materials for such purposes. For example, although the safe walls and door may be made of highly tempered steel or alloy, the lock bolt itself may be made of a softer metal such as brass or an alloy such as “ZAMAK,” and so may other elements of the mechanism.
[0035] As also illustrated in FIG. 3 , within space 214 inside casing 208 there are also provided attachment points for biasing means such as springs 222 , 222 to be employed as discussed hereinbelow. In the embodiment illustrated in FIG. 3 , there are also provided at an inside surface of casing 208 a small reed switch 224 and a socket 226 disposed to enable push-in electrical connection of a plurality of electrical connector pins 282 which are best seen in FIG. 5 . Also provided on a wall surface of casing 208 near biasing springs 222 , 222 is a guide pin 228 which closely fits into an elongate parallel-sided aperture 230 in the sliding element 232 which is generally flat and slides along an inner surface of casing 208 . Sliding element 232 is provided with a pair of spring-engaging pins 234 , 234 which engage with biasing springs 222 , 222 , whereby sliding element 232 is biased in a preferred direction, an upward direction in the illustration per FIG. 3 .
[0036] Note that sliding element 232 is also provided with a cam-engaging pin 236 , at least one elongate straight side 238 which may be used in known manner to provide additional sliding guidance, one or more weight-reducing apertures such as 242 which may also be shaped to perform cam functions, a circular aperture 244 close to cam-engaging pin 236 , and a cam-notch 246 at the end of sliding element 232 opposite the end closest to cam-engaging pin 236 .
[0037] Lock-bolt 212 , as best seen in FIG. 3 , is provided with a pivot-mounting aperture 248 into which is mounted a pivot 250 , to pivotably connect a lever arm 252 to lock-bolt 212 to communicate a manual force for moving the lock-bolt, guided by guides 218 , 218 , between its locked and unlocked positions.
[0038] Lever arm 252 is provided with a lateral pin 254 which is disposed to be engaged by cam-notch 246 of sliding element 232 so as to be forcibly moved thereby, in a manner to be described more fully hereinbelow, when sliding element 232 is itself caused to be slidingly moved as guided by the coaction of guide pin 228 and the parallel sides of elongate aperture 230 . The distal portion of lever arm 252 extending beyond the location of lateral pin 254 is formed as a hook 256 , the shape of which is provided with an outside edge having a plurality of contiguous portions 258 , 260 and 262 which coact with a downwardly depending fixed cam portion 264 formed at an inside surface of casing 208 . This coaction, at different stages in the course of moving lock-bolt 212 between its locked and unlocked positions, is best understood with successive reference to FIGS. 6A, 6B and 6 C and is described more fully hereinbelow.
[0039] An end portion of shaft 210 which extends into space 214 preferably has a square cross-section, to which is mounted a rotary element 266 via a matchingly shaped and sized central fitting aperture 268 , as best seen in FIG. 3 . Accordingly, when a user of the safe manually applies a torque to the combination-input knob 206 (see FIG. 2 ), he or she transmits the torque to shaft 210 to thereby forcibly rotate rotary element 266 . A split ring 270 , for example, may be utilized to retain the rotary element 266 to shaft 210 in known manner. Other known techniques or structures may be used, instead of such a split ring, for such retention. By this arrangement there is readily available, through rotary element 266 , a manually provided torque at a point inside space 214 of casing 208 , i.e., within the secure containment space inside safe 1 00 , even when door 104 is locked. This is a feature essentially common to the various embodiments disclosed and claimed herein. The exact structural form of the manually-torqued rotary element is different, and is somewhat differently utilized, in the various embodiments.
[0040] In the best mode of this invention, exemplified by the preferred embodiment illustrated in exploded view in FIG. 3 , rotary element 266 , in a portion closest to an inside surface of cover 272 of casing 208 , is provided an internal ring gear 274 . Outwardly of ring gear 274 , there is provided a periphery having a toothed arcuate portion 276 , a smooth circumferential portion 278 and a radially relieved smooth circular portion 280 .
[0041] At a side of rotary element 266 between internal ring gear 274 and annular journal bearing 216 is a circular cam portion 400 provided with a radially-relieved mechanical detent 402 shaped and sized to receive hook 256 when lever arm 252 is pivoted to a predetermined degree about pivot 250 by a sliding movement of sliding element 232 and a corresponding coaction between lateral pin 254 of lever arm 252 and cam notch 246 of sliding element 232 . A small magnet 245 is mounted to rotary element 266 , at a predetermined angular disposition vis-a-vis mechanical detent 402 , at a radius such that it passes by reed switch 224 to activate it under conditions selected by microprocessor 288 as described hereinafter.
[0042] As best seen in FIG. 4 , cover 272 on the side facing space 214 of casing 208 supports a plurality-pinned electrical plug element with pins 282 located to be electrically engageable with socket 226 , an electrical power generator 284 , a power storage capacitor 286 , a microprocessor 288 , and assorted wiring 290 forming part of an electrical circuit. Details of this electrical circuit and various aspects of its functions, e.g., how a predetermined combination code may be provided to and stored in microprocessor 288 , how segments of a selected combination code are displayed in window 204 as they are input by a user operating manually rotatable combination-input knob 206 , and the like, are disclosed in U.S. Pat. No. 5,061,923, which is expressly incorporated herein by reference for all such relevant disclosure therein.
[0043] Cover 272 , as best seen in FIG. 3 , is provided with countersunk apertures 292 and one or more location-indexing projections 294 to facilitate precise fitting of cover 272 with casing 208 and secure affixation therebetween by screws 296 . When cover 272 is thus indexed and affixed to casing 208 , a sun-and-planet gear train 298 , best seen in FIG. 4 , meshes with internal ring gear 274 of rotary element 266 to be rotated thereby, plus element 282 fits to socket 226 , and lock-bolt 212 then is slidably movable in a closely fitting aperture of closed casing 208 .
[0044] As described in detail in U.S. Pat. No. 5,061,923, incorporated herein by reference for such details, such affixation of cover 272 to casing 208 , upon manual rotation of combination-input knob 206 , causes rotation of shaft 210 and rotary element 266 mounted thereto, resulting in manual rotation of planetary gear train 298 to generate electrical power in electrical generator 294 . Some of this electrical power is conveyed via a plurality of fine wires (not illustrated) which are disposed along shaft 210 , to provide a liquid crystal display of numbers relating to a combination code in display window 204 . A portion of the power generated by electrical power generator 284 , under the control of microprocessor 288 , is stored in power storage capacitor 286 . Some of this stored electrical power is thereafter available for a period of time under the control of microprocessor 288 , upon determination thereby that a correct combination code has been provided by a user, to perform a vital function of the present invention. This vital function is to create such a coaction of the above-described elements that lock-bolt 212 is positively and controllably moved, solely by a manually-provided force, from its locked position to its unlocked position.
[0045] In the best mode of this invention, as best understood with reference to FIG. 3 , there is a very low-friction, rotary, electric motor 300 provided with magnetic detents symbolized by the reference character “D” in the figure, which give a rotor 302 at least two stable positions which are angularly separated with respect to an axis of the rotor by a predetermined angle, preferably approximately 36°. Such motors are known; one example is a Seiko model. Hence, detailed illustrations of the internal structure of motor 300 , etc., are not believed necessary for an understanding of the structure or specific functioning of the present invention in any of the embodiments disclosed and claimed herein.
[0046] What is of particular importance is that motor 300 is electrically connected by a portion of circuit wiring 290 so as to be able to receive from power storage capacitor 286 at least one predetermined small pulse of electric power at a time controlled by microprocessor 288 . Microprocessor 288 is initially provided a user-input reference combination code which, thereafter, serves as reference data until and unless it is replaced or changed as is fully described in copending application U.S. Ser. No. 07/250,918, incorporated herein by reference for relevant details disclosed therein. Subsequently, when a user rotates combination-input knob 206 to actuate the lock mechanism, rotation of shaft 210 (regardless of direction of its sense of rotation), generates electrical power to display elements of the combination code as they are being input and, simultaneously, enables the storage of a quantity of power in power storage capacitor 286 . Then, upon microprocessor 288 recognizing that a correct combination code has ben provided, e.g., upon receipt of a predetermined ordered set of three numbers, a portion of the power stored in power storage capacitor 286 is released to motor 300 when further rotation of rotary element 266 in a predetermined direction next brings magnet 245 close enough to reed switch 244 to actuate it. Alternatively, power can be supplied to the motor 300 by a separate capacitor (not shown).
[0047] This motor 300 has very low-friction bearings rotatably supporting rotor 302 , preferably with no grease, oil or other lubricant being utilized therein to avoid deterioration thereof over prolonged period of time. The coaction of ring gear 274 and gear train 298 generates sufficient electric power during the process of inputting the requisite combination code to enable power storage capacitor 286 to store and deliver an adequate electrical power pulse (or more than one pulse, as needed) to cause rotor 302 to move from a stable disengaged position corresponding to a first magnetic detent to a stable engageable position corresponding to a second magnetic detent thereof. Motor 300 thus functions as a transducer in which a small amount of received electrical power is converted, i.e., transduced, to a small mechanical rotation of rotor 302 .
[0048] A variation of this arrangement can be realized using simple modifications to the circuitry, so that power to actuate the motor 300 is provided directly from power generation elements to the motor without first storing that quantity of electrical charge in one or more capacitors. Power to operate the microprocessor, however, may still be stored in and provided through one or more capacitors.
[0049] As best seen in FIG. 6A , rotor 302 has an arcuately relieved portion 304 disposed to be closest to and accommodating of the outer peripheral portion 276 of rotary element 266 when rotor 302 is in its disengaged position. In the best mode illustrated in FIGS. 6A-6C , a peripheral arcuate portion 306 of rotor 302 is provided with a plurality of teeth shaped and sized to be positively engageable with the teeth of toothed outer peripheral portion 276 to rotor element 266 . Upon the provision of the requisite electric power pulse from power storage capacitor 286 , as previously described, rotor 302 promptly rotates to its stable engageable position, this being one in which its toothed outer portion 306 is rotated to become engageable by teeth of peripherally toothed portion 276 of rotary element 266 , i.e., when rotary element 266 is turned counterclockwise in FIGS. 6A, 6B and 6 C to engage said teeth of portion 276 with the teeth of rotor 302 .
[0050] Once such an engagement is initiated, further manual rotation of rotary element 266 , due to manual torque provided by a user rotating combination-input knob 206 , rotor 302 is forcibly and positively rotated in a rotational direction opposite to that of shaft 210 . In other words, simply by the provision of a very small electrical power pulse, which is preferably in the range of only a few microwatts, rotor 302 becomes drivable solely by the manual rotary input under the control of the user, and this occurs only after the input of a correct combination code as recognized by microprocessor 288 with reference to its prestored reference combination code data.
[0051] Rotor 302 , as best seen in FIG. 6A , in a face thereof closest to sliding element 232 , has two arcuate, diametrally opposed, generally kidney-shaped openings 308 , 308 . These recesses are shaped and sized to non-bindingly receive therein a pair of drive pins 310 , 310 provided on a rotatable cam element 312 which is mounted to be freely rotatable about the same axis as rotor 302 within angular limits imposed by arcuate recesses 308 coacting with drive pins 310 . In other words, drive pins 310 , when disposed to be located near corresponding ends of arcuate recesses 308 while rotor 302 is in its disengaged position, remain unmoved while the aforementioned electric power pulse causes rotor 302 to rotate to its stable engageable position, at which point drive pins 310 are located at the corresponding opposite ends of their respective recesses 308 , 308 . Note that this ensures that with only a few microwatts of power, rotor 302 rotates from its disengaged position to its engageable position. This is an important aspect of the present invention and is common to all disclosed embodiments. However, upon further manually forced rotation of rotor 302 , arcuate recesses 308 , 308 each forcibly engage with corresponding drive pins 310 , 310 to forcibly rotate rotatable cam element 312 . Rotatable cam element 312 is located so as to then, and only then, force a portion of its outer peripheral edge into contact with cam-engaging pin 236 of sliding element 232 .
[0052] In this manner, further solely manual rotation of rotatable cam 312 will generate a forced sliding motion of sliding element 232 , as guided b guide pin 228 engaging with elongate aperture 230 , by overcoming of a biasing force provided by bias springs 222 , 222 . In the structure as illustrated in FIG. 3 and 6 A- 6 C the sliding element 232 thus is manually moved downward.
[0053] As previously noted, cam notch 246 at the upper distal end of sliding element 232 engages with lateral pin 254 of lever arm 252 . Thus, as best understood with reference to FIGS. 6A, 6B and 6 C, as sliding element 232 is forced downward, cam notch 246 thereof applies a downward pull on the hooked end of lever arm 252 to correspondingly pull hook 256 thereof downwardly toward a mechanical detent 402 provided on rotary element 266 . In the illustrations per FIGS. 6A, 6B and 6 C, as lever arm 252 is drawn downward to engage with mechanical detent 402 , edge portion 260 thereof coacts with a sloping edge of fixed cam portion 264 to be further moved downward into a positive engagement with mechanical detent 400 . Thus, as best seen with reference to FIG. 6B , the downward motion of sliding element 232 , contact between the sloping edge of fixed cam portion 264 and the outside edge portions 258 , 260 and 262 of lever arm 252 , and the eventual engagement of hook 256 with mechanical detent 402 of rotary element 266 all, eventually, lead to a manually-provided force being transmitted by lever 252 , through pivot 250 , to forcibly draw lock-bolt 212 into casing 208 . Ultimately, lock-bolt 212 becomes substantially drawn into casing 208 to its unlocked position.
[0054] Also, as best understood with reference to FIG. 6C , when this state of affairs is reached, lever arm 252 can rotate no further about pivot 250 because it is then in forced contact with the radially outermost portions of the detented side of rotary element 266 . Therefore, once lever arm 252 is engaged with rotary element 266 to draw lock-bolt 212 to its unlocked position, further forced rotation of combination-input knob 206 is prevented. Under these circumstances, door 104 may be opened and access may be had by the user to the contents of safe 100 .
[0055] Once the user has completed his or her business with the contents of the safe, door 104 may be put in a position to close safe 100 and the combination-input knob 206 rotated in the opposite sense, i.e., in a direction opposite to that which enabled lock-bolt 212 to be manually moved to its unlocked position. As best understood with reference to FIG. 6A , as the relieved detent portion of rotary element 266 is thus rotated, coaction between the same and the outer edge portion 262 of lever arm 252 forces lever arm 252 upward and in a direction that will drive lock-bolt 212 out of casing 208 toward a locked position. In this process, as the distal end of lever arm 252 slips past fixed cam portion 264 of casing 208 , lateral pin 254 of lever arm 252 is placed into engagement with cam notch 246 and serves to move sliding element upward while the biasing force provided by springs 222 also acts upward on sliding element 232 . At the same time, as rotating element 266 rotates, the meshed teeth of peripheral portion 276 of rotating element 266 and the teeth of toothed portion 306 of rotor 302 move in engagement until rotor 302 is rotated to such an extent that arcuate relieved portion 304 thereof abuts the relieved portion of the periphery of rotary element 266 .
[0056] Again, as best seen with reference to FIG. 6A , this united action of the above-described elements is such that when sliding bolt 212 eventually reaches its locked position, rotor 302 is returned to its stable disengaged position and will, thereafter, be retained there by the corresponding magnetic detent of motor 300 .
[0057] Note that the rotation of rotary element 266 required to thus project lock-bolt 212 out of casing 208 into a locked position is minimal, and that very little electrical power is generated as an incident thereto. Consequently, the electrically discharged circuit does not acquire sufficient stored electrical charge to be able to influence stepper motor 300 while lock-bolt 212 moves from its unlocked to its locked position. A very important consequence of this, in the context of the present invention, is that the entire lock mechanism becomes totally deactivated upon lock-bolt 212 reaching its locked position. Once this happens, lock-bolt 212 can not be moved to its unlocked position without the provision of the correct and entire combination code which must be found satisfactory by microprocessor 288 to enable the unlocking process as described hereinabove. In short, once the door is locked, the only way to unlock it is to correctly provide the entire combination code.
[0058] The basic concept of this invention, as realized in the preferred embodiment described hereinabove, may also be practiced with other embodiments. One such embodiment 700 is illustrated, in various operational stages, in FIGS. 7A-7C . A detailed description of this second embodiment follows.
[0059] Referring to FIGS. 7A-7C , a view intended to be generally comparable to the view of the first embodiment, per FIG. 6A , a lock-bolt 212 is slidably guided within guides 218 , 218 and a pivot 250 pivotably connects lock-bolt 212 to a lever arm 702 which has a hook 704 at a distal end thereof. The extreme distal end of lever arm 702 ends in a frontal surface 706 , the shape of hook 704 being defined by an elongate curved surface 708 which meets a rear hook surface 710 at a point 712 of the hook. These surfaces are polished smooth. Lever arm 702 , at a point intermediate its ends, is provided with a spring connection pin 714 . A first spring 716 , of selected length and stiffness, is hooked at one end to spring connection pin 714 and at another end to a first spring attachment point 718 at an upper portion of lock casing 208 . Absent the application of an externally applied force, first spring 716 provides a sufficient biasing force to hold lever arm 702 with its smooth front surface 706 in contact with a matchingly inclined face of fixed cam 264 formed as part of casing 208 .
[0060] In this second embodiment, as in the first embodiment illustrated in FIGS. 3-6C , there is provided a shaft 210 rotated by a user manually operating combination-input knob 206 , as will be understood by reference to FIG. 2 . Keyed to rotate with shaft 210 is a rotary cam element 720 which has an outer diameter such that when lever arm 702 is in its uppermost position, point 71 2 of hook 704 clears the circumferential rim of rotary cam element 720 . In this circumferential periphery, there is provided a generally triangular detent 722 having inclined sides forming a vertex directed toward a rotational axis of rotary cam element 720 , as best understood with reference to FIGS. 7A-7C . Rotary cam element 720 is also provided with a hook-engaging detent 724 formed and shaped to be able to accommodate hook 704 of lever arm 702 under conditions described hereinafter.
[0061] A low-friction, low-power, electric motor 300 is provided to receive a controlled electrical power pulse under the same conditions and is substantially the same manner as was described in detail for the first embodiment. Rotation of shaft 210 by a user, through a sun and gear train mounted on shaft 210 , will generate and store some electrical power under the control of a microprocessor. Upon satisfactory reception of a correct combination code input from a user, the microprocessor will release from an electrical storage capacitor a small controlled pulse of electrical power to cause a rotor of electric motor 300 to rotate from a first stable “disengaged” position to a second stable “engageable” position, these positions being defined by corresponding magnetic detents. For the sake of conciseness, a detailed description is not repeated herein of the manner in which the electrical power is generated and how, upon being provided the correct combination code input the microprocessor provides the necessary small electrical power pulse to motor 300 to cause the rotor thereof to turn. These details are believed to be comprehensible to a person of ordinary skill in the art upon a study of the earlier provided detailed description.
[0062] In the second embodiment 700 , as best seen in FIGS. 7A-7C , the rotor of electric motor 300 is provided with a generally radially extending engagement lever 726 and a radially eccentric elastic cam element 701 . Engagement lever 726 and eccentric cam 701 are thus mounted to be rotatable with the rotor (not expressly shown) of motor 300 . When the rotor of motor 300 is in its disengaged position, eccentric cam 701 has its periphery close to but not in contact with the circumferential periphery of rotary cam element 720 and the distal end of engagement lever 726 is located away therefrom. However, reception of the predetermined small electrical power pulse by motor 300 , (clockwise in FIGS. 7A-7C ) causes eccentric cam 701 to contact the periphery of rotary cam element 720 . Frictional force thus generated causes the rotor to be turned manually thereafter, and engagement lever 726 is thus positively moved to extend into triangular detent 722 . Continued manual rotation of the rotary cam element 720 thereafter forcibly and manually rotates the rotor of motor 300 .
[0063] It will be recalled that the location of a small magnet on the rotary element of the first embodiment actuates a reed switch 224 when the rotary element 266 turned to a predetermined position after reception by the microprocessor of a correct and complete combination input signal. For the sake of conciseness and clarity the details of such operation are not repeated and such elements are not illustrated in FIGS. 7A-7C , but it will be understood that such components are present and cooperate in the manner previously described. Thus, upon reception of a complete and correct combination input by the microprocessor in the second embodiment, motor 300 receives the required small electrical power pulse and rotates its rotor so that the distal end of engagement lever 726 , assisted by movement of the elastic eccentric cam 701 caused by the power pulse to the motor 300 and subsequent rotor rotation friction between the elastic eccentric cam 701 and the contacting periphery of rotary cam element 720 permitting rotation of the rotary cam element 720 , rotates into triangular detent 722 of manually rotated rotary sam element 720 .
[0064] As was the case in the first embodiment, there is provided a rotatable element (not shown in FIGS. 7A-7C , but similar to 312 in FIG. 3 ) mounted to rotate freely about the axis of motor 300 . Thus, when motor 300 has rotated its rotor by a predetermined small amount after receiving the small electrical pulse, the rotatable cam element 312 engages, and rotates a radial arm ending in a transverse cam pin 728 . See FIGS. 7A-7C . Rotation of cam pin 728 about the axis of the motor is thus obtained by the application of a manual torque by coaction of the rotary cam element 720 and engagement lever 726 engaged therewith.
[0065] A second spring 730 is engaged at one end to spring connection pin 714 of lever arm 702 and has a second end disposed to be pulled by cam pin 728 . The length of second spring 730 is selected such that it is put under tension only after engagement of engagement lever 726 by detent 722 of rotary cam element 720 as described in the immediately preceding paragraphs. Until that happens, second spring 730 is not subjected to any external force. However, once cam pin 728 is manually moved, as described above, it turns about the axis of motor 300 to a point where it begins to exert a force along second spring 730 and this force is to spring connection pin 714 of lever arm 702 . This force, manually provided, is sufficient to overcome the biasing force of first spring 716 , and eventually draws lever arm 702 in a pivotable motion about pivot 250 , so that point 712 of hook 704 is received within the hook engaging profiled detent 724 . Once this happens, co-action between the appropriately shaped hook engaging profiled detent 724 and rear hook surface 710 causes lever arm 702 to be drawn forcibly to thereby draw lock bolt 212 from its locking position to its unlocking position (as best seen in FIG. 7C ).
[0066] The second embodiment thus operates in the manner just described in accordance with the same basic principles as were earlier described with reference to the first embodiment.
[0067] When the user wishes to lock the mechanism, he or she simply needs to turn combination-input knob 206 , and thus shaft 210 and rotary cam element 720 , in a clockwise direction as would be seen with reference to FIG. 7C , i.e., in a direction contrary to that in which it was turned to bring lock bolt 212 into its unlocking position. When this is done, forcible co-action between the profiled hook engaging detent 724 and the elongate curved leading face 708 of hook 704 causes lever arm 702 to rotate about pivot 250 while applying a manually provided force to drive lock bolt 212 to its locking position. Eventually, when rotary cam element 720 has rotated sufficiently, co-action between triangular detent 722 and engagement lever 726 will cause the tension force in second spring 730 to be relieved and the rotor of motor 300 will return to its disengaged position as controlled by the corresponding magnetic detent. Once this is accomplished, the biasing force provided by first spring 716 will return lever arm 702 to the position best seen in FIG. 7A . Since hook 704 is then no longer in contact with rotary cam element 720 at this time, any unauthorized rotation of shaft 21 0 will not succeed in unlocking the locking mechanism. Only the provision of a complete and correct combination code input can thereafter reactuate the mechanism and cause it to move to its unlocking position. There is, thus, provided an alternative simple structure for a locking mechanism.
[0068] The third embodiment 800 , operating to the same basic principles, is illustrated in FIGS. 8A-8C . In this embodiment, the elements for generating electrical power and controlling its delivery to motor 300 are as previously described. Lock bolt 212 is slidingly guided in guides 218 , 218 as before. Lever arm 802 is pivotable about pivot 250 and has, as in second embodiment 700 , a hook 804 at a distal end. A rotary cam element 806 is manually rotatable by affixation to shaft 210 . Rotary cam element 806 has a hook-engaging profiled detent 808 , with an otherwise smooth circumferential periphery 810 smoothly contiguous therewith.
[0069] The rotor of electric motor 300 has a gear wheel 812 the teeth of which are continuously engaged with the teeth of an arcuate toothed sector 814 of an element 816 pivotably mounted at a pivot 818 attached to an inside surface of casing 208 . Element 816 , on the side opposite to toothed sector 814 , has a sideways extension 820 having a generally triangular internal opening 822 and an external edge surface cam comprising a first straight portion 824 , an obtuse angle 826 , a short external edge portion 828 , a substantially right angled corner 830 , and a second straight edge portion 832 , as illustrated in FIGS. 8A-8C .
[0070] Lever arm 802 has a spring connection point 834 , a short rotatable arm 836 pivotably mounted on a pivot 838 and a stop pin 840 against which short rotatable arm 836 rests under a biasing force provided by a spring 842 .
[0071] As illustrated in FIG. 8A , when lock bolt 212 is in its locking position, i.e., projecting outwardly of casing 208 , lever arm 802 has its distal end and hook 804 in their uppermost position, with hook 804 barely touching the smooth circumferential periphery 810 of rotary element 806 . At this time, a cam pin 844 , extending transversely of short rotatable arm 836 near an end opposite to an end attached to spring 842 , is close to but not contacting the cam surface edge of element 816 at obtuse angle 826 thereof. See FIG. 8A .
[0072] When a user inputs the correct and complete combination code, as with the previously discussed embodiments, a microprocessor acts in combination with the reed switch and a magnet (not shown) mounted to the rotary element 806 in the manner previously described with respect to the other embodiments. A small electrical power pulse is then provided to electric motor 300 when hook-engaging detent 808 is at a predetermined position with respect to hook 804 . Pivotably supported element 816 is very light in weight, therefore has a small mass inertia, and is supported at pivot 818 with very little friction, preferably without the use of lubricants that could deteriorate over time. It is also intended to be balanced about pivot 818 so that, even with a very small electrical power pulse, motor 300 can turn gear wheel 812 and, thereby, element 816 . At this time, in the disposition illustrated in FIG. 8A , a lever arm cam pin 846 is at a first corner of opening 822 of element 816 .
[0073] Upon receiving the small electrical pulse, motor 300 causes rotation of its rotor and gear wheel 812 mounted thereto, and toothed sector 814 engaged therewith causes rotation of element 816 in a clockwise direction, preferably by about 30°, as illustrated in FIGS. 8A-8C . The short cam surface edge portion 828 then slips away from under cam pin 844 , lever arm cam pin 846 coacts with an inside edge of triangular opening 822 to pivot lever arm 804 about pivot 250 so that hook 804 can then make contact against circumferential periphery 810 .
[0074] Eventually, as rotary cam element 806 is manually turned counterclockwise, hook 804 enters hook-engaging detent 808 of manually rotated rotary element 806 . Once this occurs, further counterclockwise manual rotation of rotary element 806 forcibly pulls lever arm 802 leftward, and thus lock bolt 212 slides into casing 208 . An uppermost outer edge of the hooked distal end of lever arm 802 slips under fixed cam 264 provided at an upper portion of casing 208 . The dimensions of the various elements are selected so that when lock bolt 21 2 has reached its “unlocking” position detent 808 , the hook engaging detent 808 cannot pull on lever arm 802 any further, as best understood with reference to FIG. 8C . The locking mechanism is now in its unlocked state.
[0075] Note that, as with the two previously described embodiments, in this third embodiment the basic principle utilized is to employ a very small electrical power pulse to cause a light-weight, low-friction electric motor to cause a small rotatable element to rotate to initiate an engagement between a lever arm and a manually driven rotatable rotary element to enable delivery of a manual force to drive lock bolt 212 from its locking to its unlocking position. Note also that, as with the previous embodiments, such an engagement becomes possible only after the microprocessor has received a correct and complete combination code input from the user, and only when the user manually torques rotary element 806 thereafter.
[0076] In order to put the locking mechanism in its locking state, the user must manually rotate rotary element 806 in the contrary direction, i.e., clockwise in FIG. 8C . Co-action between the smooth, curved, outer edge of hook 804 and hook-engaging detent 808 will then cause a manually provided force to drive lock bolt 212 to its locking position rightward and, at the same time, once cam pin 844 contacts the second straight edge portion 832 , element 816 will be caused to also rotate in a clockwise manner under a bias force conveyed from spring 842 . Due to the engagement between toothed sector 814 ad gear wheel 812 of motor 300 , the motor also is thus returned to its disengaged detent-controlled position. At this time, under the urging of spring 842 acting on rotatable arm 836 , cam pin 844 will again return to its location inside obtuse angle 826 of the cam surface edge of element 816 . Rotary element 806 will have rotated so that its smooth outer circumferential periphery is now immediately adjacent hook 804 .
[0077] Further uncontrolled, e.g., unauthorized, rotation of shaft 210 and rotary element 806 will not cause a lock-opening engagement between hook 804 and hook-engaging detent 808 until and unless element 816 is again caused to rotate out of the way of cam pin 844 , this being possible only under the control of the microprocessor after the microprocessor receives a correct and complete combination code input. The lock is thus safe from unauthorized opening once lock bolt 212 is put in its “locking” position, i.e., once it is extended outwardly of casing 208 as best illustrated in FIG. 8A .
[0078] As will be appreciated, to ensure against forcible or clever attempts at unauthorized unlocking operation of the locking mechanism, additional security elements may be provided. Two embodiments of such an aspect of an improving addition to th above-described invention are illustrated in FIGS. 9, 10 and 10 A, as described more fully hereinbelow.
[0079] FIG. 9 illustrates a mechanism that can act in combination with any of the above-described embodiments to further ensure against attempts at unauthorized operation of the locking mechanism by the imposition of an external magnetic field.
[0080] This security device 900 preferably has its principal components disposed within a common casing 902 shared with the electrical windings 904 and rotor 906 of the electrical motor (otherwise used in the same manner as electric motor 300 of the previous embodiments). Rotor 906 is supported on an axle 908 mounted in low friction bearings (not shown) and has an external gear wheel 910 which mechanically coacts with other elements as previously described.
[0081] At the inside end of rotor 906 , within casing 902 , there is provided a blocking member formed as a non-magnetic disk 912 which clears the inside surface of casing 902 and is rotatable with rotor 906 and shaft 908 to which external gear wheel 910 is mounted. Therefore, when blocking member disk 912 is prevented from rotating, so is external gear wheel 910 which, by its coaction with other elements previously described, is operable to put the lock in condition for unlocking.
[0082] Non-magnetic locking member disk 912 is preferably provided with a slight recess 914 , as best seen in FIG. 9 , with a through aperture 916 passing through the recessed portion to selectively receive a pin therethrough.
[0083] Also mounted within casing 902 is a small magnetic coil, e.g., a voice coil 918 mounted concentrically with an extending portion of axle 908 supported at a rear wall of casing 902 in a bearing 920 . The voice coil is free to move axially of axle 908 and is biased toward rotor 906 and blocking member disk 912 by one or more springs 922 acting against the back end of and within casing 902 . At the end of voice coil 918 closest to blocking member disk 912 , there is mounted a cantilevered pin 924 which normally extends through aperture 916 in blocking member disk 912 , as shown in FIG. 9 . This is the normal situation when the lock is in its locked state. Voice coil 918 is not rotatable about or with axle 908 but can merely slide axially thereof.
[0084] A permanent magnet 926 is mounted inside casing 902 with its north and south poles aligned in such a manner that when an electric current is provided to voice coil 918 , an electromagnetic field generated therein produces a pole of like kind so that mounted permanent magnet 926 repells voice coil 918 axially of axle 908 . Consequently, when a sufficient electric current is provided to voice coil 918 , and the magnetic field thereof interacts with permanent magnet 926 to overcome the biasing force of springs 922 , voice coil 918 bodily moves away from blocking member disk 912 . In doing so, it causes pin 924 to be totally extracted from aperture 916 in blocking member disk 912 . So long as such a current continues to be provided to voice coil 918 , and pin 924 remains retracted entirely out of aperture 916 in blocking member disk 912 , blocking member disk 912 , rotor 906 , shaft 908 and external gear wheel 91 0 are then free to rotate. On the other hand, so long as such an electrical current is not being provided to voice coil 918 , springs 922 force it in such a direction that when the distal end of pin 924 becomes aligned with aperture 916 in blocking member disk 912 it projects therethrough and prevents rotation of axle 908 and external gear wheel 910 mounted thereto.
[0085] In know manner, voice coil 918 is connected in conjunction with windings 904 of the electric motor (not numbered), which is used in the same manner as electric motor 300 of the previous embodiments. The electric current which activates voice coil 918 into retracting pin 924 out of blocking member disk 912 does so just before passing of electric current through windings 904 causes rotor 906 to turn axle 908 and, thus, external gear wheel 910 .
[0086] As will be appreciated, to avoid binding between pin 924 and th edges defining aperture 916 in blocking member disk 912 , the pin must be retracted before windings 904 generate enough torque on rotor 906 and blocking member disk 912 to turn them inside casing 902 . As a practical matter, there are numerous known mechanisms and techniques for delaying the flow of electrical current to coils 904 until pin 924 has been entirely retracted from aperture 926 , thereby setting rotor 906 free to turn.
[0087] In practice, the security device illustrated in FIG. 9 acts to prevent rotation of external gear wheel 91 0 under the action of an external spurious or intentionally applied magnetic field, which, otherwise, might actually cause rotation of rotor 906 . Thus, if an unauthorized person positions equipment capable of generating a strong rotating field immediately adjacent the locking device of this invention, and rotor 906 rotates by coacting with the imposed rotating field, the lock might be engaged and unlocked without the input of an authorized combination code. The security device illustrated in FIG. 9 would prevent such unauthorized opening of the lock. Since the externally imposed unauthorized rotating electromagnetic field would have no influence on the non-rotatable voice coil 91 8 and its pin 924 extended through aperture 916 , such a very small light pin 924 very effectively prevents unauthorized rotation of axle 908 and external gear wheel 910 .
[0088] It may be theoretically possible to apply a strong inertial force, e.g., by a violent blow, to the lock along the direction of the axis of axle 908 , sufficient to cause voice coil 918 to compress springs 922 . While doing so, in theory one could retract pin 924 from aperture 916 while, simultaneously, applying a strong rotating external magnetic field to rotate rotor 906 . However, since most safes are very heavy or are built into a structure, the likelihood of such a complex contrivance putting the lock into condition for unlocking for practical purposes is eliminated by the presence of the security device per FIG. 9 .
[0089] Persons of ordinary skill in the art will appreciate that the performance of the voice coil and pin 924 attached thereto, involving retraction during the provision of a small electric current to the voice coil, can be utilized under other comparable circumstances to prevent movement of an element capable of coacting with pin 924 , e.g., a sliding element that may be employed as a magnetic key, or the like.
[0090] Voice coil 918 is preferably connected in series with winding coils 904 of the electric motor in such a manner that when an electrical current is provided under the control of the microprocessor to enable rotor 906 to turn, the same current causes voice coil 918 to act against springs 922 to withdrawn pin 924 from aperture 916 of disk 912 . Only then can disk 912 and the rotor 906 turn to rotate the toothed element 910 into an engageable position to allow the user to apply manual force to lock bolt 212 to move it to its unlocking position. Rotation of rotor 906 by the imposition of an external magnetic field is prevented by this simple structure, while normal authorized opening of the lock mechanism is automatically made possible.
[0091] In this manner, by the use of relatively inexpensive and commonly available elements, e.g., a voice coil, springs and essential wiring, additional security can be provided against unauthorized unlocking of the locking mechanism as described hereinabove.
[0092] An alternative security device is illustrated in FIGS. 10 and 10 A. In such a device, shown sharing a common ferrous casing 1002 , electric motor 300 utilizes a small rotor 1004 mounted coaxially to the motor axle 1006 , rotor 1004 having a knurled or otherwise roughened outer peripheral surface 1008 . Surrounding rotor 1004 , but at a small distance radially outward therefrom, is an annular ring 1010 of a non-ferrous material tightly fitted within ferrous casing 1002 .
[0093] As best seen in FIG. 10A , at four equally separated radial locations in non-ferrous annular ring 1010 , there are provided four radial holes 1012 having axes in a common plane. Inside each radial hole 1012 , there is provided a small hardened linear magnet 1014 which is shaped and sized to be freely slidable within radial hole 1012 . Each of the hardened magnets 1014 has a sharp point at its end nearest to the knurled surface 1008 of rotor 1004 . These magnets 1014 are disposed in pairs, with the two magnets of each pair having “like magnetic poles” opposite to each other in a substantially radial direction with respect to the axis of axle 1006 of electric motor 300 . By this arrangement, the two magnets in each pair of magnets tend to repel each other so that they remain loosely held within their corresponding radial holes 1012 but with their respective sharp points magnetically maintained away from the knurled surface 1008 of rotor 1004 .
[0094] Under the above-described circumstances, with the magnets, by pairs, staying away from the knurled surface 1008 , the rotor of electric motor 300 remains free to operate as described previously, i.e., to turn between its two detent positions upon the reception of the required small electrical power pulse under the control of the microprocessor. However, should an unauthorized attempt be made to unlock the locking mechanism by the imposition of a large magnetic field upon the locking mechanism, the pairs of magnets will no longer balance each other radially outwardly and, therefore, their sharp ends will come into contact with knurled surface 1008 of rotor 1004 and will prevent rotation thereof. Consequently, the rotor of electric motor 300 also cannot turn and the mechanism cannot be put into condition for operation in any of its embodiments as described hereinabove. This mechanism thus insures safety against attempts at unauthorized opening of the locking mechanism by the imposition of extraneously provided large magnetic or electrical fields.
[0095] It should be appreciated that persons of ordinary skill in the art, armed with the above disclosure, will consider variations and modifications of the disclosed embodiments and various aspects of this invention. Consequently, the disclosed embodiments are intended to be merely illustrative in nature and not as limiting. The scope of this invention, therefore, is limited solely by the claims appended below.
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A self-powered electric lock includes a lock bolt and a first engagement element having disengaged and engageable positions. An electric actuator includes an output operative to move the first engagement element to its engageable position. A manually operated rotatable member is operatively coupled to the first engagement element when the first engagement element is in its engageable position. A lock bolt drive mechanism is coupled to the lock bolt and to the first engagement element when the first engagement element is in its engageable position. The movable output moves the first engagement element to its engageable position upon input of correct electronic data. An electricity generator is coupled to the manually operated rotatable member. The electricity powers the electric actuator and an electronic data input device. The manually operated rotatable member is also used to actuate the lock bolt drive mechanism and retract the lock bolt.
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BACKGROUND OF THE INVENTION
1. Field of the Invention.
2. The present invention relates to a board game suitable for playing while watching a sporting event. It is known that some sporting events while ultimately exiting, have substantial periods of time of inactivity. The present invention permits the period of inactivity in a sporting event, particularly a televised sporting event, to be utilized productively according to the knowledge of the viewer of the a televised sporting event.
2. Description of the art practices.
U.S. Pat. No. 5,582,409 issued Dec. 10, 1996 to Mayorga et al. describes a baseball board game and more particularly pertains to simulating the sport of playing baseball to aid in the learning of all aspects of the sport of baseball. U.S. Pat. No. 5,407,204 issued to Meyer, III Apr. 18, 1995 describers a board game for simulating the game of baseball in which baseball trading cards are utilized as playing pieces. The game includes a board having a baseball diamond pictured thereon and a plurality of card holders into which baseball trading cards may be positioned. A deck of pitcher cards provides a random pitch to a player at bat, such as a strike, ball, or hit, and a deck of action cards provides a random result of the batter's action, such as a hit, out, or home run. The game pieces are then moved in accordance with the rules of conventional baseball. The game board and the card holders may be provided with illumination for enhancing appearance and facilitating nighttime play.
Dileva et al., in U.S. Pat. No. 5,322,292 issued Jun. 21, 1994 discloses a baseball board game including a plurality of tokens, each of which represent one of the players, a random number generator, a multiplicity of play money, and a game board having a baseball-like playing field and a multiplicity of playing spaces formed on the baseball-like playing field which cooperatively define a continuous closed path in the form of a baseball diamond along which the tokens are moveable in random increments. The multiplicity of spaces includes a starting corner space representing home plate and three additional corner spaces representing first base, second base and third base, respectively, a first group of spaces having monetary gains specified thereon associated with certain baseball-related events in a baseball player's life both on and off the field which have a positive pecuniary effect on a baseball player and a second group of space having monetary penalties specified thereon associated with certain baseball events on and off the field in a baseball player's life which have a negative pecuniary effect on a baseball player.
U.S. Pat. No. 5,713,793 issued Apr. 5, 1996 to Holte describes a commodities options trading game is provided in which the simulated market, which determines whether the value of the simulated commodities options rise or fall, is determined by a real event occurring outside the game being played. In a preferred embodiment, the event from which the simulated market is derived is a real-life sporting event, such as a professional basketball, football, or baseball game. Preferably a host calculator or computer generates the initial option prices and displays the information to a plurality of player stations. After play begins, the host computer updates the options prices using formula based on the current score, time remaining and a other empirically determined factors. The players buy and sell options in response to the momentum of the market. At the conclusion of the sporting event, the options are cashed in for their intrinsic value and the player with the most accumulated wealth is declared the winner.
D'Aurora et al., in U.S. Pat. No. 5,681,042 issued Oct. 28, 1997 discloses a game board apparatus having multiple sets of playing space designators is disclosed. The playing space designators are adapted to be removably affixed to playing spaces of a playing board. Examples of sets would include profession baseball teams, computer and telecommunications firms, professional football teams, etc. When a set of designators is chosen, the players then affix individual designators to playing spaces on the playing board surface. Each playing space designator includes indicia representing one or more characteristics of the playing space designator.
Moran in U.S. Pat. No. 5,522,590 issued Jun. 4, 1996 describes a baseball card game including one deck of cards, the deck including 27 “out” cards, 13 “on base” cards, and 1 wild pitch card, and 9 separate “incidence” cards. Each card discloses a particularly play event, illustrates the symbol identifying same, and describes what action is taken by any base runner who may be on base when the event occurs. The deck is shuffled before each half inning, and the cards are turned-up one at a time until three “out” cards are completed. A plurality of blank box score sheets are included, adaptable to having any preferred line-up of players listed thereon, and the appropriate symbols recorded thereon as the individual cards are turned up.
To the extent that the foregoing patents are relevant to the present invention they are herein incorporated by reference.
SUMMARY OF THE INVENTION
An interactive board game is described comprising:
one or more game pieces,
a playing surface (board), for when said game is in use, receiving said game pieces on said playing surface (board),
a first set of cards (player), for when said game is in use by one or more participants, having at least one participant select a card from said first set of cards (player),
a second set of cards (batter), for when said game is in use by one or more participants, having at least one participant select a card second set of cards (batter), at the participants option,
and where said first set of cards (player) corresponds to an independently determined action in a sporting event, and said second set of cards (batter) corresponds to the independently determined action in the sporting event.
The present invention also describes a method of playing an interactive board game comprising moving one or more game pieces about a playing surface (board), said playing surface having a plurality of segments corresponding to an independently determined action in a sporting event, including moving one or more game pieces on said playing surface (board), having at least one participant select a card from a first set of cards (player) where said first set of cards (player) corresponds to an independently determined action in said sporting event, and optionally having at least one participant select a card from a second set of cards (batter), at the participants option, said second set of cards (batter) corresponds to the independently determined action in the sporting event, the participant selecting said first card and optionally said second card prior to the occurrence of the independently determined action in said sporting event based upon the participants belief that the independently determined action in said sporting event will occur, and upon the occurrence of the independently determined action in said sporting event, the participant moving the participants game piece if the independently determined action in said sporting event is correctly predicted in said sporting event according to a value assigned to the first card and the second card if played.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features of the present invention will become apparent to one skilled in the art to which the present invention relates upon consideration of the following description of the invention with reference to the accompanying drawings, wherein:
FIG. 1 shows the basic design of an interactive board game.
With more particular reference to the drawings the following is set forth.
DETAILED DESCRIPTION OF THE INVENTION
A interactive board game 10 is shown in FIG. 1 . The game board 10 has a playing surface 20 . The playing surface 20 of the interactive board game 10 has, for the purpose of exemplification, the general configuration of a baseball diamond.
One or more game pieces 30 (not shown), for when said game is in use, are adaptable for placement and moving about the playing surface 20 . A first set of cards 50 (player not shown), for when said game is in use by one or more participants is provided. The second set of cards has a value.
A second set of cards 70 (batter not shown), for when said game is in use by one or more participants is provided. In a preferred embodiment the interactive board game 10 has a third set of cards 80 (Red Bonus not shown). The third set of cards has a value. The value of the third set of cards, have a value which is a multiple of, and used as a substitute for, a card from the second set of card. In a preferred embodiment the interactive board game 10 has a fourth set of cards 90 (Stolen Base).
The playing surface 20 of the interactive board game 10 has a series of card spaces 100 . For purpose of exemplification, a first card space 10 is provided for the first set of cards 50 . When in use, a participant places one of the cards from the first set of cards 50 , on the card space 110 .
The playing surface 20 of the interactive board game 10 has a second card space 120 for the second set of cards 70 . When in use, a participant places one of the cards from the second set of cards 70 , on the card space 110 .
The playing surface 20 of the interactive board game 10 has a third card space 130 to discard the second set of cards 70 . The playing surface 20 of the interactive board game 10 has a fourth card space 140 for any unused portion of the second set of cards 70 .
The playing surface 20 of the interactive board game 10 has a base path 200 . At each intersection of the baselines 200 is a base. The bases are home plate 220 , first base 240 , second base 260 , and third base 280 .
Located along the base path 200 between home plate 220 and first base 240 are a plurality of segments 300 . The segments 300 are generally identified as various occurrences in the sporting event. For instance, in a baseball game the occurrences will be a strike out 302 , a home run 304 , a fly out 306 , a ground out 310 , a single 312 , and a double 314 .
Also located between home plate 220 and first base 240 are segments including a second strike out 316 , a second home run 318 , a pop out 320 , and a walk 322 . First base 240 is as a designed segment is a second single.
Located along the base path 200 between first base 240 and second base 260 are a second plurality of segments 400 . The segments 400 are generally identified as various occurrences in the sporting event. For instance, in a baseball game the occurrences between first base 240 and second base 260 include a walk 402 , a ground out 404 , a pop out 406 , a home run 408 and a fly out 410 .
Also located along the base path 200 between second base 240 and third base 260 are a single 412 , a ground out 414 , a fly out, 416 , a double 418 and a strike out 420 . Second base 260 as a designed segment is a ground out.
Located along the base path 200 between second base 260 and third base 280 are a third plurality of segments 500 . The segments 500 are generally identified as various occurrences in the sporting event. For instance, in a baseball game the occurrences between second base 260 and third base 280 include a strike out 502 , a home run 504 , a ground out 506 , a double 508 , a single 510 , and a fly out 512 , Also located between second base 260 and third base 280 include a pop out 514 , a single 516 , a home run 518 , and a strike out 520 . Third base 280 as a designed segment is a fly out.
Located along the base path 200 between third base 280 and home plate 220 are a fourth plurality of segments 600 . The segments 600 are generally identified as various occurrences in the sporting event. For instance, in a baseball game the occurrences between third base 280 and home plate 220 include a strike out 602 , a single 604 , a pop out 606 , a fly out 608 , and a home run 610 . Also located between third base 280 and home plate 220 are a walk 612 , a ground out 614 , a home run 616 , a double 618 and a strike out 620 . Home plate 220 is designated as a ground out.
While the method of playing the game is baseball it could be any sport which allow the participants sufficient time to make decisions on the course of action to take given a specific situation. Thus any of several sports including American football may be the subject of the interactive board game 10 .
The interactive board game 10 is played while watching a sporting event over which the participant has no control other than the participant's knowledge of the sport, the likely choice of action of the coach, and the participant's knowledge of the sporting event player's ability which results in the independently determined action of the sporting event.
The interactive board game 10 equipment comprises 10 batter cards 70 , 1 special red bonus card 80 , 1 special blue stolen base card 90 , one set of 9 player cards 50 , the board and an appropriate number of game pieces 30 , i.e. one for each participant.
The interactive board game, as applied to baseball begins before the underlying sporting event. Each participant is randomly dealt 10 cards 70 (Batter) from a shuffled deck of the cards 70 (Batter). Typically, the deck of cards 70 (Batter) will have 60 cards corresponding to the segment 300 , segment 400 , segment 500 and segment 600 . Each participant is also given 1 card 80 (bonus card) and 1 card 90 (Stolen Base Card).
The object of the interactive board game 10 is to be the first participant to score and win the game by going around the segments to first base 240 , second base 260 , and third base 280 , and ultimately reaching home plate 220 , Play of the interactive board game 10 commences with the participant(s) placing one of the 9 player cards 50 in play in front of the participant(s). Each participant(s) may also set one of the participant(s) batter cards 70 in the in play in front of the participant(s). The selection of the player cards 50 and the batter cards 70 each participant attempts to move off home plate 220 toward first base 240 by “predicting” or “guessing” what each batter will do (the independently determined action of the sporting event).
If the participant correctly determines what the batter does (the independently determined action of the sporting event) the participant moves the participant's game piece 30 according to the value assigned to the player cards 50 and the batter cards 70 along the segments 300 , If the participant correctly determines what the batter does (the independently determined action of the sporting event) the batter card 70 is retained, if not the batter card 70 is surrendered and is out of play for the rest of the game. The player card 50 is retained by the participant for the entire game regardless of whether the independently determined action of the sporting event is correctly predicted.
As an example of scoring for example, a participant may play the batter 70 as a single by putting the participant's player card bearing the designation single in play. If the batter in the sporting event singles, that participant moves ahead 1 space. If the same participant had also played a batter card 70 bearing the designation single that participant would be entitled to additional 2 spaces.
As an additional feature of the invention, when a participant's game piece 30 lands on certain of segments 300 , segments 400 , segments 500 , or segments 600 including, but not limited to first base 240 , second base 260 , third base 280 that participant is entitled to pick up one batter card 70 from the remaining batter cards 70 in the pile.
As an additional feature of the invention, when a participant's game piece 30 is one on of the one of the segments 300 , segments 400 , segments 500 , or segments 600 , for example ground out 310 , and the participant moves ahead one segment to single 312 regardless of whether the player card 50 and the batter card 70 are correctly played if the player card 50 and the batter card 70 are correctly played then the corrects situation results in the moving of the game piece 30 as previously described.
All player cards 50 are worth one space except double cards and home run cards, which are each worth two spaces, and triple cards which is worth 3 spaces. Batter cards 70 values are double the value of the corresponding player cards 50 . For example, if a participant is on a segment marked home run (value=2 segments), the participant plays a home run player card 50 (value=2 segments), and the participant also plays a home run batter card 70 (value=4 segments) and the batter hits a home run, that participant would move ahead a total of 8 segments. A fly out is a fly ball caught by an outfielder. A pop out is any ball caught by an infielder. A hit batter is a walk. If an error is made the play is what should have happened. In other words, if an outfielder drops a fly ball and it is declared an error, it is counted as a fly out.
A stolen base card 90 can be used in place of a batter card and is worth 3 spaces. As soon as the runner steals, is caught stealing or the batters at bat is over, the blue stolen base card 90 is retired for that game, while a white stolen base card 90 is put in the discard pile, regardless of the outcome.
The bonus cards 80 may be used in place of a batter card 70 and are worth two value segments, except when used on first base 240 , second base 260 , third base 280 in which case they are worth four segments. A bonus card 80 , regardless of what the batter does, moves your player ahead two or four segments. As with the stolen base cards 90 , the red bonus cards 80 are, once used, retired for the game, while the white bonus cards 80 are put in the discard pile.
The game can be started or ended at any point of the real baseball game. Suggestions for a shorter game are for three or six innings, with who ever being furthest along the board declared the winner. The first participant to reach or cross home plate is the winner. If no participant reaches home by the time the game is over, the participant furthest around the board is the winner. If more than one participant reaches or crosses home at the same time, the person with the most batter cards 70 left wins. Otherwise, the game is a tie.
By way of strategy a participant should try to use the batter cards 70 sparingly, as you can run out of them fairly quickly. If the participant plays the cards right you could have a few batter cards 70 to play near the end to finish strong. The participant is wise to use a bonus card 80 to get started and/or save the bonus card 80 for those bases, where they are worth double.
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The present invention permits the period of inactivity in a sporting event, particularly a televised sporting event, to be utilized productively according to the knowledge of the viewer of the a televised sporting event. According to the present invention a game is played during a sporting event utilizing a game board and several sets of cards.
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FIELD OF THE INVENTION
The invention relates generally to the field of high voltage sensors for use on digging implements. In particular, the invention relates to a high voltage sensor that may be used to detect the presence of high voltage cables that are buried underground.
BACKGROUND OF THE INVENTION
Work vehicles, including, but not limited to construction work vehicles such as front loaders, backhoes, drills, and boring equipment, can be configured with sensing equipment, that senses the presence of hazards underground.
Many such sensing devices sense the presence of high voltage cables by sensing high voltages or by sensing voltage gradients in the earth. A single alarm is sounded if the voltages or voltage gradients surpass a predetermined limit. Conventional sensors do not provide multiple alarms corresponding to different conditions of the boring or digging equipment with respect to the high voltage lines and soil conditions. For example, an alarm is only sounded when a voltage predetermined limit is exceeded because the boring or digging equipment has contacted a high voltage line. Using predetermined limits and latching the signal has the disadvantage that false triggering may occur due to a single aberrational voltage spike in the sensing equipment.
Due to the critical need and critical nature of high voltage sensors on drilling equipment, it is important that the sensing equipment be easily tested. Conventional sensing systems require that the sensor be placed in a situation where a high voltage source is present, the sensor is then placed in contact with the source to test the alarm. The clear disadvantage to a system of this type is that it requires a high voltage line to be provided to and exposed to the sensor system.
Thus, it would be desirable to have a high voltage sensor that picks up stray electrical current from a damaged or exposed high voltage line through the earth. Because the earth has a very high impedance to the flow of electricity, it is not desirable to rely on the magnitude of the current sensed by the sensor system. Thus, it would be desirable to have a high voltage sensor that interprets the characteristics of the electrical signal being received by the sensor system. It would also be desirable for an alarm to sound when the drilling tool hits a high voltage line, the drilling tool remains in contact after hitting the high voltage line, and the drilling tool is in close proximity to an exposed or damaged high voltage line.
Because sensor systems dealing with high voltages and large currents are susceptible to damage caused by overload of sensor elements, it would be desirable to have a high voltage invasive sensor with a self-tester that checks the sensor's functionality and the integrity of all of the relevant connections before and during each use. It would be desirable to have a self-tester of this type integrated into the circuitry of the sensor system. Furthermore, it would also be desirable to have a high voltage sensor having rejection circuitry that rejects incoming electrical signals that could possibly cause damage to the sensor electronics.
SUMMARY OF THE INVENTION
The present invention relates to a sensor system for a drilling implement adapted to detect the presence of a high voltage line buried in the earth during drilling. The sensor system includes an alternating current (AC) probe that senses a first electrical signal from the high voltage line when the high voltage line is present. The sensor also includes an AC sensing circuit receiving the first electrical signal from the probe and providing a second electrical signal representative of the first electrical signal. The sensor system also includes an amplifier circuit having an input and an output. The input receives a third electrical signal representative of the second electrical signal and is configured to amplify the third electrical signal and provide a fourth electrical signal representative of the first electrical signal. The fourth electrical signal can be utilized to produce an alarm signal when the high voltage line is present.
The present invention also relates to a method of detecting the presence of high voltage lines underground. The method includes sensing by using an alternating current sensor. The method also includes converting the alternating current sensed to a first electrical signal. The method further includes rectifying the first electrical signal into a second electrical signal. Further still, the method includes providing an alarm when the second electrical signal corresponds to a predetermined characteristic.
Further, the present invention relates to a sensor system adapted to detect the presence of high voltage lines during underground operations. The sensor system includes means for sensing an alternating current underground by using an alternating current sensor. The system also includes means for converting the current sensed into a first electrical signal and means for bidirectional clipping the first electrical signal into a second electrical signal. The sensor system further includes means for providing an alarm when the second electrical signal corresponds to a predetermined characteristic.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will become more fully understood from the following detailed description, taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts, in which;
FIG. 1 is a block diagram of a drill showing a high voltage sensor;
FIG. 2 is a generalized block diagram of the high voltage sensor circuit; and
FIG. 3 is a circuit diagram of the high voltage sensor circuit shown in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a horizontal drilling system 10 is depicted, representative of drilling or boring equipment, or any other type of digging or excavating equipment. Drilling system 10 includes a supporting frame 12, a power source 14, a drilling implement or probe 18 (the body of the vehicle, drill bit and probe are electrically transparent) an equipment earth ground 15, an insulated grounding stake 16 and a sensor system 20. In a preferred embodiment, drilling system 10 is a horizontal direction drilling (HDD) machine. The HDD is capable of drilling channels underground up to a mile or more in length and is steerable in four directions. In operation, drilling system 10 bores a hole 22 into the earth 24. Engine 14 drives drilling implement 18 into earth 24 creating hole 22. Probe 18 itself is the drill bit which is attached to the drilling implement. Probe 18 is electrically connected to body sheet metal of the equipment. The equipment may have one or more earth connection for safety. At relatively higher voltages and currents, these earth connections become completely useless. High voltage lines 26 may be buried underneath the surface of earth 24. High voltage lines 26 may have alternating current (AC) voltages anywhere from 75 volts (AC) up to 4,000 volts (AC) or more. Lines 26 typically are insulated lines, however current may escape from lines 26 if the insulation is damaged (cracked or broken) or if the insulation is breached by probe/drilling implement 18. Probe 18 and sensor system 20 are configured to sense the close proximity or the contacting of drilling implement 18 to underground high voltage line 26. Typically the earth will conduct small amounts of current due to the inherent moisture and other conducting materials in the earth.
Referring now to FIG. 2, sensor system 20 includes equipment earth ground 15, an insulated grounding stake 16, probe 18, a current sensing circuit 25, a clipping circuit 28, a self-test circuit 29, an amplifier circuit 30, a comparator circuit 32, and an alarm output device, shown as a speaker 34. Sensor system 20 uses the magnitude of the small pulsating alternating loop current between the live wire (i.e., high voltage line 26) and the nearby single-earth connection through a grounding stake 16. The current is picked up by probe 18, communicated to current sensing circuit 25 along connection 19, and returned to the earth by equipment earth ground 15 and also through grounding stake 16. Current sensing circuit 25 communicates a signal along connection 23 to clipping circuit 28. Clipping circuit 28 converts the AC signal communicated along connection 19 into an amplitude-limited or "clipped" sinusoidal signal. The clipped sinusoidal signal is communicated along a connection 27 to amplifying circuit 30, which in a preferred embodiment is a transistor amplifier that avoids noise pick up and also maintains the input characteristic. Amplifying circuit 30 amplifies the amplitude-limited high voltage signals, converting the incoming sinusoidal signal into a substantially square wave signal. (Alternatively, other amplifier circuits known to those of ordinary skill in the art may be used and other preferred signal waveforms may be obtained.) The square wave signal is communicated along a connection 31 to a comparator circuit 32.
Comparator circuit 32 compares the square wave signal to a direct current (DC) reference voltage signal. In a preferred embodiment, if the reference voltage is exceeded by the magnitude of the square wave signal, an alarm signal is communicated over connection 33 to speaker 34. (Alternatively, speaker 34 may be any suitable output device including, but not limited to a visual output on a display screen, an indicator lamp or LED, or an electrical signal communicated to a device controlling drill 10.) The speaker sound is modulated at a rate determined by the frequency of the sensed alternating current. (Conventionally this is at a rate of 60 Hz, however other frequencies such as 50 Hz, especially found in non-U.S. countries, may be sensed.) Any number of alarm sounds corresponding to different signal characteristics input to speaker 34 may be used to represent different drilling conditions (including soil moisture content, e.g.) with regards to high voltage line 26 or a single alarm sound may be used to alert an operator to a hazardous condition. To identify different drilling conditions a signal processing device (not shown) may be used to distinguish between different signal characteristics.
Referring now to FIG. 3, probe 18 is configured to pick up very small leakage currents between high voltage line 26, drilling implement 18, and earth 24. These leakage currents are typically on the order of few tens of microamps (μA), when the drill bit at the end of implement 18 has not contacted high voltage line 26. When insulation is breached on high voltage line 26, probe 18 is configured to pick up currents with a relatively high amperage.
When a current is picked up by probe 18 or drilling implement, the current from probe 18 is communicated through current sensing circuit 25 including a resistor 42, the secondary winding 44 of a transformer 46, and a second resistor 48. The combination of resistor 42, secondary winding 44, and resistor 48 is used to dissipate energy when a high voltage line is contacted directly and large currents flow through probe 18. The series combination of resistors R1 and R2 are preferably on the order of 2-3 Megaohms (MΩ). Alternatively, any combination of resistors having a suitable total magnitude may be used. Furthermore, other energy dissipating devices may replace the series resistors 42 and 48.
After a portion of the incoming energy has been dissipated in resistor 42, secondary winding 44, and resistor 48, the current signal flows to clipping circuit 28. Clipping circuit 28 includes a diode 52, a diode 54, a diode 56, a diode 58, a capacitor 60, a capacitor 62, and a capacitor 64. Diodes 52, 54, 56, and 58 are all voltage-limiting diodes. The series combination of diodes 52 and 54 clip the positive cycle of the incoming sinusoidal signal. In a preferred embodiment, the limiting voltage will be about 1.4 volts, however other limiting voltages may be used without departing from the spirit and scope of the present invention. The main goal of clipping circuit 28 is to prevent subsequent electronics from being exposed to high voltages, that is voltages of the Kilovolt (KV) magnitude. In other words, clipping circuit 28 prevents the base of a transistor 66 from being exposed to more than the limiting voltage of 1.4 volts. Diodes 56 and 58, having an opposing polarity to diodes 52 and 54, are configured in series to clip the negative cycle of the incoming sinusoidal signal. Capacitor 60 acts as a low-pass filter to block out any high-frequency components of the incoming signal. Capacitor 62 is used as a direct current block to prevent any DC component of the sinusoidal signal from entering the base of transistor 66. Further, capacitor 64 is also configured as a filtering element to filter out any undesirable frequency components. Capacitor 60, which acts as a low pass filter also is used to prevent any momentary high voltage spikes from entering the base of transistor 66. Preventing spikes may be important in the case of any static charges entering the system or any high frequency interference caused by devices like cellular phones which could possibly trigger the unit.
The clipped sinusoidal signal 65 is communicated to an amplifying circuit 30 (FIG. 2), shown as a class A single ended current amplifier circuit 68 (FIG. 3). Single ended current amplifier circuit 68 includes a transistor 66, such as a bipolar junction transistor or any type of suitable general purpose transistor. Single ended current amplifier circuit 68 also includes resistors 70, 71, 72, and 73. The configuration of resistors 70, 71, 72, 73, and transistor 66 forms a standard class A transistor amplifier which is well known to those of ordinary skill in the art. Single ended current amplifier circuit 68 is configured to be operated by a single power supply 86, wherein this configuration inherently amplifies the amplitude-limited high voltage signals. However, any of a number of other transistor amplifiers may be applied in place of single ended current amplifier circuit 68, or any of a number of other amplifying devices may be substituted for single ended current amplifier circuit 68 without departing from the spirit and scope of the present invention.
Single ended current amplifier circuit 68 has an output signal 74, associated therewith. Output signal 74 communicates an amplified and slightly modified version of signal 65. Output signal 74 is substantially a square wave signal. The square wave is communicated to a comparator 76. Comparator 76 compares the maximum values of square wave 74 with a DC reference voltage 78 generated by a reference voltage source 79. DC reference voltage 78 may be, in a preferred embodiment 7 or 8 volts, however any suitable DC reference voltage may be used without departing from the spirit and scope of the present invention. Comparator 76 compares output signal 74 and DC reference voltage 78. If output signal 74 moves beyond the magnitude of reference voltage 78, comparator 76 outputs a signal along line 80 which activates a transistor 82. Transistor 82 may be a field effect transistor (FET) switch, a junction field effect transistor (JFET), or a depletion-mode metal-oxide semiconductor field effect transistor (MOSFET) or any other suitable switching device. When transistor 82 is activated by a signal communicated along line 80, a buzzer or any other suitable alarm is output at speaker 34. Speaker 34 may be replaced by any other suitable output device including but not limited to an indicator lamp or a LED, a CRT display signal, or any other suitable alarm signals. In a preferred embodiment of the present invention, buzzer 34 is modulated at the same frequency as the signal sensed by probe 18. Comparator 76 can generate a limited range of variable duty cycle square waves corresponding to at least two distinct sounds, each sound being indicative of earth conductivity.
In a preferred embodiment of the present invention, self-test circuit 29 is included in the electronics of sensor system 20. The self-test circuit includes power source 86 (which also powers comparator 76 and transistor 82), a switch 88, a high voltage generator 90, and transformer 46. Transformer 46 includes secondary windings 44, and primary windings 92 electrically coupled to high voltage generator 90. Power source 86 is, in a preferred embodiment, the drilling system battery. When an operator wishes to test the sensor circuit, switch 88 is manually closed causing a current to flow to high voltage generator 90 and thereby activating high voltage generator 90. High voltage generator 90 induces a current to flow between grounding stake 16 and probe 18 and/or between grounding stake 16 and ground 15. In operation, when switch 88 is closed, high voltage generator 90 produces a high AC voltage across primary windings 92 of transformer 46 which induces an AC voltage (e.g., 110 V AC ) across secondary windings 44 of current sensing circuit 25. Thus, the actuation of switch 88 induces an electrical signal in current sensing circuit 25 which is similar to the electrical signal which would be induced when probe 18 is used to detect the presence of high voltage lines 26 during actual digging operations. In a preferred embodiment, however any other suitable alternating voltage may be used as long as it has the capability of triggering the alarm. Once a current is generated in secondary windings 44, the sensor circuit operates the same as if probe 18 had contacted a high voltage line. Thus, if the circuit is operating correctly an alarm should be produced.
Although only a few exemplary embodiments of this invention have been described above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. As is readily indicated, the invention can be employed in a variety of ways and on a variety of drilling and excavating equipment. Further, the precise circuitry disclosed may be varied insofar as it continues to accomplish functions related with the high voltage sensor. Further, the output signals created by the signal processor may be any of a variety of alarm signals. Accordingly, all such modifications are intended to be included within the scope of the invention as defined in the following claims. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions and arrangement of the preferred and alternative embodiments without departing from the spirit of the invention as expressed in the appended claims.
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A sensor system for use on drilling equipment to detect the presence of high voltages during horizontal or vertical drilling and providing an alarm signal corresponding to one of three possibilities: (1) the drilling tool hitting a high voltage line; (2) the drilling tool remaining in contact after hitting the high voltage line; and (3) an exposed or damaged high voltage line in close proximity to the drilling implement. The sensor system detects alternating current, converts the alternating current signal to a pseudo square waveform signal, compares the magnitude of the square waveform signal with a reference voltage, and sounds an alarm if the magnitude of the square waveform signal exceeds the reference voltage. The sensor system also incorporates a self-test circuit which allows an operator to check its functionality before use. The operator can also check the sensor at any time during drilling process.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to stabilized, encapsulated fuels and methods for the encapsulation of fuels. More particularly, the invention relates to the encapsulation of water reactive, hydrogen gas generating fuels.
[0003] 2. Description of the Related Art
[0004] Similar to batteries, fuel cells function to produce electricity through chemical reactions. Rather than storing reactants as batteries do, fuel cells are operated by continuously supplying reactants to the cell. In a typical fuel cell, hydrogen gas acts as one reactant and oxygen as the other, with the two reacting at electrodes to form water molecules and releasing energy in the form of direct current electricity. This direct current electricity may then be converted into an alternating current. The apparatus and process may produce electricity continuously as long as hydrogen and oxygen are provided. While oxygen may either be stored or provided from the air, it is generally necessary to generate hydrogen gas from other compounds through controlled chemical reactions rather than storing hydrogen, because storing hydrogen gas requires that it either be compressed or cryogenically cooled. As fuel cell technology evolves, so do the means by which hydrogen gas is generated for application with fuel cells.
[0005] Currently, there are various methods which are known and employed for generating hydrogen gas. One method is by a process known as reformation in which fossil fuels are broken down into their hydrogen and carbon products. However, this system is undesirable in the long term because it is dependent upon a non-renewable resource. Another means of generating hydrogen gas is by reversibly adsorbing and releasing hydrogen gas from metal hydrides or alloys through heating. While this method is useful, it is not preferred because the metal hydrides are typically very heavy, expensive and only release small quantities of hydrogen. Yet another means by which hydrogen gas is generated is through reactive chemical hydrides. This process involves chemically generating hydrogen gas from dry, highly reactive solids by reacting them with liquid water or acids. Chemicals especially suitable for this process are lithium hydride, calcium hydride, lithium aluminum hydride, sodium borohydride and combinations thereof, each of which is capable of releasing plentiful quantities of hydrogen. Compared to the above methods, the use of reactive chemical hydrides is highly desirable in the art, particularly for generating power for use by small, portable electronic devices, such as cellular phones. However, it also has its disadvantages. For example, it has been found that the reaction products from the chemical hydride and liquid water typically form a cake or pasty substance which interferes with further reaction of the reactive chemical with the liquid water or acid. Furthermore, the reaction of chemical hydrides with liquid are difficult to control, and typically generally results in the production of much more hydrogen gas than needed to power such small electronic devices.
[0006] In order to combat this problem, methods have been introduced wherein a hydrogen fuel can be reacted with only gaseous water vapor, instead of liquid water. For example, U.S. Pat. No. 4,155,712 teaches an apparatus for generating hydrogen by the reaction of a metal hydride with water vapor, wherein a water reservoir is provided and the metal hydride is housed in a separate fuel chamber. A liquid water source is provided in a water chamber, and water molecules from the liquid water source are introduced into the fuel chamber by diffusing through a porous membrane. U.S. Pat. No. 4,261,955 also teaches an apparatus for generating gas by the reaction of a metal hydride fuel with water vapor, wherein water vapor from a liquid water reservoir is introduced into a fuel chamber through a pair of spaced porous hydrophobic membranes. In each of these designs, an elaborate power generator system is required in order to regulate the quantity of water vapor that reacts with the chemical fuel and to regulate the reaction rate of water vapor with the chemical fuel.
[0007] It would be desirable in the art to provide a method in which the rate of reaction between water molecules and a water reactive chemical fuel can be regulated independently of the apparatus containing the chemical fuel. Further, it has been discovered that hydrogen gas generators that operate based on reactions between a chemical hydride and water can explode or generate hydrogen at an excessive rate if they are damaged and the chemical hydride is exposed to liquid water. Accordingly, it would be further desirable in the art to provide a secure fuel system for a hydrogen gas generator wherein the hydrogen generation rate is limited such that the generator will not explode or rapidly generate hydrogen gas if the generator is damaged.
[0008] The present invention provides a solution for this need in the art. The invention provides a stabilized, or passivated, chemical hydride which is encapsulated in a water vapor permeable, liquid water impermeable material, such as Gore-Tex®. Alternately, the chemical hydride may be coated with an oil or rubber substance to passivate the surface of the chemical fuel and prevent liquid water permeation while allowing water vapor permeation.
SUMMARY OF THE INVENTION
[0009] The invention provides an encapsulated fuel comprising a solid, water reactive fuel which fuel is encapsulated by a water vapor permeable, liquid water impermeable material.
[0010] The invention also provides a process for producing an encapsulated fuel comprising substantially encapsulating a solid, water reactive fuel with a water vapor permeable, liquid water impermeable material.
[0011] The invention further provides a power generator apparatus comprising a fuel chamber, which fuel chamber contains an encapsulated fuel comprising a solid, water reactive fuel which fuel is encapsulated by a water vapor permeable, liquid water impermeable material.
[0012] The invention still further provides an electrical power generator comprising:
[0000] a) a housing;
[0013] b) at least one fuel cell mounted within the housing, the fuel cell comprising a cathode, an anode and a water vapor permeable electrolytic membrane positioned between the cathode and the anode; which fuel cell is capable of generating electricity and fuel cell water at the cathode by the reaction of hydrogen gas and oxygen gas;
[0000] c) at least one fuel chamber mounted within the housing, which fuel chamber contains an encapsulated fuel comprising a solid, water reactive fuel which fuel is encapsulated by a water vapor permeable, liquid water impermeable material;
[0000] d) at least one air inlet for admitting atmospheric air into the housing;
[0000] e) a water retention zone within the housing extending from the air inlet to the fuel cell cathode, which water retention zone deters the diffusion of generated fuel cell water out of the air inlet; and
[0000] f) a cavity within the housing extending from the fuel cell to the fuel chamber, which admits a flow of hydrogen gas from the fuel chamber to the fuel cell, and which admits a flow of water vapor from the fuel cell to the fuel chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates a cross-sectional schematic representation of a power generator including encapsulated fuel pellets of the invention.
[0015] FIG. 2 illustrates a schematic representation of an encapsulated fuel pellet of the invention, including a cut out portion showing a layer of water vapor permeable, liquid water impermeable material surrounding a fuel substance.
[0016] FIG. 3 illustrates a schematic representation of an encapsulated fuel of the invention, wherein a layer of a water vapor permeable, liquid water impermeable material is wrapped around a fuel substance.
[0017] FIG. 4 is a schematic representation of a fuel cell.
DETAILED DESCRIPTION OF THE INVENTION
[0018] A stabilized fuel system for use in a hydrogen generating device is provided. The stabilized fuel system comprises an encapsulated fuel 10 which is encapsulated by a water vapor permeable, liquid water impermeable material. As used herein, the term “encapsulated fuel” defines a fuel 14 which is enclosed by a protective coating or membrane 16 . The fuels of the invention are particularly useful in hydrogen gas generating power generators that incorporate one or more fuel cells. See, for example, FIG. 1 which illustrates a cross-sectional view of a preferred power generator 20 that incorporates the encapsulated fuels 10 of the invention. Reaction of the fuel substance 14 with water vapor produces hydrogen gas that is used by the fuel cells 18 of a power generator 20 to generate electricity.
[0019] As seen in FIG. 1 , a preferred power generator 20 includes a generator housing 22 , a fuel chamber 12 within the housing 22 , which fuel chamber 12 holds the encapsulated fuels 10 ; at least one fuel cell 18 mounted within the housing 22 ; and a cavity 30 within the housing 22 extending from the at least one fuel cell 18 to the fuel chamber 12 . Cavity 30 admits a flow of hydrogen gas from the fuel chamber 12 to the fuel cell 18 , and admits a flow of water vapor from the fuel cell 18 to the fuel chamber 12 . Fuel cell 18 generates electricity and fuel cell water from the reaction of hydrogen gas and oxygen gas, e.g. oxygen from the air. In the embodiment of FIG. 1 , atmospheric oxygen enters into the housing 22 through at least one air inlet 32 . The oxygen gas then travels to the fuel cell 18 where it reacts with hydrogen gas, generating electricity and water molecules. The type of fuel cell exemplified herein is well known in the art and is referred to in the art as a Proton Exchange Membrane (PEM) fuel cell, also known as a Polymer Electrolyte Membrane.
[0020] As seen in FIG. 4 , a typical PEM fuel cell comprises an electrolytic membrane 26 positioned between a negatively charged electrode, or cathode 24 , on one side of the membrane, and a positively charged electrode, or anode 28 , on the other side of the membrane. In typical hydrogen-oxygen PEM fuel cell behavior, a hydrogen fuel (e.g. hydrogen gas) is channeled through flow field plates to the anode, while oxygen is channeled to the cathode of the fuel cell. At the anode, the hydrogen is split into positive hydrogen ions (protons) and negatively charged electrons. The electrolytic membrane allows only the positively charged ions to pass through it to the cathode. The negatively charged electrons must instead travel along an external circuit to the cathode, creating an electrical current. At the cathode, the electrons and positively charged hydrogen ions combine with oxygen to form water molecules.
[0021] While the encapsulated fuels 10 of the invention are suitable for use with any type of power generator design that utilizes hydrogen-oxygen fuel cells, the power generator illustrated in FIG. 1 is a particularly preferred “waterless” power generator embodiment that is capable of producing hydrogen gas and electricity without an independent water supply. Inside the generator, on the anode 28 side of the fuel cell, an initial flush of hydrogen gas is preferably provided to remove residual air from within the power generator. This initial flush of hydrogen gas serves a dual purpose, as it will also react with atmospheric oxygen at the fuel cell, generating an initial amount of electrical energy and generating an initial amount of fuel cell water at the fuel cell cathode 24 . This initial amount of fuel cell water is then reclaimed and reacted with the fuel substance 14 . Alternately, hydrogen generation may be initiated by the permeation of water molecules from the humidity of the atmosphere outside the power generator, through the air inlet 32 , and into the power generator. Although less preferred, it is also possible to add an initial amount of non-fuel cell water to the generator, in an amount substantially less than the amount of fuel cell water generated by the fuel cell, to react with the fuel substance 14 and initiate hydrogen gas generation. Such start-up water may be added to the generator, for example, through an opening in the fuel chamber 12 , or through another suitable means, such as through air inlet 32 . However, the preferred process and apparatus utilizing the encapsulated fuels 10 of the invention are designed to operate without an externally provided water supply, i.e. the system is water-less except for water that is generated by the fuel cell and water molecules present in the atmosphere outside of the power generator. There is no incorporated or connected water supply, such as a water chamber or water reservoir, to provide water for reaction with the hydrogen fuel substance. This results in a significant improvement in the energy density and specific energy of the power generator compared to conventional systems. Accordingly, it is a continuous, self-regulating process since the hydrogen-oxygen reaction produces exactly the required water corresponding to the electrical power generated, wherein stoichiometric amounts of recycled water and solid fuel are used.
[0022] The preferred power generator 20 is also preferably passive, running without actively controlled valves or pumps. More particularly, once water is formed as a by-product of the oxygen-hydrogen reaction at the fuel cell 18 , the produced water passively diffuses back through the fuel cell 18 , into the cavity 30 and to the fuel chamber 12 . This passive diffusion is enabled in part due to one or more water retention zones 34 , and in part due to the low humidity inside the cavity 30 . Water retention zone 34 comprises the channel extending from the air inlet 32 to each the fuel cell cathode 24 . A water retention zone 34 is present at each fuel cell 18 which generates fuel cell water. Due to the geometry of the water retention zone 34 , diffusive water loss of fuel cell generated water molecules out of the air inlet is deterred, thereby maintaining a high concentration of water vapor at the fuel cell cathode 24 . Instead of losing water molecules to the ambient air, water retention zone 34 causes generated water molecules to accumulate at the cathode 24 , creating a region of high humidity between the cathode 24 and air inlet 32 .
[0023] During operation of the power generator, more generated water vapor will diffuse back into the cavity than is lost out of the air inlet. Furthermore, fuel cell output is directly dependent on the flow of oxygen and hydrogen reactants to the fuel cells, and hence the flow of water vapor the fuel chamber. Accordingly, fuel cell output is proportional to the ratio of the area of the water retention zone to its length. Preferably, the ratio of zone area to zone length per unit of power is from about 0.01 cm/mW to about 0.05 cm/mW of power output for a single fuel cell. If multiple fuel cells are incorporated, this ratio of zone area to zone length per unit of power is divided by the number of fuel cells which share the reactants. The preferred dimensions of the component parts of the power generator 20 are preferably very small in scale, but may also vary with respect to the use of the power generator 20 . The power generator of the invention is particularly useful as a micro-power generator for powering miniature devices such as wireless sensors, cellular phones or other hand held electronic devices that are electrically connected to the anode and cathode of the one or more fuel cells.
[0024] In the preferred embodiments of the invention, the fuel substance 14 preferably comprises a non-fluid, hygroscopic, porous material in powder, granule or pellet form that allows for the diffusion of gases and vapors. Preferred materials non-exclusively include alkali metals, calcium hydride, lithium hydride, lithium aluminum hydride, lithium borohydride, sodium borohydride and combinations thereof. Suitable alkali metals non-exclusively include lithium, sodium and potassium. The preferred material for the fuel substance 14 is lithium aluminum hydride. As is well known in the art, when contacted with water molecules, these fuel substances react, releasing hydrogen gas. The fuel substance 14 may optionally be combined with a hydrogen generation catalyst to catalyze the reaction of the water vapor and the non-fluid substance. Suitable catalysts are well known and include cobalt, nickel, ruthenium, magnesium and alloys and combinations thereof.
[0025] FIG. 2 illustrates a schematic representation of an encapsulated fuel pellet 10 encapsulated with a water vapor permeable, liquid water impermeable coating 16 . In general, the water vapor permeable, liquid water impermeable material 16 may comprise any material having such properties, and includes porous polymer films and fabrics, as well as oils and rubbers. The fuels 14 may be encapsulated using any suitable method which would be appropriate for the chosen encapsulation material, such as wrapping, coating and the like using conventional, well known techniques. FIG. 3 provides a schematic representation of an encapsulated fuel 10 of the invention wherein a layer of a water vapor permeable, liquid water impermeable material 16 is wrapped around the fuel substance 14 .
[0026] In a preferred embodiment of the invention, the water vapor permeable, liquid water impermeable material 16 comprises a micro-porous polymeric film. Preferred polymeric films non-exclusively include mono- and multilayer fluoropolymer containing materials, a polyurethane containing materials, polyester containing materials or polypropylene containing materials. Suitable fluoropolymer containing materials include polytetrafluoroethylene (PTFE) polymers, expanded polytetrafluoroethylene (ePTFE) polymers, perfluoroalkoxy polymers (PFA) and fluorinated ethylene-propylene (FEP) polymers. Particularly preferred fluoropolymer containing materials are films and fabrics commercially available under the Gore-Tex®, eVent® and HyVent® trademarks. Gore-Tex® is an e-PTFE material commercially available from W.L. Gore and Associates of Newark, Del., and eVENT® is a PTFE material manufactured by BHA technologies of Delaware. HyVent® is polyurethane containing material commercially available from The North Face Apparel Corp., of Wilmington, Del. Of these, ePTFE GORE-TEX® materials are preferred.
[0027] Each of these materials may be in the form of single or multilayer films or fabrics, or as coatings, and are known as waterproof, breathable materials. Breathable membranes are typically constructed from a micro-porous layer of expanded PTFE, polyurethane or polypropylene that is laminated to the face of a film such as nylon or polyester. Breathable coatings are typically formed by spreading a thin layer of a micro-porous or hydrophobic polymer directly on the surface of a material, such as the solid fuels of the invention. Breathability is generally measured in two ways. In one method, the water vapor transmission rate of a material may be tested as a rating in grams of how much vapor a square meter, or alternately 100 in 2 , of fabric will allow to pass through in 24 hours (g/m 2 /24 hours or g/100 in 2 /24 hours). Conventional testing methods include the procedures set forth in ASTM E-96 Method B and the procedures set forth in ASTM F1249. The second method is known as Evaporative Resistance of a Textile (RET). The lower the RET, the higher the breathability, i.e. the greater the amount of moisture that will pass through. For the purposes of this invention, the preferred films or fabrics of the invention have a breathability as determined by the ASTM E-96 Method B test of from about 100 g/m 2 /24 h to about 10,000 g/m 2 /24 h, more preferably from about 500 g/m 2 /24 h to about 2000 g/m 2 /24 h and most preferably from about 700 g/m 2 /24 h to about 1200 g/m 2 /24 h. The micro-porous materials generally have a pore size of from about 0.001 μm to about 1 μm in diameter, and a thickness of from about 0.1 μm to about 100 μm. The porosity and thickness of the materials can be tailored to give a desired water vapor flux, while preventing liquid water penetration. In the preferred embodiment of the invention, the preferred films or fabrics have a pore size of from about 0.001 μm to about 1 μm, more preferably from about 0.01 μm to about 0.5 μm, and most preferably from about 0.05 μm to about 0.1 μm. Further, in the preferred embodiment of the invention, the preferred films or fabrics have a thickness of from about 0.1 μm to about 100 μm, more preferably from about 0.5 μm to about 10 μm, and most preferably from about 1 μm to about 5 μm.
[0028] In another preferred embodiment of the invention, the water vapor permeable, liquid water impermeable material 16 comprises a micro-porous oil or rubber coating. Preferred oils non-exclusively include mineral oil, petroleum based oils consisting primarily of saturated hydrocarbons, oily solvents such as xylene, and paraffin waxes. Preferred rubbers non-exclusively include curable rubber, isoprene, silicone, polyurethane, neoprene, and fluoropolymer based rubbers, particularly fluoropolyether based rubbers. Of these, fluoropolymer based rubbers are preferred. Any conventional coating method may be used to encapsulate the fuel substance 14 with a micro-porous oil or rubber coating. For example, a fuel substance 14 may be mixed with an oil or rubber solution, a solvent and a curing agent to form a blend, which blend is warmed and stirred to a desired consistency, granulated, dried and optionally pelletized. Suitable solvents for forming an oil or rubber solution non-exclusively include ketones such as methyl ethyl ketone, methyl isobutyl ketone, ethers and esters. Suitable curing agents non-exclusively include organosilanes containing at least one isocyanate group. Such blends may be formed in a suitable vessel at a temperature of from about 0° C. to about 1000° C., more preferably from about 20° C. to about 500° C., and dried for from about 1 to about 24 hours. Useful granulation and pellet forming techniques are well known in the art. In addition to covering the surfaces of the fuel or fuel pellets, the oil substances used herein are also absorbed by the fuel substance, filling the pores of the fuel substance. Typically, to coat a pellet of the fuel substance the quantity of oil combined with the pellet is much larger than the amount necessary to coat the pellet. The amount of oil mixed with the pellet is approximately 0.5 grams/pellet. The amount of oil actually soaked into the pellet is approximately 0.01 gram to 0.1 gram, wherein the dimensions of a fuel pellet are approximately 1.25 cm in diameter and 0.95 cm in height.
[0029] Similar to the films described above, the porosity and thickness of the oil or rubber coating materials can be tailored to give a desired water vapor flux, while preventing liquid water penetration. In the preferred embodiment of the invention, the oil or rubber coating materials have a pore size of from about 0.001 μm to about 1 μm, more preferably from about 0.01 μm to about 0.5 μm, and most preferably from about 0.05 μm to about 0.1 μm. Further, in the preferred embodiment of the invention, the oil or rubber coating materials have a thickness of from about 0.01 μm to about 10 μm, more preferably from about 0.05 μm to about 5 μm, and most preferably from about 0.1 μm to about 1 μm. In addition, high viscosity oils, such as high molecular weight hydrocarbons, reduce the rate of reaction between the fuel substances and water more than low viscosity oils. In the preferred embodiments of the invention, an oil has a preferred viscosity of from about 0.001 Pascal-second (Pa-sec) to about 100, more preferably from about 0.01 Pa-sec to about 10 Pa-sec and most preferably from about 0.1 Pa-sec to about 1 Pa-sec.
[0030] As discussed herein, the present invention provide a method in which the rate of reaction between water molecules and a water reactive chemical fuel can be regulated independently of the apparatus containing the chemical fuel. In the preferred embodiments of the invention, the fuel reaction rate, e.g. for LiAlH 4 fuel, is preferably from about 1 E −10 to 1 E −2 grams of fuel/second, more preferably from about 1 E −7 to about 1 E −3 grams/second, and most preferably from about 1 E −6 to 1 E −4 grams/second. Such fuel reaction rates are capable of generating quantities of hydrogen gas sufficient to produce from about 1 uW to about 100 W of electrical power, depending on the desired generator structure and application.
[0031] While the encapsulated fuels 10 of the invention are particularly well suited for use in a power generator apparatus 20 as illustrated in FIG. 1 , the encapsulated fuels 10 may be used with virtually any type of power generator device that is designed to utilize in-situ generated hydrogen gas. As stated above, the encapsulated fuels 10 of the invention have been found to significantly improve the stability of such power generators if they are damaged and the fuel substance 14 is exposed to large quantities of liquid water. In addition, the encapsulated fuels 10 of the invention may be effectively employed in myriad other non-power generator related applications in which the generation of hydrogen gas is desired, serving as a stabilized, water-reactive fuel source.
[0032] The following examples serve to illustrate the invention:
EXAMPLE 1
[0033] Fifty grams of fine lithium aluminum hydride (LiAlH 4 ) powder is mixed in 100 ml hexane and approximately 0.1 grams of a curable rubber solution. The curable rubber solution includes a curing agent. The mixture is warmed in a hood to 500° C. and stirred. The mixture is stirred continuously as it is warmed, until the entire mixtures has a soft, rubbery consistency. The soft mass is removed from the hood and granulated over a 400 mesh sieve. The granules are collected and dried at approximately 600° C. in an air oven in a hood for approximately 8 hours. The dried granules are pelletized in a press and ready for use.
EXAMPLE 2
[0034] LiAlH 4 in pellet form is mixed with 0.5 g of mineral oil. The mixture is placed in vacuum chamber for about 1 hour to draw the oil into the pellet and to remove any gas from the pellet. The mixture is then removed from the vacuum and the LiAlH 4 is separated from the mineral oil by filtration, thereby preparing the coated LiAlH 4 for use in a power generator. The quantity of oil that is “mixed” with the pellet is much larger than the amount necessary to coat the pellet. The amount of oil soaked into the pellet is about 0.05 gram.
EXAMPLE 3
[0035] LiAlH 4 in pellet form is sealed with an adhesive epoxy inside of a package constructed from a water vapor permeable, liquid water impermeable Gore-Tex® membrane. The package containing the LiAlH 4 is shaped such that it conforms to the shape of the fuel chamber of a power generator. The package is placed into a power generator and ready for use.
[0036] While the present invention has been particularly shown and described with reference to preferred embodiments, it will be readily appreciated by those of ordinary skill in the art that various changes and modifications may be made without departing from the spirit and scope of the invention. It is intended that the claims be interpreted to cover the disclosed embodiment, those alternatives which have been discussed above and all equivalents thereto.
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Stabilized fuels and methods for the encapsulation of fuels are provided. More particularly, methods for the passivation or encapsulation of water reactive, hydrogen gas generating fuels. Water reactive fuels are encapsulated in a water vapor permeable, liquid water impermeable membrane, or coated with a water vapor permeable, liquid water impermeable oil substance to control the quantity of water that is permitted to reach the chemical fuel. In the event of damage, hydrogen generators incorporating the fuels of the invention are protected from explosions that might otherwise result from rapid, uncontrolled hydrogen generation.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to a magnetic glass door holder, particularly to one capable to prevent shock and ensure positioning of a mobile frameless tempered glass door so as to be applied to a single door, and a mobile door and a stationary one combined in an angle of 90°, 135° or 180°
[0002] A known conventional magnetic door holder shown in FIG. 1 generally includes a magnetic plate 2 fixed on a door, and a stopper 3 fixed on a wall. The stopper 3 has a magnet 4 in a front end to stop and suck the magnetic plate 2 so as to hold the door immovable in the opened position when the glass door is opened. Thus the door is prevented from blown closed by a wind.
[0003] The conventional door holder looks extremely protruding out, having to be hidden behind a wooden door or metal door for keeping its appearance neat. The conventional door is holder impossible to be applied on a glass door as it can be applied on a wooden or metal door only. But if it is applied to a glass door, it may look quite protruding out, as the glass door is transparent. Besides, the magnet exposes out, having no buffer function so that the glass door may be apt to produce breaking owning to shocks caused by collision of the stopper with the magnet plate.
[0004] The conventional magnetic door holder can only be applied to a wooden or metal door located before a wall, impossible to be applied to a frameless glass door or an angled door, etc.
SUMMARY OF THE INVENTION
[0005] One purpose of the invention is to offer a magnetic glass door holder provided with a position device and a fix device, and a sucking device respectively affixed hidden on the position device and the fix device, and the sucking devices have a buffer gasket to prevent a mobile glass door from receiving shocks and also ensure to keep it in the closed position when it is closed
[0006] Another purpose of the invention is to offer a magnetic glass door holder having a position device provided with plural lateral columns extending laterally from the position column, and a locking device fixed on one of the lateral columns so that the lateral column may be locked on a stationary door, and another has a sucking device to suck another sucking device fixed on a stationary door so as to secure a single door or a mobile one and a stationary one combined together in an angle such as 90°, 135° or 180° in a closed position.
BRIEF DESCRIPTION OF DRAWINGS
[0007] This invention will be better understood by referring to the accompanying drawings, wherein:
[0008] [0008]FIG. 1 is a perspective view of a known conventional magnetic door holder;
[0009] [0009]FIG. 2 is an exploded perspective view of a first embodiment of a magnetic glass door holder in the present invention;
[0010] [0010]FIG. 3 is a perspective view of the first embodiment of a magnetic glass door holder in the present invention;
[0011] [0011]FIG. 4 is a perspective view of the first embodiment of a magnetic glass door holder applied to a glass door in the present invention;
[0012] [0012]FIG. 5 is an upper view of a second embodiment of a magnetic glass door holder applied to a glass door in the present invention;
[0013] [0013]FIG. 6 is an upper view of a third embodiment of a magnetic glass door holder applied to a stationary glass door and a mobile glass door in the present invention;
[0014] [0014]FIG. 7 is an exploded perspective view of a locking device in the third embodiment of a magnetic glass door holder in the present invention;
[0015] [0015]FIG. 8 is an upper view of a fourth embodiment of a magnetic glass door holder in the present invention; and,
[0016] [0016]FIG. 9 is an upper view of a fifth embodiment of a magnetic glass door holder applied to a glass door in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] A first embodiment of a magnetic glass door holder in the present invention, as shown in FIGS. 2, 3 and 4 , includes a position device 10 , a fix device 20 , two sucking devices 30 as main components combined together.
[0018] The position device 10 consists of a position column 11 provided with a lateral column 12 extending laterally from an outer surface of the position column 11 , male threads 13 formed on the lateral column 12 , a nut 14 with a slot 15 screwing with female threads formed in a vertical hole in a substantial length of a lower portion of the position column 11 , and a bolt 16 partly located in the vertical hole of the position column and passing through the slot 15 of the nut 14 to extend in the ground or a wall to secure the position column 11 after the position column 11 is adjusted a little by moving the bolt 16 in the slot 15 , if necessary.
[0019] The fix device 20 consists of a sleeve 21 embedded in a hole bored in a mobile door T 1 , a washer 22 respectively placed before and behind the sleeve 21 and at two sides of the mobile door T 1 , a fix washer 23 and a fix base 24 respectively positioned outside each of the washers 22 , and a locking bolt 25 passing through the sleeve 21 , the washers 22 , the fix washer 23 and engaging a threaded hole 241 of the fix base 24 . Further, the fix base 24 has male threads formed on the other end.
[0020] The two sucking devices 30 respectively screw with the lateral column 12 and the fix device 20 . Each sucking device 30 includes a sleeve 31 , a magnet 32 , and a spacer 33 . The sleeve 31 is provided with female threads 311 to engage with the male threads 13 of the position device 10 or with the male threads 242 of the fix base 24 , and a center hole 312 .
[0021] The magnet 32 is fitted in the sleeve 31 , having a buffer gasket 321 formed in a front end, and exposing out of the hole 312 of the sleeve 31 .
[0022] The spacer 33 is made of non-metal, positioned behind the magnet 32 , keeping the magnet 32 from contacting with other components.
[0023] Next, how to assemble and use the magnetic glass door holder is to be described. As shown in FIGS. 3 and 4, the locking bolt 16 locks the nut 14 screwed with the position column 11 on the ground or a wall, and then the position column 11 with the nut 14 is capable to be adjusted in its position a little by means of the locking bolt 16 movable in the slot 15 , if necessary. After that, the magnet 32 and the spacer 33 are placed in the sleeve 31 , with the female threads 311 engaging with the male threads 13 of the position column 11 .
[0024] Then the sleeve 21 is inserted in a hole bored in the mobile door T 1 , and the washers 22 are respectively placed before and behind the sleeve 21 and at an inner side and the outer side of the mobile door T 1 . Further, the fix washer 23 and the fix base 24 are respectively placed at two sides of the mobile door T 1 . Then the locking bolt 25 locks the fix device 20 on the mobile door T 1 , and one of the sucking devices 30 is screwed tightly with the fix base 241 , with the female threads 311 of the sleeve 31 engaging the male threads 242 of the fix base 241 .
[0025] When the mobile door T 1 is opened and contacts the positioned device 10 , the two magnets 32 of the two sucking devices 30 suck each other, securing the mobile door in the stopped position. Meanwhile the buffer gaskets 321 of the magnets 32 buffer the two sucking devices 30 when they come to contact each other so that the glass door may not be broken. This is one of the advantages of the invention. In addition, the position device 10 and the fix device 20 and the sucking devices 30 are all shaped circular, giving a balanced appearance, not damaging impression of the whole glass door, and elevating worthiness of a glass door.
[0026] Moreover, the fix device 20 may be positioned on an upper edge of a mobile door T 2 , as shown in FIG. 5, and the position device 10 is fixed on a wall corresponding to the mobile door T 2 . Then it may not become an obstacle to be tipped over by a person as it is positioned on the ground.
[0027] Next, FIGS. 6 and 7 show respectively a second and a third embodiment of a magnetic glass door holder in the invention, having a position device 40 provided with a position column 41 comparative longer than that in the first embodiment, and a sucking device 60 fixed on the position column 41 additionally provided with two extension columns 42 , which have respectively a threaded hole 241 in a lower end surface. Each extension column 42 has a locking device 50 provided with a sleeve 51 to be fitted in a hole of a stationary door T 3 . A washer 52 is positioned before and behind the sleeve 51 and located at an inner and an outer side of the stationary door T 3 . A clamping disc 53 is placed outside of the outer washer 52 , and a locking bolt 54 passes through the sleeve 51 , the two washers 52 and the clamping disc 53 and further engaging the threaded hole 421 of the extension column 42 , forming two locking devices 50 fixed on the stationary door T 3 . Thus, the position column 41 of the position device 40 is secured in parallel with the stationary door T 3 , but the sucking devices 60 are located near the mobile door T 4 . The mobile door T 4 is the same as that in the first embodiments, having a sucking device on one side and a fix device 70 on the other side.
[0028] Next, FIGS. 8 and 9 show respectively a fourth and fifth embodiment of the invention, having respectively a position column 41 of the fix device 40 shaped curved for an angle or vertically curved to suit to an angled door or a vertical door.
[0029] While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications that may fall within the spirit and scope of the invention.
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A magnetic glass door holder includes a position device fixed on a mobile door and a fix device fixed on a stationary door, and a sucking device respectively provided hidden in the position device and the fix device. Then the two sucking devices suck each other to keep the mobile door from receiving shocks to secure it in an opened or closed position. The magnetic glass door holder can be applied to a frameless tempered glass door consisting of a stationary one and a mobile door combined in an angle such as 90°, 135° or 180°.
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TECHNICAL FIELD
[0001] The present invention relates to an image processing device and method that compresses a vector-based image by removing duplicate information and simplifying the shape(s) of complex edge(s) in vector object(s).
BACKGROUND
[0002] Electronic based images are commonly used today because they are easy to store, retrieve and manipulate when compared to paper based images. Plus, electronic based images are commonly used today because they are easy to distribute when compared to paper based images. With the advent of the Internet this last advantage is an important consideration. If desired, the paper based images can be converted into electronic based images to make them easier to manipulate and distribute. This conversion can be achieved by using a scanner which scans a paper based image and then creates an electronic based image. Of course, an electronic device such as a digital camera (for example) can be used to take a picture and then create an electronic based image. In either case, the electronic based image is created by first generating a raster (bitmap) image and then converting the raster image into a vector-based image (vector graphic image). The procedure used to convert the raster image into the vector-based image is known in the field as a vectorization process.
[0003] There are many types of vectorization programs available on the market today which can be used to convert a raster image into a vector-based image. Some of the more well-known vectorization programs include (for example): Vector Eye, Adobe Streamline, Silhouette, Synthetik Studio Artist and Macromedia Freehand. How these vectorization programs perform and what parameters they use such as numbers of colors, numbers of shapes, complexity of shapes, etc. . . . , varies greatly and depends on the desired result. However, all of these vectorization programs function to analyze color information within the raster image and then create several larger areas known as vector objects which share the same colors. FIGS. 1A-1B (PRIOR ART) are provided to respectively illustrate a raster image and a vector-based image of two automobiles (the vector-based image will be discussed in detail below with respect to the present invention). These vectorization programs all work well to create a suitable vector-based image but they could be improved to better compress the representation of the vector-based image. This need and other needs are satisfied by the image processing device and method of present invention.
SUMMARY
[0004] Today's computer programs that convert raster images into vector-based images do not optimize/compress the vector representation of the vector-based images. Instead, they simply keep all of the complex edges for the vector objects within the vector-based images. The present invention described herein functions to create a compressed vector-based image by simplifying the shapes of common complex edges which are shared by adjacent vector objects. The compression (lossless compression) of the vector objects is done without affecting the perceived quality of the vector-based image.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] A more complete understanding of the present invention may be obtained by reference to the following detailed description when taken in conjunction with the accompanying drawings wherein:
[0006] FIGS. 1A-1B (PRIOR ART) respectively illustrate a raster image and a vector-based image of two automobiles which are used to help explain a problem with the state-of-the-art vectorization programs which is addressed by the present invention;
[0007] FIG. 2 is a block diagram illustrating the basic components of an image processing device which compresses a vector-based image in accordance with the present invention;
[0008] FIG. 3 is a flowchart illustrating the basic steps of a method for compressing a vector-based image in accordance with the present invention;
[0009] FIGS. 4A-4D is a set of drawings which are used to help explain how a first vector-based image can be compressed by the method shown in FIG. 3 in accordance with the present invention;
[0010] FIGS. 5A-5D is a set of drawings which are used to help explain how a second vector-based image can be compressed by the method shown in FIG. 3 in accordance with the present invention;
[0011] FIGS. 6A-6E is a set of drawings which are used to help explain how a third vector-based image can be compressed by the method shown in FIG. 3 in accordance with the present invention;
[0012] FIGS. 7A-7D is a set of drawings which are used to help explain how a fourth vector-based image can be compressed by the method shown in FIG. 3 in accordance with the present invention; and
[0013] FIG. 8 is a flowchart illustrating the basic steps of a method for compressing a vector-based image which is transmitted to a mobile terminal in accordance with the present invention.
DETAILED DESCRIPTION
[0014] Referring to FIG. 2 , there is illustrated a block diagram of an image processing device 200 which implements a preferred method 300 so it can compress a vector-based image in accordance with the present invention. The image processing device 200 includes a processor 202 which processes instructions stored within a memory 204 to compress a vector-based image 212 (for example) as follows: (1) identify a complex edge 206 that is shared by two adjacent non-transparent vector objects 208 and 210 which are part of the vector-based image 212 (step 302 in FIG. 3 ); (2) select one vector object 208 (for example) which is going to have an unchanged complex edge 206 when it is used later to form a compressed vector-based image 212 ′ (step 304 in FIG. 3 ); (3) simplify the complex edge 206 of the other vector object 210 (for example) (where the unchanged vector object 208 and the simplified vector object 210 ′ are shown separated) (step 306 in FIG. 3 ); and (4) draw the unchanged vector object 208 (and possibly other vector objects) on top of at least a portion of the simplified edge 206 ′ of the simplified vector object 210 ′ to form the compressed vector-based image 212 ′ (step 308 in FIG. 3 ). How this method 300 can compress a vector-based image is described in more detail below where it is used to compress four different vector-based images.
[0015] In example #1, the method 300 compresses the vector-based image of a windshield located within the automobile shown on the left side in FIG. 1B . The vector-based image of the windshield 402 is shown in FIG. 4A (note: the vector-based image is shown darker than normal to better help describe the present invention). The three vector objects 404 a , 404 b and 404 c which make-up the vector-based image of the windshield 402 are shown separated from one another in FIG. 4B . In this example, the method 300 compresses the windshield image 402 by simplifying two complex edges 406 a and 406 b where the first complex edge 406 a is shared between vector objects 404 a and 404 b and the second complex edge 406 b is shared between vector objects 404 b and 404 c.
[0016] In particular, the method 300 simplifies the first complex edge 406 a by performing the following steps: (1) identifying the complex edge 406 a which is shared by two adjacent vector objects 404 a and 404 b (step 302 ); (2) randomly selecting (or intelligently/iteratively selecting) one of the vector objects 404 a and 404 b (e.g., vector object 404 b ) to remain unchanged so it can be used later as is to form the compressed vector-based image 402 ′ (in this example however the vector object 404 b will be subsequently changed as discussed below when another shared complex edge 406 b is simplified) (step 304 ); and (3) simplifying the first complex edge 406 a associated with vector object 404 a by replacing the shape of the complex edge 406 a with a simpler shape 410 a which in this case is a straight line but any arbitrary shape can be used so long that it is a simpler shape than the original complex edge 406 a (see FIG. 4C ) (step 306 ). The method 300 repeats these steps to simplify the second complex edge 406 b (associated with vector object 404 b ) by replacing it with a simpler shape 410 b which in this case is a straight line but again any arbitrary shape can be used so long that it is a simpler shape than the original complex edge 406 b (see FIG. 4C ).
[0017] The method 300 then draws the unchanged vector object 404 c (with the original complex edge 406 b ) on top of the changed vector object 404 b ′ (with the original complex edge 406 a and the simplified edge 410 b ) which was drawn on top of the changed vector object 404 a ′ (with the simplified edge 410 a ) to form the compressed vector-image of the windshield 402 ′ (see FIG. 4D ) (step 308 ). As can be seen, there are no gaps between the vector objects 404 a ′, 404 b ′ and 404 c which means that the simplified edge 410 a of the changed vector object 404 a ′ was formed so it will be completely hidden underneath the changed vector object 404 b ′ and the unchanged vector object 404 c . Plus, the simplified edge 410 b of the changed vector object 404 b ′ was formed so it will be completely hidden underneath the unchanged vector object 402 c . To draw the compressed vector-image of the windshield 402 , the method 300 could use a depth buffer or more specific a vector-graphic description language which uses a depth buffer so it can describe what vector object is to be drawn on top of another vector object. One such language is SVG (Scalable Vector Graphics standardized by W3C) which is an XML-based language that renders vector objects in the same order as they appear in the file.
[0018] As can be seen, the original non-compressed vector-image of the windshield 402 shown in FIG. 4A looks the same as the compressed vector-image of windshield 402 ′ shown in FIG. 4D . This indicates that the method 300 is indeed an improvement over the state-of-the-art vectorization programs because it reduces the amount of information needed to form the same visual representation of the windshield 402 . Basically, the method 300 reduces the amount of information needed to describe vector objects 404 a and 404 b by replacing their shared complex edges 406 a and 406 b with simplified shared edges 410 a and 410 b . This process can be referred to as lossless compression or lossless optimization.
[0019] In example #2, the method 300 compresses a vector-based image 500 containing two vector objects 502 a and 502 b that are defined in accordance with the following SVG file:
[0000]
<?xml version=“1.0” encoding=“utf-8”?>
<svg width=“400” height=“400”>
<path fill=“#00015F” d=“M0,0L100,0L150,50L100,100L0,100z”/>
<path fill=“#FF0100” d=“M200,0L100,0L150,50L100,100L200,100z”/>
</svg>
[0020] When drawn this SVG file creates the vector-based image 500 which is shown in FIG. 5A (where the top left corner is at coordinate x, y=0,0 and the bottom right corner is at x, y=200,100). FIG. 5B shows the two vector objects 502 a and 502 b separated. Next, a discussion is provided to explain how the first path in the SVG file is used to draw the vector object 502 a :
[0000] fill = “#00015F” Fill the shape with this color. d= Start the path here. M0, 0 Move to 0, 0, meaning start to draw from this coordinate (e.g., put the “pen” here) L100, 0 Line to (absolute) 100, 0, meaning draw a line to coordinate x, y = 100, 0 (from previous point). L150, 50 Line to (absolute) 150, 50, meaning draw a line to coordinate x, y = 150, 50 (from previous point). L100, 100 Line to (absolute) 100, 100, meaning draw a line to coordinate x, y = 100, 100 (from previous point). L0, 100 Line to (absolute) 0, 100, meaning draw a line to coordinate x, y = 0, 100 (from previous point). z Close the shape, which is the same as drawing a line from the last point to the end point.
Note: SVG enables one to describe paths in several ways, e.g. using “l” or “L” which means “line to” in both cases but in the first case it is relevant (from previous drawing point) and in the second case it is definite (to a fixed coordinate). Plus, one can use “C” which means to “curve to” the next coordinate, using a Bezier curve.
[0021] Thus, when method 300 compares the two paths within the SVG file it sees that the part “L100, 0L150, 50L100, 100” is the same in both paths. This is how method 300 can identify a common complex edge 504 which is shared by two vector objects 502 a and 502 b (step 302 ). Note: in SVG the order in which the paths are drawn might be reversed meaning it is possible to travel the same path but in different directions, this means the method 300 should also compare the reversed paths in the SVG file to discover the common edges. In either case, the method 300 compares the description of the paths and decides if they are actually the same which indicates a common edge between adjacent vector objects.
[0022] The method 300 uses this knowledge to simplify the vector image 500 by replacing the complex edge 504 associated with one of the vector objects (e.g., vector object 502 b ) with a simplified edge 506 (step 306 ). The vector object 502 b can be simplified in the SVG file as follows:
[0000]
<?xml version=“1.0” encoding=“utf-8”?>
<svg width=“400” height=“400”>
<path fill=“#FF0100”d=“M200,0L100,0L100,100L200,100z”/>
<path fill=“#00015F” d=“M0,0L100,0L150,50L100,100L0,100z”/>
</svg>
[0023] As shown in FIG. 5C , the method 300 has simplified the two lines in the complex edge 504 associated with vector object 502 b by replacing them with one vertical line 506 from x, y=100,0 to x, y=100,100. In addition, the method 300 has changed the drawing order of the two vector objects 502 a and 502 b ′ such that the unchanged vector object 502 a is now drawn on top of the changed vector object 502 b ′ in order to form the compressed vector image 500 ′ (step 308 ) (see FIG. 5D ). As a result, the method 300 reduced the amount of information which was needed to form the compressed vector image 500 ′. As can be seen, the compressed vector image 500 ′ has the same visual representation as the non-compressed vector image 500 (compare FIGS. 5A and 5D ). In this example, the method 300 enabled a gain of 7 characters (L150,50) out of 198, which is approximately a 3.5% gain in size. In fact, the more complex the shared edge, then the more the method 300 can gain by simplifying that shared edge with a theoretical maximum gain approaching 50%. This is desirable because the method 300 by simplifying a shared edge in effect reduces the amount of information needed to describe the associated vector object.
[0024] In example #3, the method 300 compresses the vector-based image 600 shown in FIG. 6A . The three vector objects 602 a , 602 b and 602 c which make-up the vector-based image 600 are shown separated from one another in FIG. 6B . As can be seen, the vector objects 602 a and 602 b share a complex edge 604 a and vector objects 602 b and 602 c share a complex edge 604 b . Assume, the method 300 simplified the two complex edges 604 a and 604 b and created two simplified edges 604 a ′ and 604 b ′ which are part of the simplified vector image 600 ′ shown in FIG. 6C . If this happened, the simplified edge 604 a ′ would be too small because there would be a space 608 between the simplified vector objects 602 a ′ and 602 b ′. Of course, the method 300 would not do this however the defective simplified edge 604 a ′ was created to illustrate a point that a simplified edge needs to be completely hidden underneath one or more vector objects.
[0025] In practice, the method 300 would simplify the two complex edges 604 a and 604 b and possibly create simplified edges 604 a ″ and 604 b ′ respectively associated with changed vector objects 602 a ″ and 602 b ′ to form the simplified vector image 600 ″ shown in FIG. 6D . Now, it can be seen that the simplified edge 604 a ″ associated with changed vector object 602 a ″ is completely hidden under the simplified vector object 602 b ′ (compare FIGS. 6C and 6D ). This all works fine. However, the method 300 could also have logic that knows when one can draw another vector object in this case vector object 602 c on top of the other two vector objects 602 a and 602 b . Then, the method 300 can use that information to simplify the simplified edge 604 a ″ even further so as to create the simplified edge 604 a ′″ shown in FIG. 6E . This particular simplified edge 604 a ′″ is a bit of a construction but it helps illustrate a point that if desired one could simplify an edge so it would be hidden under multiple vector objects. In either case, the visual appearances of the simplified vector images 600 ′″ and 600 ′″ are the same as the visual appearance of the non-simplified vector image 600 (compare FIGS. 6A , 6 D and 6 E). But, the simplified vector objects 602 a ″, 602 a ′″ and 602 b ′ require less data to form them when compared to the data needed to form the unchanged vector objects 602 a and 602 b which are associated with the non-simplified vector image 600 .
[0026] In example #4, the method 300 compresses the vector-based image 700 shown in FIG. 7A . The three vector objects 702 a , 702 b and 702 c which make-up the vector-based image 700 are shown separated from one another in FIG. 7B . As can be seen, the two vector objects 702 a and 702 b share a complex edge 704 a and the two vector objects 702 b and 702 c share a complex edge 704 b . The method 300 could simplify these two complex edges 704 a and 704 b by creating two simplified edges 704 a ′ and 704 b ′ which are respectively associated with the changed vector objects 702 a ′ and 702 b ′ (see FIG. 7C ). Then, the method 300 could draw the unchanged vector object 702 c on top of the changed vector object 702 b ′ which was drawn on top of the changed vector object 702 a ′ to form a simplified vector image 700 ′ (see FIG. 7D ). As can be seen, the simplified edge 704 a ′ of the changed vector object 702 a ′ is completely hidden under two different vector objects 702 b ′ and 702 c . And, the simplified edge 704 b ′ of the changed vector object 702 b is completely hidden under one vector object 702 c . After this simplification, the visual appearance of the simplified vector image 700 ′ remains the same as the visual appearance of the non-simplified vector image 700 (compare FIGS. 7A and 7D ).
[0000] From the foregoing, it should be appreciated that a basic idea of method 300 is that a complex edge shared between two vector objects is simplified to have one complex shape and one simplified edge. The simplified edge can be created by using lines, curves or any other shapes that are simpler than the original complex edge. Here simpler means that it can be defined using less information. The method 300 also draws the unchanged vector object which has the complex edge on top of the changed vector object which has the simplified edge. The drawing order can be controlled by using a depth buffer which specifies what vector object is to be drawn on top of another. This drawing order concept is also known as the “painters model”. Simply described it means that what is painted last is what is seen. If for example, a picture is painted on the screen and then a red circle is painted on top of it, then one will not see the part of the picture underneath the red circle. Because of this drawing order, the method 300 works well with oblique (non-transparent) adjacent vector objects but it does not work with “see-through” vector objects. Lastly, the method 300 as described above effectively provides for a more compact representation of a vector-based image than was output by a vectorization program. However, the method 300 could also be used as part of the vectorization program itself meaning that the enhanced vectorization program would immediately create and output the compressed vector-based image.
[0027] In one application, the present invention can be used to create smaller files to be sent to a mobile terminal (e.g., mobile phone, PDA, laptop computer) which satisfies an important goal of the mobile community. In this case, the enhanced method 300 ′ would have the following steps: (1) identify a complex edge that is shared by two adjacent vector objects which are part of a vector-based image (step 302 in FIG. 8 ); (2) select one of the vector objects (e.g., first vector object) which will have an unchanged complex edge when it is later used to form a compressed vector-based image (step 304 in FIG. 8 ); (3) simplify the complex edge of the other vector object (e.g., second vector object) (step 306 in FIG. 8 ); (4) use a scalable vector graphics language (e.g., SVG, SVG Basic (SVGB), SVG Tiny (SVGT)) to prepare a file which indicates that the simplified edge of the changed vector object (e.g., simplified second vector object) is to be drawn so as to be completely hidden underneath the unchanged vector object (e.g., unchanged first vector object) or is to be drawn so as to be completely hidden underneath the unchanged vector object (e.g., unchanged first vector object) and at least one more additional vector object (step 308 in FIG. 8 ); and (5) transmit the file to the mobile terminal which then draws/forms the compressed vector-based image (step 310 in FIG. 8 ). Note: SVGT is a format which was included in the 3GPP release 5 and 6 for Personal Shopping System (PSS) and Multimedia Messaging Service (MMS) (see 3GPP PSS Release 5 & 6 (3GPP TS 26.234 v5.7.0 & 3GPP TS 26.234 v.6.7.0) and 3GPP MMS Release 5 & 6 (3GPP TS 26.140 v5.2.0 & 3GPP TS 26.140 v.6.3.0)).
[0028] Although one embodiment of the present invention has been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it should be understood that the invention is not limited to the disclosed embodiment, but is also capable of numerous rearrangements, modifications and substitutions without departing from the spirit of the invention as set forth and defined by the following claims.
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Today's computer programs that convert raster images into vector-based images do not optimize/compress the vector representation of the vector-based images. Instead, they simply keep all of the complex edges for the vector objects within the vector-based images. The present invention described herein functions to create a compressed vector-based image by simplifying the shapes of common complex edges which are shared by adjacent vector objects. The compression (lossless compression) of the vector objects is done without affecting the perceived quality of the vector-based image.
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BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates generally to building structures with wood roofs, and more particularly to structures exposed to extreme wind conditions, such as Tornadoes and Hurricanes, where building codes dictate that such structures be protected against structural failure to save lives of occupants. In particular, the present invention relates to a roof tie for anchoring a wood frame roof on a block construction building in order to resist uplift forces encountered during a high wind situation.
BACKGROUND OF THE PRIOR ART
It is well known what high winds can do to a building, particularly to a wood frame construction low-rise structure. Generally, uplift forces tending to lift the roof off the structure or the entire structure off its foundation cause much of the damage sustained by the building.
Wood structures predominate in residential and light commercial construction, and when wood framing is employed the structure must be protected from upward loads developed by high wind, which differs with geographical location and is enforced by different building codes for such areas. For example, the Bahamas and Florida, including the Florida Keys are situated in the pathway of the yearly Caribbean hurricane travel course and as such, encounter hurricanes and/or tornadoes from time to time. Houses in the Bahamas are typically constructed of cement block with a wooden top plate fastened to the top of cement block walls, for attaching a wooden roof. In the case of upward loads, the roof is generally tied to the walls using a variety of steel connectors that tie the top plate to the walls. The size and number of these steel connectors vary depending on the severity of the wind conditions in the locality of the building, and the building's geometry. Due to the house location in a susceptible high wind area, some building codes require that houses built with wooden roof support beams have a “Hurricane Tie” in place on every rafter.
“Hurricane Ties” are usually installed during the foundation and framing stages of construction. Laborers hired by the framing contractor generally install connectors and sheathing. Correct size, location and number of fasteners (nails or bolts) are critical to sustaining the required load. Commonly, such laborers are inexperienced which results in improper or inadequate installation. In all structures, locations of connectors mandate their installation during the framing stage due to related components being placed at the same time. This process slows the foundation and framing stages of construction, which in turn increases labor costs.
From the foregoing, it is apparent that there is a critical need for a strong roof tie system that provides for uplift loads which is cost effective and easy to install.
SUMMARY OF THE INVENTION
The present invention provides a solution to the above and other problems by reinforcing and anchoring the roof structure to the building top plate, wherein a hold down force is applied to the ceiling rafters to counter the uplift and horizontal forces generated by high winds. The present invention can be incorporated during initial construction of a wooden roof structure.
It is an object of the present invention to provide a bracket system for a wooden roof structure of a building that reinforces the roof against damage in a high wind situation, such as a hurricane.
It is another object of the present invention to provide a roof-tie bracket system for a wooden roof construction building that provides a downward force around the periphery of the roof, thereby to better resist any upward lift imparted to the roof by high winds.
It is another object of the present invention to provide a roof-tie bracket system for a wood frame roof that provides reinforcement to the roof structure, thereby providing greater resistance to damage during high wind conditions. A related object is to increase public safety in structures existing in high wind areas.
It is yet another object of the present invention to enable cost effective construction of wooden roof structures while meeting all building code requirements. A related object is to provide a roof-tie bracket system for a low-rise building that complies with the recommendation of all major building codes.
This invention relates to a novel roof-tie bracket system for bracing a wood framed roof of a building, e.g., a residential dwelling, having a structure including a foundation upon which rests a wall construction and horizontal ceiling plates. The structure is reinforced against the destructive forces of the atmosphere by high strength brackets preferably attached to every rafter where it joins the ceiling plates. The roof-tie bracket is connected to the structure by way of a plurality of fasteners, such as nails or lag bolts.
The roof-tie bracket disclosed herein offers more body, more nailing surfaces, more wrapping capability, more strength and more durability to the purchasing public. Such roof-tie brackets may be made from a graduated increase in sheet metal gauges in a variety of straps or ties to fit many framing applications and strength requirements. Moreover, such roof-tie brackets may be pre-pitched to a predetermined angle of a roof, keeping in mind the different sizes of wood that may be used to pitch a roof. Such roof-tie brackets create a solid attachment between a rafter and ceiling top plate. This simple invention enables a family of roof-tie brackets that can be mass-produced and sold for a reasonable price that, in fact, can be made or put in place by any skilled or semi-skilled person.
Some of the advantages of this invention include: increase in surface area of a roof-tie bracket, thereby creating more surfaces through which nails could penetrate the substructure; “prepitched” roof-tie brackets that create a snug fit over all substructures and angles, at angles consistent with industry roof pitch standards; a “decking window” that allows fastening of nails through the “deck” to the rafter beneath; “plate flaps” that further secures the roof-tie bracket to the top plate; and, in some embodiments, a “ceiling joist and cradle” that provides further for the “strapping” of ceiling joists, all in one simple Hurricane and Tornado Tie.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features, aspects, and advantages of the present invention are considered in more detail, in relation to the following description of embodiments thereof shown in the accompanying drawings, in which:
FIG. 1 a shows an illustration of a roof tie in perspective according to one embodiment of the present invention;
FIG. 1 b shows an illustration of a roof tie, with a top plate and rafter in phantom, according to one embodiment of the present invention;
FIG. 2 shows an illustration of a roof tie in perspective according to an alternate embodiment of the present invention;
FIG. 3 a shows an illustration of a gable-end roof tie in perspective according to one embodiment of the present invention;
FIG. 3 b shows an illustration of the gable-end roof tie of FIG. 3 a , with top plate and gable in phantom, according to one embodiment of the present invention;
FIG. 3 c is rear elevation view of a gable-end roof tie, with top plate and gable in phantom, according to another embodiment of the present invention;
FIGS. 4 a and 4 b show an illustration of a gable-end roof tie in perspective according to an alternate embodiment of the present invention;
FIG. 5 shows an illustration of a hip-rafter roof tie in perspective according to one embodiment of the present invention;
FIGS. 6 a and 6 b show an illustration of a hip-rafter roof tie in perspective according to an alternate embodiment of the present invention;
FIG. 7 shows an illustration of a joist cradle tie in perspective according to one embodiment of the present invention;
FIG. 8 shows and illustration of a joist cradle tie in perspective according to an alternate embodiment of the present invention;
FIG. 9 a shows an illustration of a roof tie in perspective according to an alternate embodiment of the present invention;
FIG. 9 b shows an illustration of the roof tie of FIG. 9 a , with top plate and rafter in phantom; and
FIG. 9 c shows an illustration of the roof tie of FIG. 9 a , in perspective, showing a ceiling joist in place.
DETAILED DESCRIPTION OF THE INVENTION
The invention summarized above and defined by the enumerated claims may be better understood by referring to the following description, which should be read in conjunction with the accompanying drawings in which like reference numbers are used for like parts. This description of an embodiment, set out below to enable one to build and use an implementation of the invention, is not intended to limit the enumerated claims, but to serve as a particular example thereof. Those skilled in the art should appreciate that they may readily use the conception and specific embodiments: disclosed as a basis for modifying or designing other methods and systems for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent assemblies do not depart from the spirit and scope of the invention in its broadest form.
Referring to FIG. 1 a , a roof tie according to the present invention, indicated generally as 10 , is illustrated, having an upper portion 13 and a lower portion 16 . Such upper portion 13 comprises two risers 22 , 24 , substantially parallel to each other and a bridge 27 connecting the top of risers 22 , 24 . Bridge 27 provides separation between risers 22 , 24 and presents a large window area 30 . The amount of separation between risers 22 , 24 should conform to the standard thickness of construction materials, such as wooden 2×4s. The lower portion 16 of such roof tie 10 comprises fastener extensions 33 , 35 , which extend at right angles from risers 22 , 24 , respectively and each of which fastener extensions 33 , 35 further comprise top plate flaps 36 , 37 , 38 , 39 . Top plate flaps 36 , 37 , 38 , 39 extend at right angles down from fastener extensions 33 , 35 , and are designed to wrap on the sides of a ceiling top plate. A plurality of apertures 42 for inserting fasteners, such as nails, are disposed on such risers 22 , 24 , fastener extensions 33 , 35 , and top plate flaps 36 , 37 , 38 , 39 . Such plurality of apertures should be disposed in a staggered fashion to prevent splitting of the top plate and rafter when inserting such fasteners.
In some embodiments, the length of the forward edge 45 of riser 22 may be longer than the rear edge 48 of such riser 22 , correspondingly, the forward edge 49 of riser 24 may be longer than the rear edge 50 of such riser 24 in order to have bridge 27 angled to correspond to a selected pitch for a roof.
An application showing use of such roof tie 10 is illustrated in FIG. 1 b presenting roof tie 10 in a position for fastening to top plate 52 and rafter 53 . Fasteners are attached to top plate 52 and rafter 53 through apertures 42 . Using a fastener in each opening ensures a strong and secure attachment. Additional embodiments using various numbers of holes can be used based on specific engineering requirements as determined by one skilled in the art. As shown in FIG. 1 b , top plate flaps 36 , 37 , 38 , 39 are fastened to the sides of top plate 52 , providing a wrap around most of such top plate 52 . Window area 30 is provided to enable fastening of decking material to rafter 53 .
FIG. 2 illustrates an alternate embodiment of a roof tie, indicated generally as 57 , according to the present invention. For heavy-duty applications, roof tie 57 further comprises reinforcing wings 60 , 61 , 62 , 63 (not shown). Such reinforcing wings 60 , 61 , 62 , 63 (not shown) are generally triangular in shape. For example, reinforcing wing 60 extends from the forward edge 45 of riser 22 to the end of forward edge 68 of fastener extension 33 and reinforcing wing 61 extends from the rear edge 48 of riser 22 to the end of rear edge 69 of fastener extension 33 . Similarly, reinforcing wing 62 extends from the rear edge 50 of riser 24 to the end of rear edge 70 of fastener extension 35 and reinforcing wing 63 (not shown) extends from the forward edge 49 of riser 24 to the end of forward edge 71 of fastener extension 35 . Such reinforced heavy duty roof tie 57 provides vertical reinforcement to prevent balking while enabling increased rigidity to roof tie 57 , resulting in a sturdier, stronger roof tie 57 . Such increased strength can be obtained at reduced cost by enabling use of lower galvanized steel gauges for its construction. Balking is caused by misalignment of trusses due to warping of roof timbers or loosening of fastened joints, resulting in roof decking being heaved up along such misaligned roof truss.
Referring to FIG. 3 a , a gable-end roof tie according to the present invention, indicated generally as 73 , is illustrated, having an upper portion 75 and a lower portion 78 . Such upper portion comprises riser 81 , substantially parallel to back 85 and a bridge 87 connecting the top of riser 81 to the top of back 85 . Bridge 87 provides separation between riser 81 and back 85 and presents a large window area 91 . The amount of separation between riser 81 and back 85 should conform to the standard thickness of construction materials, such as wooden 2×4s. The lower portion 78 of such gable-end roof tie 73 comprises a fastener extension 94 , which extends at a right angle from riser 81 , further comprising top plate flaps 98 , 99 . Top plate flaps 98 , 99 extend at right angles down from fastener extension 94 , and are designed to wrap on the sides of a ceiling top plate. A plurality of apertures 102 for inserting fasteners, such as nails, are disposed on such riser 81 , back 85 , fastener extension 94 , and top plate flaps 98 , 99 (shown more particularly in FIG. 3 b ). Such plurality of apertures should be disposed in a: staggered fashion to prevent splitting of the top plate and gable when inserting such fasteners.
In some embodiments, the length of the forward edge 105 of back 85 may be longer than the rear edge 107 of such back 85 , correspondingly, the forward edge 109 of riser 81 may be longer than the rear edge 111 of such riser 81 in order to have bridge 87 angled to correspond to a selected pitch for a roof, as illustrated in FIG. 3 c.
An application showing use of such gable-end roof tie 73 is illustrated in FIG. 3 b presenting gable-end roof tie 73 in a position for fastening to top plate 52 and gable 115 . Fasteners are attached to top plate 52 and gable 115 through apertures 102 . Using a fastener in each opening ensures a strong and secure attachment. Additional embodiments using various numbers of holes can be used based on specific engineering requirements as determined by one skilled in the art. As shown in FIG. 3 b , top plate flaps 98 , 99 are fastened to the sides of top plate 52 , providing a wrap around most of such top plate 52 . Window area 91 is provided to enable fastening of decking material to gable 115 .
FIG. 3 c is a rear elevation view of gable-end roof tie 73 . The length of the forward edge 105 of back 85 is shown as longer than the rear edge 107 of such back 85 in order to have bridge 87 angled to correspond to a selected pitch for a roof. The length of such forward edge 105 and rear edge 107 should be long enough, such that back 85 extends, at least partially, over the butt end 120 of top plate 52 .
FIGS. 4 a and 4 b illustrate an alternate embodiment of a gable-end roof tie, indicated generally as 123 , according to the present invention. For heavy-duty applications, gable-end roof tie 123 further comprises reinforcing wings 126 , 127 . Such reinforcing wings 126 , 127 are generally triangular in shape. For example, reinforcing wing 126 extends from the rear edge 111 of riser 81 to the end of rear edge 130 of fastener extension 94 and reinforcing wing 127 extends from the forward edge 109 of riser 81 to the end of forward edge 131 of fastener extension 94 . Such reinforced heavy duty gable-end roof tie 123 provides vertical reinforcement to prevent balking while enabling increased rigidity to gable-end roof tie 123 , resulting in a sturdier, stronger tie. Such increased strength can be obtained at reduced cost by enabling use of lower galvanized steel gauges for its construction.
Referring to FIG. 5 , a hip-rafter roof tie according to the present invention, indicated generally as 139 , is illustrated, having an upper portion 142 and a lower portion 145 . Such upper portion 142 comprises two risers 147 , 149 , substantially parallel to each other and a bridge 151 presenting a large window area 154 connecting the top of risers 147 , 149 . Bridge 151 provides separation between risers 147 , 149 . Such separation should conform to the standard thickness of construction materials, such as wooden 2×4s. The lower portion 145 of such hip-rafter roof tie 139 comprises fastener extensions 157 , 159 , which extend at right angles from risers 147 , 149 , respectively, each of which fastener extensions 157 , 159 further comprise top plate flaps 161 , 162 . A plurality of apertures 165 for inserting fasteners, such as nails are disposed on such risers 147 , 149 , fastener extensions 157 , 159 , and top plate flaps 161 , 162 . Such plurality of apertures should be disposed in a staggered fashion to prevent splitting of the top plates and rafter when inserting such fasteners.
In some embodiments, the length of the forward edge 168 of riser 147 may be longer than the rear edge 169 of such riser 147 , correspondingly, the forward edge 171 of riser 149 may be longer than the rear edge 172 (not shown) of such riser 149 in order to have bridge 151 angled to correspond to a selected pitch for a roof.
Top plate flaps 161 , 162 extend at right angles down from fastener extensions 157 , 159 , and are arrayed to be substantially perpendicular to each other for attachment to top plates 52 , 175 , which are illustrated as intersecting at a right angle, such as at a corner of a building. For applications in which top plates 52 , 175 intersect at an angle other than a right angle, top plate flaps 161 , 162 should be arrayed at an angle corresponding to the angle of intersection of top plates 52 , 175 . Fasteners are attached to top plates 52 , 175 through apertures 165 . Using a fastener in each opening ensures a strong and secure attachment. Additional embodiments using various numbers of holes can be used based on specific engineering requirements as determined by one skilled in the art.
FIGS. 6 a and 6 b illustrate an alternate embodiment of a hip-rafter roof tie, indicated generally as 177 , according to the present invention. For heavy-duty applications, hip-rafter roof tie 177 further comprises top plate flaps 178 , 179 , substantially parallel to top plate flaps 161 , 162 , respectively. To accommodate such top plate flaps 178 , 179 , fastener extensions 157 , 159 are slightly larger. As shown in FIGS. 6 a and 6 b , top plate flaps 161 , 162 , 178 , 179 are fastened to the sides of top plates 52 and 175 , providing a wrap around most of such top plates for reinforcement of such hip-rafter roof tie 177 .
As can be seen in FIG. 6 b , the length of the forward edge 171 of riser 149 is shown as longer than the rear edge 172 of such riser 149 in order to have bridge 151 angled to correspond to a selected pitch for rafter 182 . Window area 154 is provided to enable fastening of decking material to rafter 182 .
FIG. 7 shows a joist cradle tie according to the present invention, indicated generally as 185 , comprising a tie component 188 and a cradle component 189 , such tie component 188 having an upper portion 192 and a lower portion 194 and such cradle component 189 having an upper portion 196 and a lower portion 198 . Such upper portion 192 of such tie component 188 comprises a riser 201 having a plurality of apertures 204 . The lower portion 194 of such tie component 188 comprises fastener extension 207 , which extends at a right angle from riser 201 and further comprises top plate flaps 208 , 209 . A plural ity of apertures 204 for inserting fasteners, such as nails are disposed on such fastener extension 207 , and top plate flaps 208 , 209 . Such upper portion 196 of such cradle component 189 comprises a wall 212 having a plurality of apertures 204 . The lower portion 198 of such cradle component 189 comprises fastener extension 214 , which extends at a right angle from wall 212 and further comprise top plate flaps 215 , 216 and cradle wall 219 . A plurality of apertures 204 for inserting fasteners, such as nails, are disposed on such fastener extension 214 , top plate flaps 215 , 216 , and cradle wall 219 . Such plurality of apertures should be disposed in a staggered fashion to prevent splitting of the top plate and rafters when inserting such fasteners.
Cradle wall 219 is disposed on an outward edge of fastener extension 214 and extends upward, substantially perpendicular to such fastener extension 214 . In general, cradle wall 219 is preferably shorter than and substantially parallel to wall 212 .
FIG. 8 illustrates an alternate embodiment of a joist cradle tie, indicated generally as 222 , according to the present invention. For heavy-duty applications, joist cradle tie 222 further comprises reinforcing wings 225 , 226 . Such reinforcing wings 225 , 226 are generally triangular in shape. For example, reinforcing wing 225 extends from the forward edge 230 of riser 201 to the end of forward edge 233 of fastener extension 207 and reinforcing wing 226 extends from the rear edge 236 of riser 201 to the end of rear edge 239 of fastener extension 207 . Such reinforced joist cradle tie 222 provides vertical reinforcement to prevent balking while enabling increased rigidity to such joist cradle tie 222 , resulting in a sturdier, stronger roof tie. Such increased strength can be obtained at reduced cost by enabling use of lower galvanized steel gauges for its construction.
FIGS. 9 a and 9 b illustrate an alternate embodiment of a joist cradle tie, indicated generally as 241 , according to the present invention. Joist cradle tie 241 comprises a tie component 188 and a cradle component 189 , such tie component 188 having an upper portion 192 and a lower portion 194 and such cradle component 189 having an upper portion 196 and a lower portion 198 . Such upper portion 192 of such tic component 188 comprises a riser 201 having a bridge 244 connecting to a short riser 247 , substantially parallel to riser 201 . The lower portion 194 of such tie component 188 comprises fastener extension 207 , which further comprise top plate flaps 208 , 209 . A plurality of apertures 204 for inserting fasteners, such as nails are disposed on such riser 201 , short riser 247 , fastener extension 207 and top plate flaps 208 , 209 . Bridge 244 presents a large window area 250 to permit fastening decking to a rafter.
Such upper portion 196 of such cradle component 189 comprises a wall 212 having a plurality of apertures 204 and slots 253 , 254 . In use, short riser 247 overlaps wall 212 . Such slots 253 , 254 are disposed such that, in use, fasteners inserted in apertures 257 , 258 in short riser 247 can penetrate such slots 253 , 254 , respectively. The lower portion 198 of such cradle component 189 comprises fastener extension 214 , which further comprise top plate flaps 215 , 216 and cradle wall 219 . A plurality of apertures 204 for inserting fasteners, such as nails, are disposed on such fastener extension 214 , top plate flaps 215 , 216 , and cradle wall 219 . Such plurality of apertures should be disposed in a staggered fashion to prevent splitting of the top plate and rafters when inserting such fasteners.
Cradle wall 219 is disposed on an outward edge of fastener extension 214 and extends substantially perpendicular to such fastener extension 214 . In general, cradle wall 219 is preferably shorter than and substantially parallel to wall 212 .
Joist cradle tie 241 can adapt to rafters of varying heights for application in a variety of construction scenarios. Slots 253 , 254 enable fasteners to be inserted in such a manner to ensure a snug fit for bridge 255 on the top of rafter 53 . Short riser 247 overlaps wall 212 such that fasteners inserted in apertures 257 , 258 also enter slots 253 , 254 at a variable position depending on the height of rafter 53 for attachment to such rafter 53 .
As illustrated in FIG. 9 b , joist cradle tie 241 is presented in a position for fastening to top plate 52 and rafter 53 . Fasteners are attached to top plate 52 and rafter 53 through apertures 204 and through apertures 257 , 258 in alignment with slots 253 , 254 , respectively. When joist cradle tie 214 is attached to top plate 52 and rafter 53 , a ceiling joist 263 can be set in the cradle component 189 as shown in FIG. 9 c . Fasteners are attached to ceiling joist 263 through apertures 266 , 267 in cradle wall 219 . Using a fastener in each opening ensures a strong and secure attachment. Additional embodiments using various numbers of holes can be used based on specific engineering requirements as determined by one skilled in the art.
It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with said underlying concept. It should be understood, therefore, that the invention may be practiced otherwise than as specifically set forth herein. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.
While specific values, relationships, materials and steps have been set forth for purposes of describing concepts of the invention, it should be recognized that, in the light of the above teachings, those skilled in the art can modify those specifics without departing from basic concepts and operating principles of the invention taught herein.
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A building roof tie for attaching roof trusses and rafters to wood top plates in building structures, such roof tie having a sheet metal body with risers and a bridge for overlapping a rafter and flaps for wrapping on the sides of the top plate. Generally triangular shaped reinforcing wings provide strength and stability, allowing the roof tie to be manufactured from different weights of steel. The roof ties are pitched to conform to a variety of framing applications. A plurality of apertures is formed in the roof tie to provide openings for fasteners for connecting the tie to the wood top plate and rafter.
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BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for cleaning a photoconductive element and an apparatus for collecting residual toner both installed in an electrophotographic copying machine or the like.
In electrophotographic copying machines or the like using a photoconductive element, particularly one in the form of a belt, a cleaning apparatus is installed to clear a photoconductive element of toner particles remaining thereon after the transfer of a toner image onto a sheet. A known type of cleaning apparatus includes a cleaning member constituted by a roller on which bristles are set and which has magnets thereinside. A counter member is formed of a soft material and located at the back of a belt in facing relation with the cleaning member. A photoconductive element is held between the cleaning member and the counter member while the cleaning member is kept in pressing contact with the photoconductive element. In this type of prior art cleaning apparatus, the cleaning member is required to clean the photoconductive element in even and soft contact with the surface of the latter. To set up an even pressure distribution between the cleaning member and the belt, that surface of the counter member which engages with the back of the belt needs be processed to a high precision. Poor flatness of the mentioned surface of the counter member would make the pressure distribution irregular; in a lower pressure area, cleaning would be incomplete while, in a higher pressure area, either surface of the belt would be worn out or shaved off to deteriorate the strength of the belt or even the recording characteristics thereof. Usually, the base of a belt is formed of an organic material such as a polyester film or an inorganic material such as a stainless steel sheet. During repeated movements of the belt, the base of the material is progressively shaved off and the resulting particles are deposited on the belt. Thease particles are entrained by the belt to adhere to the surface of a drive roller which is engaged with the belt, reducing the friction between the belt and the drive roller. Furthermore, the particles shaved off the belt are deposited on the counter member to disturb the even contact of the belt surface with the cleaning member. Shaving of the base of the belt per ce causes such uneven contact between the cleaning member and the belt as well as a decrease in the drive transmission force from the drive roller. A solution heretofore proposed to this problem is the provision of an additional cleaning member which is engaged with the back of the belt. This, however, results in the intricacy of construction and increase in cost.
In the meantime, the residual toner removed from the belt surface by the cleaning apparatus is discharged from the cleaning apparatus by toner discharging means which comprises a toner discharge casing, a screw disposed inside the casing, etc. The residual toner is then collected in a container to be wasted. When filled up with the toner, the container is taken out from the machine and discarded. Vibration entailed by the removal of the container tends to allow the toner particles to drop from the vicinity of a toner outlet of the casing and/or from the toner outlet itself where they may form light bridges. Then, the toner would contaminate various parts located below the casing or even affect their functions.
After the filled container has been unloaded from the machine, a new empty container has to be loaded. Should one forget to load an empty container, the toner discharged from the toner outlet during operation of the machine would drop onto the parts located below to invite the same results as the above-stated.
Furthermore, when the orientation of the container inside the machine is incomplete or inverted, the toner discharged from the toner outlet will partly miss the container to contaminate the interior of the machine due to the asymmetrical shape of the container. Though such an accident may be avoided if a stop or the like is used to prevent the container from being oriented inproperly, this adds to the number of structural elements and, therefore, the production cost.
SUMMARY OF THE INVENTION
It is an object of the present invention to eliminate the above-described various drawbacks inherent in the prior art apparatuses for cleaning a photoconductive element and collecting residual toner.
It is another object of the present invention to provide a photoconductive element cleaning apparatus which permits a cleaning member to engage with the surface of a photoconductive element under even pressure to prevent the back of the photoconductive element from being worn out or damaged.
It is another object of the present invention to provide a new toner collecting apparatus which prevents toner particles from being irregularly scattered or dropped due to vibration which would occur during movement of a container into or out of a machine and, thereby, keep the interior of the machine clean.
It is another object of the present invention to provide a new toner collecting apparatus which causes an empty container to be surely loaded in the machine after the removal of a filled container.
It is another object of the present invention to provide a new toner collecting apparatus which readily senses misorientation of a container inside a machine.
It is another object of the present invention to provide generally improved apparatuses for cleaning a photoconductive element and for collecting residual toner.
Other objects, together with the foregoing, are attained in the embodiments described in the following description and illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an electrophotographic copying machine equipped with a cleaning apparatus embodying the present invention;
FIG. 2 is a sectional side elevation showing details of the cleaning apparatus indicated in FIG. 1;
FIG. 3 is a fragmentary sectional side elevation of a second embodiment of the cleaning according to the present invention;
FIG. 4 is a fragmentary sectional side elevation of a third embodiment of the cleaning apparatus according to the present invention;
FIG. 5 is a fragmentary sectional side elevation of a fourth embodiment of the cleaning apparatus according to the present invention;
FIG. 6 is a sectional side elevation showing a modified form of a base included in the apparatus of FIG. 5;
FIG. 7 is a fragmentary sectional side elevation of a fifth embodiment of the cleaning apparatus according to the present invention;
FIG. 8 is a fragmentary sectional side elevation of the sixth embodiment of the cleaning apparatus according to the present invention;
FIG. 9 is a fragmentary sectional side elevation of the seventh embodiment of the cleaning apparatus according to the present invention;
FIG. 10 is a sectional side elevation of a toner collecting apparatus also embodying the present invention;
FIG. 11 is a fragmentary sectional side elevation of the apparatus shown in FIG. 10 illustrating the movement of a closure member;
FIG. 12 is a sectional front view of the apparatus shown in FIG. 10;
FIG. 13 is a sectional side elevation of a second embodiment of the toner collecting apparatus according to the present invention;
FIG. 14 is a sectional front view of the apparatus shown in FIG. 13;
FIG. 15 is a fragmentary sectional side elevation of an exemplary arrangement for guiding a closure member;
FIGS. 16 and 17 are a sectional side elevation and a sectional front view of a third embodiment of the toner collecting apparatus according to the present invention, respectively; and
FIG. 18 is a sectional side elevation of a fourth embodiment of the toner collecting apparatus according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the photoconductive element cleaning apparatus and residual toner collecting apparatus of the present invention is susceptible of numerous physical embodiments, depending upon the environment and requirements of use, substantial numbers of the herein shown and described embodiments have been made, tested and used, and all have performed in an eminently satisfactory manner.
Referring to FIG. 1 of the drawings, an electrophotographic copying machine is schematically shown which uses a photoconductive element in the form of a belt to which the cleaning apparatus of the present invention is applicable. The copying machine comprises a photoconductive belt 10 passed over a drive roller 12 and a driven roller 14 to be moved in the direction indicated by an arrow. The photoconductive belt 10 may be a belt with or without ends. Disposed around the belt 10 are a charging unit 16, an exposing unit 18, a developing unit 20, a transferring unit 22, a discharging unit 24 and a cleaning unit 26. In the illustrated arrangement, the developing unit 20 employs magnet brush development for which a magnetic toner is used as a developer. A latent image electrostatically formed on the belt 10 is processed by the developing unit 20 into a toner image which is then electrostatically transferred onto a sheet S by the transferring unit 22. The sheet S carrying the toner image is separated from the belt 10 and conveyed to a fixing unit 28 to have the toner image fixed permanently thereon. The discharging unit 24 clears the belt 10 of needless residual charge while the cleaning unit 26 removes the residual toner.
Referring to FIG. 2, the cleaning unit or apparatus 26 includes a cylindrical sleeve 30 formed of a non-magnetic material and rotatable clockwise as indicated by an arrow. Short bristles 32 made of nylon or rayon, for example, are set on the outer periphery of the sleeve 30. Permanent magnets 34 are fixed in place within the sleeve 30. A magnetic roller 36 is positioned above and to the left of the sleeve 30 to be engaged by the bristles 32 on the sleeve 30, the roller 36 being counterclockwise as also indicated by an arrow. A scraper 38 is pressingly engaged with the periphery of the magnetic roller 36. Located below the scraper 38 is a toner discharging means 40 for toner collection which may comprise a screw or a spiral blade, as will be described in detail. The sleeve 30, roller 36, toner discharging means 40 and other associated elements are installed in a casing 42 which is open toward the belt 10. A counter member 44 is positioned on the opposite side to the sleeve 30 with respect to the belt 10. The counter member 44 is made of a soft material such as felt, rubber, sponge or brush. The counter member 44 is mounted on a support member 46 which in turn rests on a base 48. Projecting above the top of the base 48, the counter member 44 is so mounted on the support 46 as to urge the belt 10 against the sleeve 30.
In operation, the sleeve 30 is engaged with the belt 10 which has passed through the image transfer station 22 so that the bristles 32 on the sleeve 30 agitate the residual toner on the belt 10. The bristles 32 remove the toner from the belt 10 and entrain almost all the toner therewith. Where the toner is a magnetic toner, the magnets 34 placed within the sleeve 30 as in the illustrated embodiment will effectively help the residual toner be removed from the surface of the belt 10 or attracted onto and carried by the sleeve 30 due to their magnetic attraction. The magnetic field between the magnets 34 and the magnetic roller 36 causes the toner thus deposited on the sleeve 30 to be transferred onto the roller 36. The scraper 38 scrapes the toner off the roller 36 and let it fall onto the toner discharging means 40, which conveys the removed toner out of the cleaning apparatus 26.
The counter member 44 and support member 46 extend over substantially a same width as the belt 10 and is so adjusted in position that the belt 10 be engaged by the bristles 32 on the sleeve 30 evenly throughout the width.
The support member 46 may be formed of a magnetic material and arranged to be movable up and down. This will cause the support member 46 to be attracted toward the sleeve 30 by the magnetic force of the magnets 34 in the sleeve 30, so that the belt 10 is engaged with the sleeve 30 by the counter member 46. The contact pressure depends on the magnetic force of the magnets 34, the distance between the magnets 34 and the support member 46, etc.
Referring to FIG. 3, there is shown a second embodiment of the cleaning apparatus of the present invention. In this embodiment as well as others which will follow, the same parts and elements as those shown in FIG. 2 will be designated by the same reference numerals and will not be described any further for the sake of simplicity.
In FIG. 3, the support member 46 and base 48 are constituted integrally by a single flat support member 50. The counter member 44 is mounted on the support member 50. While the support member 50 is made of a non-magnetic material, a magnetic plate 52 is carried on the underside of the support member 50 to enhance the cleaning effect provided by the magnets. As in the first embodiment, the counter member 44 projects above the support member 50 so that a suitable gap or space is defined between the belt 10 and the support member 50. With this arrangement, particles of dust and toner removed by the counter member 44 from the belt 10 will be deposited in the space and prevented from being carried by the belt 10.
Referring to FIG. 4, a third embodiment of the cleaning apparatus of the present invention is shown. This embodiment is similar to the first embodiment in basic construction but differs therefrom concerning that part of the base 48 which holds the support member 46. The base 48 in FIG. 4 defines a space 54 in a position ahead of the counter member 44 with respect to the direction of movement of the belt 10. The space 54 serves to collect the toner and like particles therein. The support member 46 is placed in a recess which is formed in the base 48 to such a shape as shown in the drawing. As the belt 10 moves as indicated by an arrow, the counter member 44 and support member 46 are moved by the belt 10 in the same direction whereby a leg of the support member 46 becomes positioned by the right edge of the recess of the base 48. The space 54 is defined in this manner to the left of the other leg of the support member 46. Again, the support member 46 may be formed of a magentic material.
Referring to FIG. 5, a fourth embodiment of the present invention is shown in which the base is divided into two parts. Each base part is shaped to have a recess for supporting the support member 46 at its end which faces the end of the other base part. One 58 of the recesses is positioned ahead of the counter member 44 with respect to the direction of movement of the belt 10. The recess 58, apart from its supporting function, serves to collect the toner and other particles removed by the counter member 44 due to its substantial dimensions. The other recess or, rather, a groove 62 serves both the functions of positioning and guiding the support member 46. In detail, the groove 62 serves as a guide which facilitates the movement of the support member 46 out of the apparatus which will be required for maintenance purpose or replacement of the belt 10, for example. When the support member 46 is removed from the apparatus, the toner and like particles deposited in the recess 58 can be cleared.
A modified form of the embodiment shown in FIG. 5 is illustrated in FIG. 6. A recess 58a formed in a base 56a collects the needless particles removed from the belt 10 by the counter member 44. Here, the recess 58a is provided with an inclined wall to prevent the particles from adhering to the support member 46 when the support member 46 is moved into or out the apparatus.
Referring to FIG. 7, a fifth embodiment of the present invention is shown which is common to the fourth embodiment in that a support member 64 is removably supported on two base parts 66 and 68. Different from the fourth embodiment, however, a part of the support member 64 defines a recess 70 for depositing the particles removed by the counter member 44. Naturally, the recess 70 is located ahead of the counter member 44 with respect to the direction of movement of the belt 10. Because the recess 70 is defined by the removable support member 64, the needless particles will be taken out when the support member 64 is removed, to facilitate cleaning work. The support member 64 may be designed disposable and wasted together with the counter member 44 whose service life is limited. For this purpose, the support member 64 should be made of an incostly material.
Referring to FIG. 8, a sixth embodiment of the present invention is shown. In this embodiment, a plate-like magnetic element 72 rests on the bottom of the space 65 which is defined in that part of the base 48 which faces the sleeve 30. The magnetic element 72 may comprise a magnet which is opposite in polarity to the magnets 34 housed in the sleeve 30. Short bristles 74, like the bristles 32 on the sleeve 30, are arranged on one surface of the magnetic element 72 which is engaged with the belt 10. The bristles 74 may be directly set on the magnetic element 72 or may be constituted by a cloth or any other suitable member with bristles and bonded to the magnetic element 72. Thus constructing the sleeve 30, belt 10 and magnetic element 72 will allow the magnetic element 72 to be attracted toward the magnets 34 in the sleeve 30 so that the belt 10 can be pressingly engaged with the sleeve 30 through the bristles 74. It will be seen that the bristles 74 cushion the belt 10 into even pressing contact with the surface of the sleeve 30, though the surface of the magnetic element 72 may not be strictly flat. Also, because the underside of the belt 10 is engaged not by the magnetic element 72 which is hard but by the bristles 74 which are soft, its wearing or shaving is minimized to prolong the life of the belt 10 while stabilizing the recording characteristics of the belt 10.
Referring to FIG. 9, a seventh embodiment of the present invention is shown which employs a flat and vertically movable base 48. The flat base 48 carries the short bristles 74 on its surface which faces the sleeve 30 and the magnetic element on the other or back surface. With this construction, the magnetic element 72 is attracted toward the sleeve 30 together with the base 48 by the magnets 34 housed in the sleeve 30. The belt 10, therefore, is held in pressing contact with the sleeve 30 by the bristles 74.
In the embodiments shown in FIGS. 8 and 9, the bristles 74 can be made of various materials depending on the strength and weight of the photoconductive element. Typical examples of such materials may be synthetic fibers such as nylon and rayon, natural fibers such as cotton and wool, and mineral fibers.
In all the first to seventh embodiments, while a magnetic toner has been used as a developer, it may be replaced by a non-magnetic toner. The non-magnetic sleeve with bristles is only illustrative and may be constituted by any other cleaning member as exemplified by a cleaning blade or a fur brush. Though the bristles on the sleeve 30 are not essential, they would afford a better cleaning effect and less wear of the recording element.
Now, various embodiments of the toner collecting apparatus of the present invention will be described which are all designed for collecting the residual toner removed from the belt surface by any one of the cleaning arrangements discussed hereabove.
Referring to FIGS. 10-12, the toner collector includes a toner discharge casing 82 interposed between the cleaning apparatus 26 and a position where a container 80 is removably mounted. Above the container mounting position, the casing 82 is formed with an opening 82a for dropping the toner which has been removed from the belt surface and conveyed by a screw 84. A closure member 86 made of a non-magnetic material is slidable along the direction of movement of the container 80 into and out of the collector, thereby selectively closing the opening 82a. The closure member 86 is guided by guide channels 82b formed in a bottom portion of the casing 82. The innermost end of the closure member 86 is bent to form an abutment 86a. A compression spring 90 is preloaded between the back of the abutment 86a and a rigid frame member 88 in order to constantly bias the closure member 86 to close the opening 82a. The gap between the opening 82a and the container 80 is sealed by seals 92. Guide plates 94 guide the container 80 when the latter is loaded or unloaded. Generally designated by the reference numeral 96 is a photoelectric sensor made up of a light emitting element 96a and a light receiving element 96b and adapted to sense a toner level collected in the container 80.
As the container 80 is pushed into the collector along the guides 94 as far as a predetermined position, its shoulder designated 80a pushes the abutment 86a against the action of the spring 90. Then the closure member 86 is moved to unblock the opening 82a of the casing 82.
When the container 80 has become filled up with the collected toner, such a condition is displayed on a panel (not shown) by an output signal of the sensor 96. At the same time or upon the lapse of a certain period of operation time thereafter, such as after the production of several hundreds of copies, the copying machine is disabled. As the container 80 is manually removed from the collector, the closure member 86 released from the shoulder 80a of the container 80 is moved to the left in the drawing by the spring 90 to the position indicated in FIG. 11. In this position, the closure member 86 blocks the opening 82a to prevent the toner from dropping from the casing 82.
Referring to FIGS. 13 and 14, an alternative form of the toner collector of the present invention is shown in which the same parts and elements as those of the first embodiment are denoted by the same reference numerals. In FIGS. 13 and 14, a light intercepting plate 86b is slidably received in a guide channel 82b which is formed in a side wall of the casing 82. When the closure member 86 closes the opening 82a of the casing 82, the light interceptor 86b will intercept the transmission of light from the light emitting element 96a to the light receiving element 96b. As shown, the light emitting element 96a and light receiving element 96b in this embodiment are located to face each other through an upper part of the container 80 and the light interceptor 96b. Again, the container 80 is guided by guide plates 98 when moved into or out of the collector.
In the arrangement shown in FIGS. 13 and 14, as the container 80 is pushed into a predetermined position along the guides 98, its shoulder 80a urges the abutment 86a against the force of the compression spring 90 so that the closure member 86 is moved to the position shown in FIG. 13, where it blocks the opening 82a of the casing 82. Such a movement of the closure member 86 brings the light interceptor 86b on one side of the closure member 86 out of the optical path of the sensor 96. Then, the light from the light emitting element 96a becomes incident on the light receiving element 96b so that the machine is abled in response to an output of the element 96b. When the container 80 has been filled up with the collected toner, this condition is displayed on the panel and the machine is disabled with or without a certain delay as in the embodiment described with reference to FIGS. 10-12. Taking the container 80 out of the collector to empty it releases the closure member 86 from the shoulder 80a. This causes the closure member 86 to move to the left in the drawing under the action of the compression spring 90, thereby blocking the opening 82a of the casing 82. In this situation, not only the drop of the toner from the casing 82 is prevented, but the drop of the toner attributable to erroneous operation is checked because the optical path of the sensor 96 is intercepted to make the machine inoperable.
FIG. 15 illustrates an example of a guide mechanism for the closure member 86. As shown, the guide mechanism comprises a guide channel 82c which is formed in the bottom wall of the casing 82.
Referring to FIGS. 16 and 17, a third embodiment of the toner collector of the present invention is shown. Light interceptors 100 in the form of seals or marks are bonded to or printed on laterally opposite upper surfaces of the container 80. The positions of the light interceptors 100 are such that, in a proper position of the container 80 inside the collector, they do not interfere with the optical path of the sensor 96, that is, the positions offset either to the front or the rear (front in this embodiment).
Where the orientation of the container 80 loaded in the collector is proper, the light interceptors 100 are located outside the optical path of the sensor 96 so that the light receiving element 96b coactive with the light emitting element 96a makes the machine operable with its output.
As the container 80 becomes filled up with the collected toner, the machine is disabled through the procedure described in connected with the foregoing embodiments. Then, the container 80 is taken out of the collector to be replaced with another. If the new container is misoriented inside the machine, the light interceptors 100 on the container 80 will block the optical path of the sensor 96 to disable the machine and, thereby, prevents the fall of to toner.
Referring to FIG. 18, there is shown a fourth embodiment of the toner collector in which the container 80 is removably laid on a plate 102. The plate 102 is vertically movable along a guide plate 106. A bellcrank lever 108 is pivotable about a pin 110 and supports the plate 102. One arm of the bellcrank lever 108 is bent at its free end to form a surface 102a which is engagable with the lower surface of the plate 102, while the other arm is formed with a lug 102b which is engagable with the inner surface of a cover 112 of the machine body. When the cover 112 is moved about a hinge 114 to its closing position, the lever 108 engaged with its surface will be moved counterclockwise to push the plate 102 upwardly until the mouth of the container 80 becomes abutted against the edge of the opening 82a through seals 92. The lever 108 is constantly biased clockwise by a spring 116.
When the cover 112 is opened about the hinge 114 to take out the container 80, the lever 108 having been supported by a part of the cover surface is rotated clockwise about the pin 110 by the spring 116. Then, the plate 102 is moved downwardly by gravity carrying the container 80 thereon, whereby the mouth of the container 80 moves clear of the edge of the opening 82a. Accordingly, if the toner deposited on the casing 82 around the opening 82a drops during the removal of the container 80, it will safely be collected in the container 80 with the interior of the collector thus kept clean. Meanwhile, a spacing of about several to 10 mm is defined between the casing 82 and the mouth of the container 80 upon the downward movement of the plate 102. This spacing permits the cleaning apparatus 26 connected with the casing 82 to be readily moved into or out of the machine without removing the container 80.
As the cover 112 is closed with the new container 80 laid on the plate 102, it moves the lever 108 counterclockwise about the pin 110 against the action of the spring 116 thereby raising the container 80 through the plate 102 to a position where the seals 92 lightly abut against the casing 82.
While various embodiments of the toner collector of the present invention have been shown and described in connection with an electrophotographic copying machine, it will be apparent that they are similarly applicable to any other type of recording machine such as an electrostatic or magnetic recording machine. The photoelectric sensor 96 may naturally be substituted for by a microswitch, a magnetic sensor or the like.
Various modifications will become possible for those skilled in the art after receiving the teachings of the present disclosure without departing from the scope thereof.
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Residual toner carried on the imaging surface of a photoconductive belt is removed by a cleaning sleeve, conveyed to a toner discharging station and let fall through an opening into a removable container. A spring biased closure member stops the opening when the container is removed for disposal, thereby preventing contamination to the adjacent structural elements. Means is provided for urging one to position the container always in a predetermined orientation relative to the opening at the toner discharging station. Undesirable particles entrained by the other surface of the belt is collected by a counter member which is located at the opposite side to the cleaning sleeve with respect to the belt. The counter member may take the form of a block of soft material or bristles carried on a support member.
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.Iadd.This is a division of reissue application Ser. No. 565,574, filed 12/27/83. .Iaddend.
BACKGROUND OF THE INVENTION
This invention relates in general to polyimide resins and, more specifically, to compositions and methods for making resilient, flame resistant modified polyimide and polyimide-amide foams.
Prior U.S. Pat. Nos. 4,161,477, 4,183,838 and 4,183,839 disclosed and claimed certain polyimide compositions which are flame resistant and useful as coatings and adhesives.
The coating and adhesive compositions described in the above-mentioned prior patents are made by first preparing a suitable bisimide by reacting an aromatic tetracarboxylic acid dianhydride with a cyclic amide or oxoimine. The ratio of oxoimine to dianhydride is preferably in the 2.3:1 to 2.7:1 range and the imidization reaction is preferably conducted at a temperature of 170°-200° C. for 20-60 minutes.
The polyimide forming material is then prepared by dissolving the bisimide in an inert solvent; then adding thereto a suitable diamine, producing a viscous fluid containing an intimate, unpolymerized mixture of N-substituted cyclic bisimide dicarboxylic acid and diamine which is capable of being converted to a high molecular weight polymer by the application of heat.
The solution is coated onto a surface and polymerized by heating to a temperature in the 177°-316° C. range for 30 minutes to 5 hours. The following is exemplary of the exchange reaction which occurs: ##STR1## where n is a positive integer.
The resulting coating is tough, highly adherent to various surfaces, with very few pinholes or bubbles. It has excellent peel strength and is resistant to high temperatures, peeling and abrasion.
The prior coating material, however, was not suitable for use in applications requiring a cellular or foam material, since conventional agitation foaming and addition of known blowing agents add to process costs and complexity and are not entirely effective at the relatively high polymerization temperature required.
SUMMARY OF THE INVENTION
We have now found that, by suitably varying reaction conditions and certain ingredients, within specified limits, materials similar to those described above and in the cited prior patents can be used to produce a resilient, flame resistant, modified polyimide cellular structure. For the purposes of this application, "modified polymide" will be used to mean a mixture of polyimide and polyimide-amide resins varying from almost entirely polyimide to almost entirely polyimide-amide.
The basic steps in producing our improved resilient foam are reacting a suitable aromatic dianhydride with a suitable oxoimine in a ratio to dianhydride between about 1.5:1 and 0.05:1 to produce a monoimide (excessive quantities of bisimide are produced above 1.5:1, which are not suitable for the foaming reaction), dissolving this mixture in a reactive solvent which is an esterifying agent, to esterify the imide, adding a suitable diamine and any desired additives, drying the solution to a film or powder and finally heating the dry material to a temperature sufficient to cause the dry material to melt and spontaneously foam. The heating causes the dry material to simultaneously undergo a condensation reaction and an exchange reaction. The condensation reaction produces water and alcohol vapors which cause the molten mass to expand. As the reactions proceed, the molten mass forms a cellular structure which becomes self-supporting and finally cures to an imide and/or an imide-amide polymer depending on heating conditions.
DETAILED DESCRIPTION OF THE INVENTION
Any suitable aromatic dianhydride may be used in the preparation of the desired imides. Typical aromatic dianhydrides include those described and referenced in the patents listed above. Due to their ready availability at reasonable prices and the excellent foams which result, pyromellitic dianhydride and 3,3', 4,4' benzophenone tetracarboxylic acid dianhydride (BTDA) are preferred.
Any suitable oxoimine may be reacted with the selected dianhydride to produce the desired imide. Preferably, the oxoimine has the general formula: ##STR2## where "x" is a positive integer from 2 to 4. Of these, best results are obtained with caprolactam because larger ring structures tend to open with heat and react with the aromatic dianhydride.
While any suitable reaction conditions may be used, we have obtained the best results where the dianhydride is added to the oxoimine and the mixture is heated to about 150°-200° C. until imidization is complete, about 5-90 minutes. Optimum results have been obtained at about 180° C. for about 30 minutes.
In order to produce a superior foaming material, we have found that it is essential that the mole ratio of oxoimine to dianhydride be in the range of about 1.5:1 to 0.05:1. Above this range, the material forms a coating without foaming, while below this range excessively rigid material is produced. Within this range optimum results occur with a mole ratio of oxoimine to dianhydride of about 1.0 to 1.0.
The imides produced by the above reaction have the general formula: ##STR3## wherein "x" is an integer from 2 to 4 and "A 2 " is selected from the group consisting of: ##STR4## and mixtures thereof.
The imide thus produced is then esterified by dissolving it in a suitable reactive solvent at a suitable temperature. Any suitable reactive solvent which acts as an esterifying agent may be used. Typical of these are aliphatic alcohols having up to 7 carbon atoms and aromatic alcohols, which may have halogen or amino substitutions, and mixtures thereof. Best results have been obtained with methyl alcohol. The esterification reaction takes place as follows: ##STR5## wherein "x" is an integer from 2 to 4, "A 2 " is as listed for the imide above and "R" is an aliphatic or aromatic radical which may have halogen or amino substitutions. This esterification may take place under any suitable conditions. Typically, a mole ratio of imide to esterifying agent of from about 1:8 to 1:15 is preferred to assure rapid esterification at reflux temperature. This solution is heated to reflux (about 70°-80° C.) until clear, which takes about 60-90 minutes.
Once the esterification is complete, the selected diamine or diamines are added to the solution. Preferably, an approximately stoichiometric quantity of diamine is used.
Any suitable diamine may be used. Typically diamines include meta-phenylene diamine, para-phenylene diamine; 4,4'-diaminodiphenyl ether, 4,4'-diaminodiphenyl sulfone, 3,3'-diaminodiphenyl sulfone, 4,4'-diaminodiphenyl sulfide, 4,4'-diaminodiphenyl methane, 3,3' diaminodiphenyl methane and mixtures thereof. Of these, best results are obtained with 4,4'-diaminodiphenyl methane which is, therefore, preferred. If desired, aliphatic diamines may be used in combination with these aromatic diamines. Typical aliphatic diamines include 1,3 diamino propane, 1,4 diamino butane, 1,6-diamino hexane, 1,8-diamino octane, 1,12 diamino dodecane and mixtures thereof.
Additives to improve various characteristics of the final foam may be added as desired. Any appropriate additives may be used, such as fillers, surfactants to improve uniformity of the cellular structure, ultraviolet absorbers or the like. Typical surfactants include Dow Corning Corp. 190 or 193, (a silicone surfactant), FC430 from Minnesota Mining & Manufacturing Co., Zonyl FSC from E. I. dePont de Nemours & Co., and L550 from Union Carbide Corp. While any suitable concentration may be used, from about 0.01 to 2% (by weight, based on the weight of the solution prior to drying) is preferred. Of these surfactants, best results have been obtained with Zonyl FSC. Fillers and reinforcing additives may be added prior to drying the resin. Typical fillers include Kevlar aramid fibers, graphite fibers, glass fibers, carbon and graphite fibers. Teflon fluorocarbon powders and mixtures thereof.
The solution is then dried by any suitable method. Simply heating the solution in an oven to a temperature of about 65°-95° C. until dry is satisfactory. Other conventional methods, such as spray drying, rotary drying, thin film evaporation, etc. may be used as desired. The resulting free-flowing powder or flakes may be further ground or treated as desired and may be stored indefinitely at room temperature.
The final step is converting the powder into a foam is accomplished by heating the powder to the selected foaming temperature for a suitable period.
The reaction which takes place is quite complex, since it is a combined condensation and exchange reaction. When the exchange reaction is forced to completion by higher temperatures and/or prolonged heating, in the range of 230°-315° C. for 30-60 minutes (optimally, about 260° C. for about 45 minutes) the polyimide structure is primarily formed as shown by the following general reaction: ##STR6## where "x" is an integer from 2 to 4 and A 2 is as listed for the imide above.
If, however, the exchange reaction is stopped prior to completion the products of the intermediate condensation reaction will still be present, so that a variable (depending on reaction time, temperature and conditions) amount of a polymer having the following imide-amide structure will remain: ##STR7## where "x" is an integer from 2 to 4 and A 2 is a radical as listed for the imide above.
As the powder is heated it first melts and, as the condensation reaction begins water and alcohol are released and vaporized, causing the molten mass to expand. The resulting cellular structure becomes self-supporting and finally cures to an imide and imide-amide polymer, with proportions of the two polymers depending on heating (time and temperature) conditions. The resulting foam is tough, resilient and will not emit significant smoke or toxic by-products when exposed to open flame.
Where substantially entirely imide-amide foam is desired, heating should be at from about 120° C. to about 220° C. for about 10 to 40 minutes, with optimum results at about 200° C. for about 30 minutes. As temperature is increased above this range (and the somewhat longer heating period is used) the proportion of polyimide will increase. The foam is more flame resistant, but less flexible, with the higher proportion of polymide. Thus, by varying heating conditons flexibility and flame resistance can be tailored to meet specific requirements.
Details of the invention will be further understood upon reference to the following examples, which describe preferred embodiments of the methods and compositions of this invention. All parts and percentages are by weight, unless otherwise indicated.
EXAMPLE I
About 120.8 g. (0.375 M) of 3,3',4,4'-benzophenonetetracarboxylic acid dianhydride (BTDA) and about 28.29 g. (0.25 M) caprolactam are placed in a one liter flask and heated to about 175° C. After about 30 minutes at this temperature the mixture is cooled to about 50° C. and about 100 g. of ethanol is added. This mixture is heated to reflux temperature (about 75° C.). Reflux is continued until the mixture appears clear, about 70 minutes. The mixture is cooled to just below about 70° C. and about 75 g. (0.375 M) 4,4'-diaminodiphenyl methane is added. This mixture is refluxed (at about 75° C.) for about 15 minutes, then is cooled to room temperature and coated onto aluminum foil. The coating has a heavy, syrup-like consistency, with a thickness of about 20-40 mils. The coating is dried for about 3 hours at about 65° C. The dry residue is removed from the foil and placed in an oven preheated to about 260° C. After about 45 minutes of heating, the material is found to have expanded into a flexible, resilient foam sheet having a homogenous cellular structure. When exposed to an open flame, the foam produces no visible smoke. This foam is found to consist primarily of polyimide.
EXAMPLE II
The procedure of Example I is repeated four additional times, varying only the quantity of caprolactam used. Where Example I used about 28.29 g. (0.25 M) of caprolactam to give a molar ratio of caprolactam of BDTA of about 0.66:1, the four additional experiments use caprolactam quantities of about: II(a) 43.4 g (0.375 M, 1:1 ratio), II(b) 53 g. (0.468 M, 1.25:1 ratio), II(c) 63.6 g. (0.5625 M, 1.5:1 ratio) and II(d) 84.8 g (0.75 M, 2:1 ratio). The foam produced in experiments II(a) and II(b) have excellent foam rise characteristics, while that produced in II(c) has low foam rise and II(d) does not foam. This demonstrates that ratios of oxoimine to dianhydride in the 0.05:1 to 1.5:1 ratios are necessary for the production of good quality foam.
EXAMPLE III
The procedures of Example I are repeated, except that in place of ethanol, the following solvents are used: III(a) isopropyl alcohol, III(b) aminoethyl alcohol, III(c) benzene, III(d) dimethyl acetamide and III(e) acetone. In each case [III(a) and III(b)] where a reactive solvent is used to esterify the imide, an excellent foam results. Where an inert solvent is used, in III(c) through III(e), foaming does not take place.
EXAMPLE IV
The procedures of Example I are followed with five samples, but only up to the heating to foam step. The five dry powder samples are placed in preheated circulating air ovens at the following temperatures for the following time periods: IV(a) about 125° C. for about 40 minutes, IV(b) about 200° C. for about 30 minutes, IV(c) about 220° C. for about 10 minutes, IV(d) about 235° C. for about 30 minutes, and IV(e) about 310° C. for about 30 minutes. Each sample forms a foam of good resiliency and flame resistance. Samples IV(a) and IV(b) are found to be primarily imide-amide and to have outstanding flexibility but lower flame resistance. Example IV(c) is found to be a relatively even mix of imide and amide-imide and to have intermediate flexibility and flame resistance. Examples IV(d) andd IV(e) are found to be primarily polyimide and to have less flexibility but outstanding flame resistance. In general, higher temperatures and longer heating periods produce a greater polyimide proportion and a stiffer foam. The higher temperatures are found to be more significant than the longer heating periods in producing the high polyimide foams.
EXAMPLE V
The procedures of Example I are repeated, except that the following diamines are used in place of the 4,4'-diaminodiphenyl methane: V(a) m-phenylene diamine (0.375 M), V(b) 4,4'-diaminodiphenyl sulfone (0.375 M), V(c) 4,4'-diaminodiphenyl oxide (0.375 M), V(d) 4,4'-diaminodiphenyl oxide (0.1875 M) and 4,4'-diaminodiphenyl sulfide (0.1875 M). In each case the resulting foam has a uniform cellular structure and has excellent heat and flame resistance. The flexibility and resiliency varies somewhat among the sub-examples.
EXAMPLE VI
The procedures of Example I are repeated with the only change being the substitution of the following oxoimines for the 0.25 M caprolactam specified in Example I: VI(a) 2-pyrrolidone (0.25 M), VI(b) 2-piperidone (0.25 M), VI(c) caprolactam (0.125 M) and 2-piperidone (0.125 M). The product in each case is an excellent, flame resistant foam, with slight changes in physical properties with the different oxoimines.
EXAMPLE VII
About 322 g. (1 M) 3,3',4,4'-benzophenone tetracarboxylic acid dianhydride and about 226 g. (2 M) caprolactam are added to a 5 liter flask and heated at about 170° C. for about 30 minutes. The mixture is cooled to about 70° C., then about 800 g. of methanol is added. After the esterification reaction product is fully dissolved, an additional about 644 g. (2 M) of 3,3'4,4'-benzophenonetetracarboxylic acid dianhydride is added. The material is refluxed until clear and then is cooled to about 45° C. About 297 g. (1.5 M) 4,4'-diaminodiphenyl methane and about 192 g. (0.96 M) 4,4'-diaminodiphenyl oxide are added and stirred at about 50° C. until dissolved. About 64 g. (0.54 M) 1,6-diamine hexane is dissolved in about 100 g. of methanol and added to the mixture while maintaining the mixture at a temperature below about 55° C. The mixture is then heated to about 65° C. and held there for about 10 minutes. About 17 g. of Dow Corning 193, a silicone surfactant, is added to the mixture, which is stirred while cooling to room temperature. The resulting liquid mixture is dried using a high speed atomizer spraying into a chamber pre-heated to about 75° C. The dried resin is collected and stored at room temperature. A layer of the powder is placed in a thermal oven (pre-heated to about 200° C.) for about 60 minutes. The powder is observed to first melt, then expand into a very flexible and resilient foam sheet with very uniform cell structure and having a compression set value at about 90% compression of less than about 20%. This demonstrates the usefulness of aliphatic diamines with the aromatic diamines.
EXAMPLE VIII
The procedures of Example VII are repeated, except that the heating step is accomplished using a microwave oven. The powder is placed in the oven and a power of about 1.0 KW is applied for about 6 minutes. Rapid melting and expansion result, producing an excellent resilient foam after about 6 minutes.
Although specific components, proportions and conditions have been specified in the above examples, these may be varied with similar results, where suitable. In addition, other materials may be added to the foamable material, such as fillers, colorants, ultraviolet absorbers, or the like.
Other applications, modifications and ramifications of the present invention will occur to those skilled in the art upon reading the present disclosure. These are intended to be included within the scope of the invention, as defined in the appended claims.
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Methods of making modified polyimide/polyimide-amide foams and the resulting compositions. An N-substituted aliphatic imide is prepared by reacting a suitable aromatic dianhydride with a suitable oxoimine. A polyimide forming material is prepared by dissolving the N-substituted aliphatic imide in an esterifying solvent, then adding a suitable aromatic diamine. This material is dried to a powder or film. A foam is produced by heating the material to reaction temperature for a period sufficient to produce a stable foam. The material melts, then spontaneously expands into a foam which becomes self supporting and cures to a resilient flexible foam. Depending upon heating conditions, a polyimide, polyimide-amide or mixture thereof may be produced, resulting in foams having varying physical properties.
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RELATED APPLICATIONS
This application is related to an application entitled "Apparatus for the Reclamation of Slurry from the Bottom of a Slurry Silo" filed on the same date as this application by Ronald L. Oda, Jeffrey L. Beck, Robert M. Blubaugh, Gary R. Harris, Ricky L. Shaw and Michael P. Evans.
DISCUSSION OF THE PRIOR ART
The prior art known to applicants can be divided into three general categories; first, that art dealing with the measurement of density in a pipeline with subsequent control attempting to correct density errors; second, vertical storage silo apparatus used in a mine to assist in the processing of slurry from a mine; and third, sumps other than vertical sumps useful for handling slurry in a mine.
In the first category are the patents to K. R. Shellene et al, U.S. Pat. No. 3,400,984 and L. P. Reiss, U.S. Pat. No. 3,514,217. These patents both deal with methods and apparatus for controlling the density of slurry in a pipeline. The Shellene patent adds fluid or removes fluid in attempting to control density.
The second group of patents are issued to Richard E. Doerr et al, U.S. Pat. No. 3,966,261; David L. McCain et al, U.S. Pat. No. 3,942,841; William T. Sweeney, U.S. Pat. No. 3,993,359; and Harold 0. Kester et al, U.S. Pat. No. 3,617,094. Each of the above patents discloses a vertical sump for the storage of slurry and the removal of the slurry being stored. The Sweeney patent discloses a jet type pump which removes slurry from a vertical tank and includes fluidizing jets to prevent clogging of the slurry in case it stands and becomes solidified. The patents to Doerr et al and McCain et al both disclose vertical storage tanks used for the storage of slurry in a mine. In these patents, however, the slurry is removed from the bottom of the tank either through the utilization of a pump or by gravity feed and subsequently removed by means of a pump. The patent to Kester discloses a portable slurry tank where the slurry is removed from the bottom by means of a pump sucking the material out of the tank.
U.S. Pat. Nos. 4,060,281; 3,981,541; 4,143,921; 3,870,373; and 3,545,618 all disclose various sumps useful in or out of a mine and the large reclamation sump which incorporates pumps either fixed or movable for removing slurry from the bottom of the sump.
BRIEF DESCRIPTION OF THE INVENTION
In the related application, an invention is disclosed which is an improved apparatus for providing temporary storage of slurry during mining operations and then reclaiming the slurry at a constant density for efficient transportation through subsequent apparatus such as a pipeline. In the previous patents, slurry density is generally controlled by moving the pump either vertically or horizontally in attempting to maintain a fairly constant density in the subsequent pipeline. Thus, if the density is decreased, the pump is trammed faster to pick up more material.
An apparatus similar to that disclosed in U.S. Pat. No. 4,143,921 was constructed in a mine, however, such an apparatus has distinct problems when the sump is placed underground. One distinct problem is the physical difficulty in excavating the mine floor and in supporting the mine roof so that a large horizontal sump can be fabricated underground. A second problem is the economical reliability of the apparatus used to remove the slurry, such apparatus requiring tracks above the sump for moving pumps and attendant housing and all of the other necessary features required to fill the sump in a uniform manner such as controlled hoppers which communicate the slurry from one location to another as the pump is reclaiming the slurry from the bottom of the sump.
The apparatus disclosed herein clearly simplifies the reclamation problems in a mine or in a mining operation either below or above ground. First, the addition of the slurry into the tank does not require any elaborate apparatus. Second, no moving apparatus such as pumps and the like are necessary to reclaim the slurry. Furthermore, a tank can be formed in the bottom of the mine floor as a vertical shaft thus greatly easing the complication of construction in the mine. Third, with no moving parts the mechanical difficulties are drastically reduced.
The related application comprises a vertical tank with apparatus at the top for introducing the slurry in a controlled manner. A bell mouth is placed at the bottom of the tank with the mouth directed toward the bottom of the tank. A pipe communicates with the bell mouth and exits the tank. A bell mouth, which is directed in a downwardly direction, will not plug when the tank is not used for an extended period of time and the slurry solidifies. To ease in the breakup of slurry, various fluidizing jets are incorporated around the bell mouth. First, fluidizing jets are directed downwardly toward the bottom. Second, fluidizing jets are incorporated at the bottom of the tank to move the slurry toward the bell mouth. Third, a fluidizing jet can be incorporated which is directed into the mouth for breaking any compacted particles which might occur at that location.
The density in the pipeline is measured by a densitometer attached to the pipeline after it exits the sump. A flow meter can be attached to the pipeline with the outputs from the flow meter and densitometer being applied to the input of a process controller. The density of the slurry being removed can be carefully controlled by adding fluid to the pipeline connecting the bell mouth with the pump used to remove the fluid from the tank. This fluid is added by a density controlled pump which has its input connected to a sump and its output connected to a pipe which is inputted to the interconnecting pipe.
In the preferred embodiment it is directed at the 90° elbow which couples the bell mouth to the horizontal portion of the pipe leaving the slurry tank. The amount of fluid being added by the pump can be controlled by either varying the speed of rotation of the density control pump or by controlling a valve between the density control pump and the port where the fluid is added to the interconnecting pipe, either or both of which is controlled from the output from the process controller. An overflow is provided at the top of the tank for excess fluids. The overflow is directed to a sump.
One of the problems with the previously disclosed invention is the handling of the solid material which passes out the overflow during the reclaim operation. The amount, size and density that passes out of the overflow is directly related to the flow rate over the overflow during its operation, that is, the higher the flow rate the more solid material passes over the overflow and into the overflow sump.
In order to handle the overflow solids material apparatus must be included in the sump for removing the solids such as a reclaim dredge or the like. In order to alleviate this problem, this invention discloses the use of a second reclaim tank similar in construction to the original reclaim tank. The overflow from the reclaim apparatus is directed into the second tank where the solids material settles to the bottom as in the first tank. A second bell mouth is mounted near the bottom of the second tank with its mouth directed toward the bottom of the second tank with the output communicated to the source of fluids for the dilution port of the first tank. The solids material, which would normally be very fine material, will be sucked up by the second bell mouth and injected along with the fluid in the second tank as the dilution fluid for the first tank. The process control apparatus can determine the density of the material leaving the first tank and adjust the addition of dilution material accordingly. Since the velocity of any overflow material leaving the second tank will be very low, two substantial benefits accrue. First, the material in the second tank will have adequate time to settle; and second, the velocity leaving the second tank will be extremely low. Any solids material passing out of the overflow from the second tank will be fine enough that any pump can remove them from the sump; however, under normal operation, it is anticipated that very little, if any, overflow will pass from the second tank to a reclaim sump.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a preferred embodiment of the invention illustrating the second reclaim tank coupled to the first reclaim tank with the solids material from the second reclaim tank being injected into the dilution port of the first tank; and
FIG. 2 illustrates a second embodiment where the solids material from the second tank is removed and deposited as a slurry input to the first tank.
DETAILED DESCRIPTION OF THE INVENTION
Referring to all of the figures but in particular to FIG. 1, a slurry tank referred to by arrow 10 includes side wall 11 and a bottom 12. The side wall and bottom can be made of metal, cement or any other convenient material. The material actually used will depend upon where it is installed and the convenience of getting the particular material to the installation location. Overflow means is provided by an enlarged portion 13 surrounding the top 14 of tank 10 and having a top 15 higher than top 14 of tank 10. Portion 13 has a bottom 16 which encloses portion 13 to the escape of fluids. An overflow pipe 17 passes through a shutoff valve 18 and to subsequent pipe 19 which is coupled to a second reclaim tank referred to by arrow 20. Slurry is inputted from one mine face 9, for example, through pipe 21 to an inlet apparatus generally referred to by arrow 22. The inlet apparatus is anchored in any means such as bracing members (not shown) to tank side wall 11, enlarged portion 13, or the mine roof (not illustrated). Inlet apparatus 22 basically functions to remove the turbulence and entrapped air from a high velocity line 21 entering tank 10, and generally is constructed of a cylindrical portion 23 and a conical portion 24 with an outlet 25. The fluids entering inlet apparatus from pipe 21 will generally be directed by means of the outlet 26 from pipe 21 so that it swirls around inlet apparatus 22. This prevents the material from splashing over the top and eliminates other problems. In order to reduce the swirl and thus reduce the turbulence inside tank 10, a plurality of vanes 27 is affixed to conical portion 24 in a manner to slow or stop the rotation of slurry 28 inside inlet apparatus 22. Only one slurry inlet pipe 21 is disclosed. It is obvious that many more can be incorporated from other mine faces.
Once slurry 28 is slowed by vanes 27, it drops in the direction of arrow 31 to a bed of slurry 32 which settles in the direction of arrows 33.
The inlet portion 22 disclosed herein is the subject of a copending application and is specifically disclaimed herein as part of this invention.
The removal of the slurry is accomplished by apparatus comprising a bell mouth 35 which communicates with a 90° elbow 36 with a horizontal pipe 37 which passes out an opening 38 in side wall 11 through a shutoff valve 39 to slurry pump 40. The output of pump 40 is connected to a pipe 41 which may be coupled to a hoist apparatus 42 if tank 10 is at a depth more than the final destination of the slurry. Hoist 42 communicates with a pipe 43 to the final destination of the slurry such as a preparation plant if the slurry were coal and water. It is obvious that, if the tank 10 is located on the surface, a hoist apparatus would not be necessary. Under these conditions pump 40 would communicate directly to pipe 41 which would be connected to the end use apparatus for the slurry and not to a hoist. Check valve 29 and cutoff valve 30 may be added as necessary.
In order to measure density of the slurry being communicated through pipe 37 to pump 40, density measuring apparatus 45 is attached in series with pipe 37 and has an output coupled through wire 46 to input 47 of process controller 48. A flow meter 49 is coupled through a wire 50 to an input 51 of process controller 48.
A second bell mouth 55 is coupled through pipe 56 through cutoff valve 57 to inlet 58 of pump 59. An outlet 60 of pump 59 is coupled through a check valve 61 and cutoff valve 62 to a pipe 63. Pipe 63 is coupled to a tee 64. One branch of tee 64 passes through a flow meter 65 to check valve 66, a control valve 67 a cutoff valve 68, and to a pipe 69 which is connected to a dilution port 70 in the 90° elbow 36 which couples bell mouth 35 to pipe 37. A variable speed drive 71 is coupled mechanically through linkage 72 to the shaft of the impeller of pump 59. Process controller 48 has an output 73 which is coupled through wire 74 to the input 75 of variable speed drive 71. Flow meter 65 is coupled through a wire 76 to the input 77 of process controller 48. Pump 40, likewise, has a variable speed drive 80 coupled through mechanical linkage 81 to the impeller shaft of pump 40. The variable speed drive 80 is controlled from the output 82 of process controller 48 which is coupled by wire 83 to the input 84 of variable speed drive 80.
In order to properly fluidize the material being removed from tank 10, several fluidizing jets are provided. A first set of fluidizing jets 85 is attached to a manifold 86. Jets 85 direct a spray into the coal bed 32 as illustrated by line 87. Manifold 86 is coupled through a pipe 88 and necessary check and cutoff valve 89 to a pump 90. The input of pump 90 is coupled through pipe 91 to a pipe 92. Pipe 92 is connected through a cutoff valve 93 to a port 94 in tank 20. Fluidizing jets 95 direct a spray as illustrated by lines 96. Jets 95 are coupled to a manifold 97 through necessary cutoff and check valve 98 to the output 99 of pump 100. The input 101 of pump 100 is coupled through a pipe 102 to pipe 92.
The other arm of tee 64 is coupled through a pipe 103 and cutoff valve 104 through a continuation of pipe 103 and can be applied as a second input 106 to inlet apparatus 22. If needed, an alternate source of water 116 can be supplied through a pipe 117 to tee 118 which can go both in the direction of pipe 119 as added water into tank 20 which is controlled by valve 120 or as a dilution fluid which is supplied through pipe 121, control valve 122 to pipe 123 and finally to dilution port 124. Valve 122 is controlled through wire 125 which is connected to an output 126 of process controller 48. The dilution port 70 as previously discussed has its fluid controlled by valve 67 which is coupled through a wire 130 to an output 131 of process controller 48. The level of tank 20 is continuously monitored by some form of level sensor. The height of the water may be controlled by use of the level sensing device 132 which is coupled through a wire 133 to an input 134 to process controller 48. If additional water needs to be added, then valve 120 can be opened, either manually or automatically by a signal from process controller 48. Level sensing device 132 will either control the closure of valve 120 when the proper level is reached or the valve can be manually closed.
Overflow from tank 20 is provided by a collection region 156 which communicates with tank 20 through port 155 and with a sump 153 through a pipe 147, valve 148 and pipe 149.
A third fluidizing apparatus illustrated in tank 10 comprises a jet 140 directed into bell mouth 35. This fluidizing jet is generally not needed and is subsequently not considered necessary to the operation of the apparatus but is included in case the bell mouth should become plugged. The jet is preferably of the type that is self-cleaning, particularly since it faces up and tends to become easily plugged. It may be coupled through a pipe 141 through valves 142 to pump 143. Pump 143 is subsequently connected to pipe 144 and finally to pipe 92. In tank 20 similar fluidizing jets are included and as a consequence they will not be discussed since they operate functionally in the identical manner as the fluidizing jets described in tank 10.
Process controller 48 has a box 145 labeled "set point." This is generally a feature which permits the operator to determine one or more control conditions for the process controller 48 and is coupled through connection 146 to a process controller 48. The set point is generally included in the process controller as a portion of the controller. The set point, for example, will determine the proper level of fluid in tank 20, the proper flow rate through hoist apparatus pipe 43, the density in pipe 37 and other necessary features to the operation of the apparatus as will be subsequently described. The process controller may comprise a single unit or several units as needed for the various controls necessary for the proper operation of the system.
Operation of the Device of FIG. 1
Material from any source of slurry which can be an underground mine face or a surface mine face generates material suspended in fluid which is communicated through pipe 21 to inlet apparatus 22. The type of material can be coal, phosphate, iron ore or any material that can be slurried. For the sake of simplicity the description will be limited to that of coal; however, the application and apparatus are not so limited.
Slurry entering pipe 21 as previously described enters inlet apparatus 22 through outlet 26. It must be added into tank 10 with as little turbulence as possible so that bed 32 is not stirred up to the point where an excessive amount of particulate matter passes over the top 14 of tank 10. Furthermore it cannot be added with such turbulence that it spills over the top of inlet apparatus 22 creating a substantial turbulence at the surface of the fluid in tank 10 thus causing large particulate matter to pass over the top of tank 10. As it enters inlet apparatus 22, it swirls around as illustrated by the drawing and strikes vanes 27 which are in the direction of the fluid. This causes the material to stop its swirl and fall out of the bottom of inlet apparatus 22. The centrifugal force created by the swirl or vortex also removes any entrapped air in the slurry being added. The diameter of the outlet 25 is quite large and is designed to provide a low velocity outlet. Furthermore, inlet apparatus 22 is submerged in the fluids in tank 10 to further reduce the turbulence generated by the entry of material from outlet 26. As the material falls in the direction of arrow 31 it creates bed 32 in the bottom of tank 10. It continues to settle in the direction of arrows 33. In order to remove the material for subsequent transmission to the hoist apparatus, pump 40 is energized through variable drive 80 and mechanical linkage 81 causing a suction in pipe 37 and a subsequent suction in bell mouth 35. Material will then begin to pass up in the bell mouth passing through pipe 37 and past flow meter 49 and densitometer 45. Both the flow and density will be measured by meters 49 and 45, respectively, and the results communicated through wires 50 and 46, respectively, to input 51 and 47, respectively, of process controller 48. Process controller 48 then samples both the flow and density being measured and compares it to the set point value in 145. If the density is proper, no change is made to the signal communicated through output 131 to wire 130. If an error is determined, the signal communicated will be changed dependent upon the error detected. If the density is too high, the signal outputted at output 131 to control valve 67 will change so that the valve will open passing more fluids through pipe 69 to port 70 adding diluent to the fluids being sucked into pipe 37.
This invention relates to a method for obtaining diluent fluid as well as a method to dispose of the particulate material which passes over the top 14 of tank 10. The material passing over top 14 will pass through overflow pipe 17, valve 18, and subsequent pipe 19 for deposit into tank 20. The amount of solids in tank 20 will be determined in part by the velocity of the fluids passing over the top 14 of tank 10. Under some conditions the amount of material can be substantial and can be in the excess of 35 tons per hour. The material passes through pipe 19 and into tank 20 and will settle to the bottom in the same manner as the material settled in tank 10 as illustrated by arrows 33. The nature of material in tank 20 will be different from tank 10 in that it will generally be of a smaller diameter, for example one millimeter in diameter or less. Since the material is fine, it can be used as a diluent for the material being removed through pipe 37 of tank 10. Furthermore, it can be disposed of completely by sucking it out of tank 20 through bell mouth 55, through pipe 56 and cutoff valve 57 to pump 59 which communicates through outlet 60 to pipe 63, flow meter 65, valves 66, 67 and 68 to port 70. The material being drawn into bell mouth 55 can be controlled in two ways. First, its flow can be detected by flow meter 65 which is coupled through wire 76 to the input 77 of process controller 48. Secondly, as previously mentioned, the output density and flow can be determined by densitometer 45 and flow meter 49. The process controller normally would control the flow as previously discussed by generating an output signal at outlet 131 through wire 130 to valve 67. One of the useful functions of flow meter 65 is to anticipate the subsequent setting for both valves 67 and rotation speed of pump 40. The flow as measured by flow meter 65 can be carefully controlled as required by process controller 48 by a signal on output 73 through wire 74 to input 75 of variable speed drive 71 which can communicate a required change in pump speed in response to a change in the flow from a predetermined set point, to linkage 72 and to the impeller of pump 59; therefore, if additional flow is required through port 70, the process controller can communicate a correspondingly increased signal to the variable speed drive 71 to increase its rotation thus increasing the flow of fluids through pipe 63. If this increase in flow of fluids causes the fluid level to drop too far in tank 20, level indicator 132 will communicate this fact to input 134 of process controller 48. Additional fluids can then be transferred from the alternate source of water 116 to pipe 117 to pipe 119 by opening valve 120. Valve 120 has not been shown as being controlled by process controller 48. It is obvious that any valve can be controlled by process controller 48. Thus level changes indicated by level control 132 can be communicated as previously described by process controller 48 and process controller 48 can then communicate this to valve 120 adding water to tank 20.
During the initial startup of the system, tank 20 can have a significant quantity of solid material settled to the bottom. Thus the dilution fluids being drawn into bell mouth 55 can substantially exceed the normal density of material drawn into bell mouth 55. Under these conditions, it might be necessary to dilute part of the fluids being drawn into bell mouth 55 so that proper control of the density can be achieved in pipe 37 as quickly as possible during the start procedure. Dilution fluids under these conditions can be monitored and added by a signal from the process controller being applied to output 126 through wire 125 to valve 122; therefore, if the density being drawn into bell mouth 55 is too high, valve 122 can be opened by an amount necessary to reduce the density of the fluids to an acceptable level. A densitometer is not shown on pipe 56, pipe 63 or any of the pipes going directly into port 70. It is obvious from the copending applications that the density of this line can be carefully controlled if desired by the inclusion of a densitometer. If fluid in tank 10 begins to drop below an acceptable level and yet the density being drawn through pipe 37 is the minimum desired to be pumped, fluids must be added to tank 10 without changing the density of the fluid being drawn through pipe 37. In order to accomplish the above, valve 104 in pipe 103 can be opened, causing additional water to flow through second input 106 to input apparatus 22 and into tank 10. In the above manner fluids can also be added passing the fluids through dilution port 70. Fluids may accumulate in tank 20 on occasions which will require removal of fluids to a temporary sump. This provision is accomplished by port 155 which communicates with collection region 156 which communicates with down pipe 147, cutoff valve 148 and another pipe 149 to sump 153.
Referring to FIG. 2 a modified embodiment is illustrated. Similar numbers will be used for similar elements in FIG. 2. The basic difference between the device illustrated in FIG. 2 and that in FIG. 1 is the means for transferring the solids from tank 20 to tank 10. In FIG. 1 the solids were transferred by sucking them into mouth 55 through pipe 56 pump 59 pipe 63 and into dilution port 70. This scheme provided for removing solids completely out of the systems without recirculating them in tank 20. FIG. 2 illustrates a method for recirculating the solids by transferring the solids from tank 20 to tank 10 and depositing them along with the slurry from the mine face being received through pipe 21. To accomplish the above the solids in bed 34 in tank 20 are drawn into mouth 55 through pipe 56 which is coupled directly to pipe 107. Material will then pass through cutoff valve 109 to the input 110 of pump 111. It is then outputted at 112 through valve and cutoff apparatus 113a and 113b, respectively, to pipe 114 where it is inputted into inlet apparatus 22 at port 115. The solids and fluids drawn into mouth 55 will then be deposited along with material from the source of slurry at pipe 21 which is also deposited into inlet apparatus 22 at port 26. During startup or at other times to agitate material in tank 20, it may be advantageous to recirculate material in tank 20 only. For this purpose a pipe 207 is coupled through a valve 208 to pipe 209 which empties into tank 20.
The system shown in FIG. 2 is not as efficient as the system shown in FIG. 1, since it will require recirculation of the solids on a continuing basis since some will again overflow over the top 14 of tank 10 and back through pipe 17, valve 18 and pipe 19 into tank 20. The level control 132 will function as previously described by its communication through wire 133 to to input 134 of process controller 48. The apparatus in tank 10 which comprises the bell mouth 35, elbow 36 and removal pipe 37 differs from that shown in FIG. 1 in that the fluids for port 70 are received by withdrawing fluid through port 94 in tank 20 through pipe 92, valve 93 and a continuation of pipe 92 to pipe 160 which includes flow meter 65 coupled through wire 76 to input 77 of process controller 48 as described in FIG. 1. Pipe 160 is connected to inlet 58 of pump 59 which is connected from its output 60 to the above described valving systems 66, 67 and 68. Overflow from tank 20, if it should occur, passes through an opening 155 down into collection region 156 to pipe 147 cutoff valve 148 and pipe 149 to sump 153.
The system of FIG. 2 operates in the following manner:
Tank 10 functions in the identical manner as that described in FIG. 1 and will not be further described. As the material accumulates through overflow over the top 14 of tank 10 down pipes 17 and 19 to tank 20, it accumulates as previously described as a bed of solids 34 in tank 20. These solids are then sucked up by mouth 55 into pipe 56 up pipe 107 to the inlet 110 of pump 111. They are then transferred under pressure to outlet 112 through check valve 113b and valve 113a and pipe 114 to inlet apparatus 22 by exiting from input 115. If recirculation is desired or necessary, valve 113a is closed and valve 208 is opened. Material is then sucked into mouth 55 through pipes 56 and 107, valve 109, pump 111, down pipe 207, valve 208 and pipe 209 to tank 20. The above process will keep all of the fines in suspension. Once the system is in use, the tank will probably have sufficient agitation to keep the solids in suspension. When the above occurs, valve 208 is closed and valve 113a is opened. Here the material enters tank 10 in the identical manner as other slurry inputs as illustrated by pipe 21 with outlet 26. It is obvious, of course, that any material which enters inlet apparatus 22 will settle in the direction of arrows 33 as previously described onto bed 32; however, a certain small percentage will pass over the top 14 of tank 10 and overflow to the tank 20. The system may, however, provide a slightly better control over the density of material in pipe 37, since it will not be mixed with solids from tank 20. It will be slightly less efficient, however, as a certain percentage of the material will be recirculated between tank 10 and tank 20.
It is obvious that other combinations can be utilized in the transfer of material from tank 20 to tank 10, and such obvious combinations are well within the scope of the specification and appended claims.
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This is an improved apparatus used with a storage and reclamation apparatus which handles slurry formed of particulate matter and fluid. The reclaim apparatus includes a tank having a side wall and bottom. The slurry is added into the tank and is subsequently removed from the tank by a downwardly facing bell mouth coupled through a pipe to a pump. Fluidizing jets surround the bell mouth with a dilution control port mounted between the mouth and the pump. The dilution control port is connected to a second pump in series with a source of fluids. Process control apparatus measures the flow and density of the material being drawn into the mouth and adds or reduces dilution fluid in accordance with a set point so that a constant density is maintained at all times. The improved version accepts the overflow from the tank into a second tank which has a second bell mouth mounted at the bottom of the tank. Solids and fluids are sucked into the second bell mouth and used as the source of fluid for the dilution port of the first tank.
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FIELD OF INVENTION
The present invention relates to switches useful in devices for ascertaining the location of a remotely located out-of-sight pet employing audible sound generated by a battery-powered transmitter which is selectively switchable between on and off positions. Particularly, the present invention relates to a device of the type described wherein the transmitter is selectively switchable by means of a rotary lid or cap switch having a foul weather, a splash proof, and/or waterproof feature.
BACKGROUND OF THE INVENTION
In the prior art, various pet locators such as bells and the like have been employed to provide as indicators of the location of an animal, such as a pet. These devices commonly provide a substantially constant or repetitive output of sound. Further, in the prior art, it has been proposed to employ a battery-powered transmitter which is attachable to a collar which encircles the neck of a pet and which is switchable between “on” and “off” modes of operation. The known prior art devices suffer from malfunction, corrosion, and/or other deleterious effects by reason of the exposure of their switching mechanism to adverse environmental conditions, such as snow or rain or instances where hunting dog enters a body of water, for example.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, there is provided a battery-powered transmitter which emits an audible sound and which includes a housing which is mountable to the collar for a pet, for example. The present device is switchable between “on” and “off” modes of operation by means of a rotary cap whose rotational position effects switching of the device between its “on” and “off” modes of operation. Tactile and visual indication of the then-current operational mode of the device is provided by means of the rotational position of the rotary cap and indicia provided on the housing of the device and on the rotary cap itself. The rotary cap of the present invention further provides for sealing of the rotary cap with respect to the housing against foul weather conditions while simultaneously providing for rotary motion of the cap for effecting switching of the device between its “on” and “off” operational modes, employing an expansible seal between the cap and the housing.
In one embodiment, the rotary cap includes a planar geometrically shaped conductor embedded within the interior wall of the closed end of the cap and having its outer surface essentially flush with the outer surface of the inner wall of the closed end of the cap, thereby positioning the conductor for simultaneous engagement with first and second electrical contacts disposed within the housing upon rotation of the cap to a preselected position relative to the housing, and resultant completion of an electrical circuit suitable to cause the device to apply power and thereby provide an indication of the then-current location of the pet. In like manner, by changing the rotational position of the cap, electrical continuity between the first and second contacts is broken to halt the generation of sound by the device.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a representation, partly exploded, of one embodiment of a device which depicts various of the features of the present invention;
FIG. 2 is top plan view of the rotary cap of the device depicted in FIG. 1 ;
FIG. 3 is a bottom plan view of the rotary cap depicted in FIG. 2 ;
FIG. 4 is a representation one embodiment of a sealing ring useful in the present invention;
FIG. 5 is a cross-sectional view of the sealing ring depicted in FIG. 4 ;
FIG. 6 is a side elevational view of the device depicted in FIG. 1 ;
FIG. 7 is a sectional view taken generally along the line 7 — 7 of FIG. 6 ; and
FIG. 8 is a partially exploded view of the bottom left corner of the embodiment depicted in FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
Referring to the several Figures, one embodiment of a device 10 embodying various of the features of the present invention is depicted. The depicted device includes a hollow housing 12 having a pair of loop-type leg members 14 and 15 projecting therefrom and defining means for mounting of the device on a collar 16 encircling the neck of a pet, for example.
The depicted housing 12 includes first and second opposite and outwardly opening ends 18 , 20 , respectively, each end being provided with external threads 22 , 24 adapted to receive thereon an internally threaded cap 26 , 28 , respectively, for effectively closing the open ends of the housing.
The housing further includes a sound generator housing 29 and serves to house a circuit board 32 containing those electrical components required to generate an audible sound at repeated time intervals when the device is switched “on”. As desired, the device may be provided with electrical components necessary to selectively alter the time interval, the duration and/or the decibel level of the audible sound emitted by the device. The electrical circuitry and associated switches, etc. are well understood by one skilled in the art and need not be described herein in detail.
Referring specifically to FIGS. 1-3 , the cap 26 is of conventional construction and includes an inner sealing ring 33 suitable to seal the first end 18 of the housing against foul weather conditions, including “waterproofing” the end 18 , when the cap is tightly threaded onto the threads 22 on the end 18 of the housing.
In accordance with one aspect of the present invention, the second end 20 of the housing and the cap 28 are complementarily designed to close the second end 20 of the housing while still providing for as much as a quarter turn of the cap without breaking the seal between the cap and the housing. It is this latitude of rotary motion of the cap 26 which the present inventor has found to permit the cap 26 to perform a switching function and a sealing function. That is, rotation of the cap between first and second rotational positions of the cap 26 relative to the threads 22 on the end 18 of the housing selective functions to turn the device “on” or “off”, but without breaking of the seal between the cap and the end of the housing. Whereas such extensive rotary movement of the cap would normally break the seal between the cap and the end of the housing and thereby allow water to enter the housing, the present inventor has found that by employing a specially designed resilient ring 33 .
The preferred resilient sealing ring 33 disposed between the cap 26 and the end 18 of the housing is depicted in FIGS. 4 and 5 . Notably, as best seen in FIG. 5 , the resilient ring 33 of the present invention includes a body portion 40 which is generally of rectangular cross-section but which further includes an outermost rim 42 which is generally hemispherical in cross-section and is integrally formed on the outer perimeter 43 of the top surface 44 of, and projects from, the body portion 40 of the ring 33 to thereby position the rim 42 between the flat circular face 34 of the end 18 of the housing and the inner end surface of the cap. One suitable material of construction for the ring of the present invention is a rubber or polymeric elastomer available from Advanced Elastermer Systems having a Shore A durometer value of between about 50 and about 90. In any event, the depicted embodiment of the sealing ring 32 of the present invention, the ring provides a preferred embodiment for effecting the desired sealing of the cap with respect to the threaded end 8 of the housing. However, it will be recognized that other cross sectional geometries may be acceptable. For example, the cross-sectional geometry of the rim 42 of the ring may be of any geometry which provides for the rim 42 to be resiliently interposed between the cap and the immediately adjacent threaded end of the housing and the side wall of the cap such that there is formed a resilient annular seal between the cap and the end of the housing, that is, between the rim portion of the ring and the outer surface 34 of the end 18 of the housing.
In the depicted embodiment of the present invention, end 18 of the housing is provided internally thereof with a mounting plate 50 of electrically non-conductive material. This plate is fixedly mounted within the end 18 of the housing substantially parallel to the longitudinal centerline 55 of the housing and serves to mount the circuit board 32 within the housing. A further generally disc-shaped end plate 53 , also of non-electrically conductive material is provided to substantially close end 18 of the housing 12 except for a slot 57 which serves to support one end 50 of an elongated battery 56 within the slot 57 in the plate. Further, a spring contact 58 which is resiliently mounted on, and in electrical communication with the circuitry on the circuit board, projects through an opening 60 in the plate and is inherently biased away from the open end of the housing. Thus, as seen in FIG. 1 , one terminal 62 of the battery 56 which is exposed outwardly from the plate and adjacent the open end 18 of the housing defines a first electrical contact 70 . The spring contact 58 defines a second electrical contact 72 which is physically spaced apart from the first electrical contact. As noted, the spring contact 58 is inherently biased away from (outwardly from) the open end 18 of the housing. That end 74 of the battery which is disposed most inwardly of the inner volume of the housing engages a spring 76 which is associated with and in electrical communication with the circuitry of the circuit board 32 . Thus, the first and second electrical contacts are both spring biased outwardly of the open end of the housing, hence toward the cap 26 when the cap is threaded onto the end 18 of the housing, and are thereby positioned to be simultaneously engaged by an electrical conductor 80 mounted in the cap 26 and thereby close the circuitry associated with the circuit board and generate an audible sound or RF signal, for example. This opening and closing of the circuitry effects the turning “on” and “off” of the device and in the depicted embodiment is effected by rotational motion of the cap 26 as the cap is threaded onto or off the threads 22 of the end 18 of the housing. More specifically, each of the first and second electrical contacts 70 and 72 are biased to respective locations outboard of the plane occupied by the outermost circular face 34 of the housing.
More specifically, and referring to FIGS. 1-3 and 7 , in the depicted embodiment, the inner end wall 82 of the cap 26 is provided with a circular depression 84 within which there is fixedly mounted an electrical conductor 80 . In the depicted embodiment, this electrical conductor is flat and planar and somewhat elongated, but is provided with a special geometry when viewed in a plan view (see FIG. 3 ). The overall length of the conductor 80 is chosen to be sufficient to permit the conductor, when the cap is rotated to a first rotational position relating to the housing, to simultaneously engage the first and second electrical contacts 70 , 72 (i.e., the battery terminal and the spring contact). In the depicted embodiment, one end 83 of the conductor 80 is of a width which is about twice the width of the opposite end 85 of the conductor. Notably, these opposite ends of the conductor are disposed about 180 degrees apart about the centerline 55 of the cap. The depth of the depression 84 in the inner end surface of the cap is chosen to be essentially equal to the thickness of the conductor so that the outer surface 86 of the conductor is mounted essentially flush with the surface 88 of the inner end wall of the cap, thereby permitting ready sliding motion between the first and second electrical contacts 70 , 72 and the conductor 80 as the cap is rotated to its first rotational position relative to the housing.
In the depicted embodiment, it will be noted that the somewhat elongated geometry of the conductor 80 and its position within the cap are chosen such that the more narrow end 83 of the conductor is disposed in electrically conductive engagement with the contact 72 , and its opposite wider end 85 is in electrically conductive engagement with the contact 70 (battery terminal) when the cap has been threaded onto the end of the housing and tightened to the “ON” position and commencement of generation of an audible sound or RF signal by the device. This sound or signal continues so long as the device is “ON”. Rotation of the cap (loosening of the cap) by about one-quarter turn or less is sufficient to move the end 83 of the conductor out of engagement with the contact 72 and thereby render the device inoperative. The wider end 85 of the connector provides for variance of the location of the battery terminal relative to the location of the terminal 70 , hence lessening of any need to precisely position the cap such that the circuit between the battery terminal and the contact 70 is closed or opened.
Referring to FIG. 7 , it will be noted that the cap 26 is provided with a further circular depression 90 in the inner surface of the cap at a location immediately adjacent the inner side wall 92 of the cap for the receipt therein of the sealing ring 32 . In the depicted embodiment, the depth of this depression is less than, about one-third to one-half, the thickness of the body portion 40 of the sealing ring. By this means, as much as one-half to two-thirds of the thickness of the sealing ring projects above the inner surface 88 of the cap. Further, this disposition of the sealing ring positions the raised circular rim 42 of the sealing ring in register with the circular outer face 34 of the cap, and when the cap is threaded onto the end 18 of the housing, this circular rim 42 engages the outermost flat face 34 of the end 18 of the housing to effect a waterproof seal therebetween before the cap has been fully threaded onto the housing. By this means, when the cap is threaded onto the end of the housing, less than full threading of the cap onto the end of the housing, effects water-tight sealing between the cap and the end of the housing, leaving as much as a quarter of a turn of the cap on the end of the housing available to further compress the sealing ring between the cap and the end of the housing. It is this additional rotational motion of the cap provided for by the compressibility and resiliency of the sealing ring, which the present inventor employs to effect movement of the conductor 80 disposed within the cap into electrical connection with the first and second electrical contacts which project from the end of the housing. That is, tightly threading the cap onto the end of the housing rotates the conductor with the rotation of the cap and brings the conductor into simultaneous electrical communication with the first and second electrical contacts 70 , 72 to turn the device “on”. To turn the device “off”, one only need to unscrew the cap by less than about a quarter turn to disengage the conductor and the electrical contacts. At all times during this limited degree of rotation of the cap relative to the end of the housing, the compressibility and resiliency of the sealing ring are chosen to be sufficient to cause the sealing ring to compress or rebound, as the case may be, as the cap is rotated through the limited degree of rotation. Thus, the action of turning the device “on” and “off” is performed by rotation of the cap without ever breaking the waterproof seal between the cap and the end of the housing.
Thus, it will be apparent to one skilled in the art that the durometer value exhibited by the material of the ring will be a function of the cross-sectional geometry of the rim in particular. That is, soft resilient materials may dictate a relatively larger size, and/or different geometry, rim to ensure adequate compression sealing, and less resilient materials may dictate another geometry for the rim. The ring must exhibit excellent resiliency and rebound properties and resist abrasion by repeated rotary motion of the cap by as much as a quarter turn relative to the housing when the cap is rotated to turn the device “on” or “off”. Moreover, it is to be recognized that the device of the present invention is exposed to substantial shock forces, such as when a pet wearing the device on its collar, for example a hunting dog, may run through thick brush, jump around in a boat, climb into a boat, etc. and thereby subject the present device to relatively severe blows which tend to loosen the cap 26 on the housing 12 with resultant turning “off” of the device and cessation of the desired emanation of sound or RF signal from the device. Such cessation of sound from the device obviously defeats the purpose of the device, as well as opens up the possibility of water entering the device and consequential damage to the device.
Notably, in the present invention the preferred resilient ring 32 is snugly, hence frictionally, held within the depression 90 such that the ring remains securely in place even when the cap 26 is fully removed from the housing 12 . Tactile identification of the rotational position of the cap is facilitated by means of elongated lugs 97 which are equally spaced apart about the outer circumference of the cap 26 . In a preferred embodiment, one of the lugs 99 is larger (e.g. wider) than the remaining lugs. The rotational position of this wider lug relative to the starting position of the cap for threading the cap onto the housing, in combination with the number and pitch of the cooperating threads on the cap and on the end of the housing, is adjacent the “ON” position of the device when the cap is fully and snugly threaded onto the housing, thereby affording the pet owner assurance that the device is in the desired operative state. Vice versa, when the lug 99 is rotational out of sync with the “ON” position of the device, the pet owner may tactically ascertain that the device is “OFF”. When the device is “ON,” it emits a continuous (or periodic) audible or radio frequency (RF) signal. Tactile indication may be useful when the device is designed to emit an RF signal.
Whereas the present invention has been described in connection with the embodiment depicted in the several Figures, it will be recognized by one skilled in the art that other embodiments are suitable for obtaining equivalent functioning of the present device. For example, the battery itself could be contained within the cap without departing from the present invention. Moreover, the precise geometry of the sealing ring may be altered while still permitting the described limited degree of rotation of the cap relative to the end of the housing without breaking the required seal between the cap and the end of the housing. It is therefore, intended that the invention be limited only as set forth in the claims appended hereto.
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A battery-powered transmitter which emits an audible sound or RF signal, including a housing which is mountable to the collar for a pet, for example. The present device is switchable between “on” and “off” modes of operation by means of a rotary cap whose rotational position effects switching of the device between its “on” and “off” modes of operation. Tactile and visual indication of the then-current operational mode of the device is provided by means of the rotational position of the rotary cap and indicia provided on the housing of the device and on the rotary cap itself. The rotary cap of the present invention further provides for sealing of the rotary cap with respect to the housing against foul weather conditions, including immersion in water, while simultaneously providing for rotary motion of the cap for effecting switching of the device between its “on” and “off” operational modes, employing an expansible seal between the cap and the housing.
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BACKGROUND OF THE INVENTION
A. Field of the Invention
This invention relates to non-toxic solid gas generants, particularly those suitable for the production of substantially pure nitrogen gas, and more particularly to the use of high nitrogen content compounds, preferably containing no hydrogen, such as the dialkali salts of bitetrazole or azobitetrazole or the like as a base for such generants
B. Description of the Prior Art
There has been considerable interest in the generation of nitrogen gas for a number of purposes including the inflation of aircraft or automobile safety crash bags, also termed air bags, and the purging of fuel lines and storage tanks for reactive or pyrogallic fuels as used in liquid fueled rocket motors.
The details of crash bag systems have been widely discussed, as have the reasons for the selection of pyrotechnic devices for the rapid and dependable generation of gases for inflating the bag. The operational constraints of crash bags are also well known. The system must supply non-toxic gas to inflate the bag because air bag systems generally vent into the passenger compartment on deflation, and because of the very real probability of bag rupture in an actual crash situation. Additionally, the gas must inflate the bag at a temperature which the vehicle occupant can tolerate. The time period for attainment of maximum inflation has been determined to be from 20 to 100 milliseconds. The device must be safe to handle and store prior to production. It must be adaptable to mass production line installation techniques and not introduce an unreasonable hazard then or during the life of the vehicle. It must assure reliable operation during the life of the vehicle containing it, which may be on the order of 10 years or longer.
The objectives of rapid generation of cool non-toxic inflation gas and long-term operability depend to a large extent on the gas generant selected and the physical form into which it is initially compounded.
If a suitable propellant can be designed, then the design of a complete passive restraint system undertaken with consideration of the characteristics of a particular propellant stands a better chance of practical success.
Naturally, from every point of view, the most desirable atmosphere inside an inflated crash bag would correspond in composition to the air outside it. This has thus far proven impractical of attainment. The next best solution is inflation with a physiologically inert or at least innocuous gas. The most practical of these gases has proven to be nitrogen.
The most successful of the prior art solid gas generants of nitrogen that are capable of sustained combustion have been based upon the decomposition of compounds of alkali metal, alkaline earth metal and aluminum derivatives of hydrazoic acid, especially sodium azide. Such a nitrogen gas generant comprising mixtures of alkali metal azides, metal and metalloid oxides, molybdenum disulfide, and optionally sulfur, pressed into pellets is disclosed in U.S. Pat. No. 4,203,787 that was granted on May 20, 1980 to George F. Kirchoff and Fred E. Schneiter.
There are disadvantages, however, to the use of these azides, particularly in the generation of the inflating gas for air bag systems.
Sodium azide, a Class B explosive, is a highly toxic material. It is easily hydrolyzed, forming hydrazoic acid which is not only a highly toxic and explosive gas, but it also readily reacts with heavy metals such as copper, lead, etc. to form extremely sensitive solids that are subject to unexpected ignition or detonation. Especial handling in the manufacture, storage and eventual disposal is required to safely handle such materials and gas generants prepared from the azide compounds.
A number of other nitrogen gas generants have been reported, as disclosed, for example, in U.S. Pat. Nos. 3,004,959, 3,055,911, 3,171,249, 3,719,604, 3,814,694, 3,873,477 and 3,912,561. Many of the prior art gas generants are based on nitrogen-containing compounds such as those derived from the various hydroxamine acid and hydroxylamine derivatives, while others consist of various polymeric binders, hydrocarbons and carbohydrates which are oxidized to produce non-corrosive and, often termed, "non-toxic" gases. The gas products from these compositions contain unacceptably high levels of CO 2 , CO and water for use in air bag applications where the possibility exists that the occupant may breathe, even for short periods of time, high concentrations of the gases produced from the gas generator. These compositions do not meet the requirements that the combustion products meet industrial standards for toxic and other gases such as CO, CO 2 , etc.
SUMMARY OF THE INVENTION
This invention relates to a solid composition capable of sustained combustion to produce an atmosphere of predominately nitrogen and nonvolatile solids as the combustion products. The gas generated is non-toxic, is suitable for use in applications such as the inflatable crash restraint systems for aircraft or automobile crash bags which have stringent requirements limiting the levels of impurities for a gas product which could be inhaled directly by an occupant.
The nitrogen atmosphere generated by the composition is inert and could also be used to purge fuel lines and storage tanks for reactive or pyrogallic fuels as used in liquid fueled rocket motors.
The nitrogen source according to the present invention is based upon high nitrogen content compounds, containing no hydrogen, such as the dialkali salts of bitetrazole or azobitetrazole. A nitrogen containing oxidizer such as an alkali nitrate or nitrite oxidizer is used to free the nitrogen and tie up the carbon in the organic molecule as the alkali carbonate, which is sufficiently thermally stable to withstand the conditions of the oxidation reaction thereby effectively removing the CO 2 from the combustion products. This also has the effect of limiting the amount of CO in the gas products.
The use of a composition having a high nitrogen content and containing no hydrogen is especially advantageous in a gas generator for air bags. It is noted, in this connection, that with hydrogen in the composition, water is a product of the combustion and results in a flow of steam into the bag, as little as 3 percent by weight of hydrogen in the composition producing up to 20 percent by volume of steam in the air bag. Condensation of the steam in the air bag causes pre-deflation, that is collapse of the bag too quickly since a reduction in volume of about 1000 to 1 occurs upon condensation of the steam. Additionally, the capacity of the bag, when wet, to transfer heat to its outer surface is increased substantially, thereby creating a situation that may result in severe burns to the vehicle occupant. The possibilities of such predeflation and injuries to the occupant including burning are avoided with the use of the composition containing no hydrogen.
The composition has the additional advantage of being insensitive to accidental ignition by friction or impact. The gas generant composition and its combustion products are not highly toxic materials and therefore do not require specialized handling techniques to minimize toxicity or contamination problems in fabrication, storage, or disposal of generator units embodying the generant. The combustion products of the compositions are primarily nitrogen gas and alkali carbonates such as sodium or potassium carbonate.
A tetrazole, as those skilled in the art understand, comprises a crystalline acid compound, CH 2 N 4 . This compound may be regarded as pyrrole in which nitrogen atoms replace three CH groups; also, any of various derivatives of the same.
The invention also provides a method for the generation of substantially pure and substantially particle free nitrogen gas at pressures below 2000 psia in the gas generator chamber, where generation is initiated at normal room temperature, which comprises:
(a) treating a nitrogen gas generant composition comprising a mixture of 35 to 60 weight percent of a dialkali salt of bitetrazole and 40 to 65 weight percent of an alkali nitrate or nitrite with hot combustion products of an igniter combustion mixture of 5 to 25 weight percent boron and 75 to 90 weight percent potassium nitrate, said hot combustion products being of sufficient quantity to induce and sustain oxidation of said dialkali salt of bitetrazole by said alkali nitrate or nitrite;
(b) passing the products of combustion of said nitrogen gas generant composition through cooling, filtration and pH adjustments means; and
(c) using the generated gas to inflate an air bag.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The manner of making and using the nitrogen gas generant compositions of the invention will now be described with reference to a specific embodiment thereof, namely a nitrogen gas generant composition consisting of a potassium salt of bitetrazole (K 2 BT) arranged to be oxidized with potassium nitrate.
In order to prepare the gas generant composition, the components, the potassium salt of bitetrazole and the potassium nitrate, which are commercially available, may be dry blended as powders by standard methods. The blended powder, may, if desired for use where rapid, controlled, repeatable, and long term reliably accurate performance is intended, be compressed into tablets, granules or pellets by conventional techniques. Since the components of the gas generant composition and the composition itself is not highly toxic, special handling techniques to minimize toxicity or contamination are not required in the fabrication of the composition or in the pelletizing thereof.
One skilled in the art will recognize that one may substitute other dialkali salts of bitetrazole or azobitetrazole for the potassium salt of bitetrazole illustrated herein above such as sodium bitetrazole or azobitetrazole compounds such as aminotetrazole, bistetrazole-tetrazine, tetrazole, polyhydrazides, or poly azo-alkyl, and that one may substitute other alkali nitrates or nitrites for the potassium nitrate, such as sodium, lithium, magnesium, strontium and barium nitrate or nitrite as the oxidizer to free the nitrogen and tie up the carbon in the organic molecule as the alkali carbonate.
The particle sizes of the generant composition components are not particularly critical and the commercially available materials sized as powders or small crystals are suitable. When rapid combustion rates are essential, the particle size must be more closely controlled. Submicron size particles may be employed in preparing pelletized gas generant compositions. Particle sizes of 0.7 to 0.9μ are particularly preferred in obtaining embodiments of the invention with burning rates within the desired range.
One skilled in the art will recognize that as the compositions of the instant invention are cooler burning than most other gas generator compositions in general, they require a hot initiator to start the combustion process reliably. Although many equivalent initiators will occur to one skilled in the art, and the use of such equivalents is comprehended in the process of the invention both in the specification and appended claims, a particularly convenient and preferred initiator composition is one consisting of 5 to 25 weight percent, preferably about 10 weight percent boron; 75 to 95 weight percent, preferably about 85 weight percent potassium nitrate to which mixture is added 3 to 10 weight percent, preferably about 5 weight percent lead azide. Firing of the initiator composition may be standard electrical means including any desired safety devices in the circuitry, such as spark gaps and/or ferrite resistors to prevent unwanted initiation from strong radio frequency or high voltage sources, at the option of the designer of the system.
While the gas generant compositions of this invention may be employed as the charge in conventional gas generators of the prior art, they are most advantageously employed in the particular gas generator construction described in the copending application of Gary Adams and Fred Schneiter bearing U.S. application Ser. No. 088,992, filed Oct. 29, 1979 and issued as U.S. Pat. No. 4,296,084 on Oct. 20, 1981.
This gas generator, which has a concentric configuration with the initiator at the center of a suitable reaction chamber surrounded by the gas generant compositions in suitable pelletized form which is in turn surrounded by wire screen, specially selected woven fiber glass cloth, and a second layer of wire screen covering radially arranged exit ports to a concentric diffusion chamber, the radially arranged exit ports of which are filtered by wire screen supporting an aluminum silicate fiber mat as a secondary filter, enables the advantageous characteristics of the inventive embodiments to be fully utilized.
Specifically, the pyrotechnic material of the initiator, the gas generant composition and the primary filter are all contained in a hermetically sealed aluminum cartridge. This insures reliability of the generator over long periods. The aluminum cartridge is positioned in the combustion chamber of the generator. Upon initiation of combustion by the firing of the squib, the rising gas pressure ruptures the side wall areas of the cartridge adjacent the orifices of the combustion chamber. This allows gas to flow through the primary filter and out of the combustion chamber through the several orifices. The combustion chamber filter consists of one to three layers of a coarse screen adjacent to the wall of the chamber. This serves as a collecting area for gas to flow along the chamber wall to the chamber orifices and permits gas to flow evenly through the primary filter regardless of the proximity of a combustion chamber orifice. Inboard of the coarse screen are one or more layers of fiberglass woven fabric. The fiberglass fabric is selected for compatibility with the temperature in the combustion chamber during burning of the selected gas generant composition thereby to provide a tacky surface for particle entrapment that does not melt or erode away under the effects of the high temperature gas. An effect accompanying the production of the tacky surface appears to be a swelling of the fibers of the fiberglass fabric that reduces the porosity of the primary filter. It is believed that this swelling causes the primary filter to restrict the flow of gas and combustion residue out of the combustion chamber. This effect is believed to continue for only a short interval, up to about 3 milliseconds, but long enough to allow cooling and condensation of hot and molten particulate residue within the voids of the filter. Inside the multiple layers of the fiberglass cloth are multiple layers of fine mesh carbon steel screen. The layers of the fine mesh carbon steel provide a large relatively cool surface for condensation of combustion solids prior to encountering the multiple layers of fiberglass woven fabric. Approximately 95 percent of all solid products of combustion are trapped in the combustion chamber filter. It is noted that outside of the combustion chamber, the velocity of the gases that are generated becomes so high that trapping of the products of combustion in that region becomes exceedingly difficult.
The secondary filter is comprised of multiple wraps of wire mesh which serves to cool the gas and provide surface for condensation of solid particles. Surrounding the wire mesh filter pack are one or more wraps of the aluminum silicate blanket.
Surrounding the aluminum silicate blanket are several wraps of fine mesh screen which provide structural support for the aluminum silicate blanket. It is noted that aluminum silicate blanket is porous, has very little strength, and tends to disintegrate under the effects of the high velocity gas stream. The filter elements, however, retain the solids entrapped. The fine mesh outer screen is used to trap these aluminum silicate filter particles and prevent them from being carried out of the exit orifices of the housing with the clean combustion gases. One skilled in the art will recognize that the successful initiation of combustion of any gas generant requires the use of an adequate quantity of initiator to insure that sufficient hot combustion products of the initiator contact enough of the exposed generant surface to kindle a self sustaining flame front. The selection of such amounts by a number of simple graduated experiments for any initiator-gas generant combination is well within the skill of a journeyman in the art. In the case of the compositions of the instant invention from 0.02 g to 0.03 g, preferably from 0.024 g to 0.026 g of the boron, potassium nitrate, lead azide initiator described herein per gram of gas generant composition may be employed.
One skilled in the art will also recognize that although the combustion temperature of the instant compositions is significantly lower than those of the prior art, in order to reduce the gas temperature in the crash bag to a level tolerable by the vehicle occupants, additional cooling means must be provided. In addition to the cooling method of the aforementioned Schneiter and Adams copending application, the standard cooling means, normally layers of woven metal mesh which additionally may serve as conventional filtration means may be employed. One skilled in the art will also recognize that the effluent gases from combustion of the instant composition may contain sufficient alkaline material to cause burns or discomfort to someone coming in contact therewith. In addition to the fiberglass of the aforementioned Schneiter and Adams application, the conventional neutralizers of the prior art, conveniently carbonate salts, may be employed to adjust the pH of the effluent gases from combustion of the compositions of this invention to levels tolerable by humans, conveniently pH levels below 10.0.
The following examples further illustrate the best mode contemplated for the practice of the present invention.
The compositions shown in the following two tables were pressed into pellets and burned in a gas generator motor that was vented into an evacuated steel tank to collect the combustion gases for analysis. These compositions have the advantage of producing nitrogen with very low concentrations of CO 2 , CO and water which allows its use for inflation of crash bags and other purposes requiring an inert atmosphere.
______________________________________NITRATE OXIDIZED COMPOSITIONS 31-1 3-2 31-3 31-4 14-1______________________________________Sample No.K.sub.2 BT 54.1 51.4 49.1 44.9 52.5KNO.sub.3 45.9 48.6 50.9 55.1 --NaNO.sub.3 -- -- -- -- 47.5Generator P (psi) 2300 2100 2270 2400 910Action Time (ms) 78 90 80 79 153Gas AnalysisCO, ppm 1000 700 800 196 371CO.sub.2, % 5 2 <1 <1 --______________________________________NITRITE OXIDIZED COMPOSITIONS 31-6 29-1 29-6 11-4______________________________________Sample No.Na.sub.2 BT -- -- -- 30.5K.sub.2 BT 49.5 48.5 43.7 --NaNO.sub.2 50.5 51.5 56.3 69.5Generator P (psi) 2530 2520 2120 2200Action Time (ms) 81 74 75 36Gas AnalysisCO, ppm 80 670 476 935CO.sub.2, % <1 <1 <1 1.3NO.sub.2, ppm <1 1 50 0______________________________________
Another class of gas generant compositions, producing a dry or substantially moisture-free atmosphere, can be prepared from the tetrazole-containing compounds such as the metal salts of bitetrazole or azobitetrazole. These compositions can result in the generation of moderate amounts of CO 2 . The application would be with conditions less affected by the CO 2 , such as, fully enclosed or sealed air bag as used in inflatable escape chutes, life rafts, etc. Cooler burning compositions result from the use of the alkaline earth salts as part of the tetrazoles and oxidizer which form less stable carbonates that liberate CO 2 . For example, the calcium salt of bitetrazole oxidized with calcium nitrate would form one or two moles of CO 2 , depending upon combustion rates and conditions, along with the nitrogen, essentially following the equation:
CaC.sub.2 N.sub.8 +Ca(NO.sub.3).sub.2 →xCaO+xCO.sub.2 +(2-x)CaCO.sub.3 +5N.sub.2
The temperature and combustion conditions control the extent of the formation of CaCO 3 or CO 2 and CaO. The result is a moisture free gaseous product containing CO 2 suitable for uses where moisture would cause corrosion or other problems. The type of tetrazole salt used would be dictated by the specific reactants and amount of CO 2 allowable in the gas product. For example, the extent of decomposition of the metal carbonate to the oxide and CO 2 depends upon the type of carbonate that would be formed. The potassium and sodium carbonates in the combustion zone are the most stable and least likely to decompose to the oxide while magnesium carbonate decomposes readily at approximately 600°-700° C., forming CO 2 and magnesium oxide.
Subject matter disclosed but not claimed in this application is disclosed and is being claimed in the copending application, filed concurrently herewith of Norman H. Lunstrum and Graham C. Shaw bearing Ser. No. 221,943.
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A solid non-azide, non-toxic, substantially moisture-free nitrogen gas generating composition intended for use in the deployment of inflatable safety crash bags for driver and passenger protection in vehicles consists essentially of a metal salt of a non-hydrogen containing tetrazole compound selected from the group consisting of alkali metal salts and alkaline earth metal salts and an oxidizer containing nitrogen and a member selected from the group consisting of an alkali metal and an alkaline earth metal, the tetrazole being an azobitetrazole, and examples of the oxidizer being sodium nitrate, sodium nitrite and potassium nitrate.
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BACKGROUND OF THE INVENTION
[0001] A. Field of the Invention:
[0002] The present invention relates to a method and system for protecting the threaded ends of pipes, such as oil field tubular goods, from physical damage and corrosion by providing an end protector formed of a polymeric body with a corrosion inhibitor integrally molded therein and to a method for recycling used end protectors.
[0003] B. Description of the Prior Art
[0004] Drill pipe, tubing and casing (tubular goods) for oil and gas drilling, completion, production and stimulation activities are typically held in a storage or pipe yard after they have been received from the fabricator or returned from downhole use. A major industry has developed in protection of such oil field tubular goods to prevent them from corroding during periods of storage. The storage is not permanent, typically extending for a number of months or until a need arises for a specific size and grade of the tubular in question. The tubular goods are typically cleaned before storage in order to prepare them for shipment to the rig site at a future date. However, corrosion due to water and oxygen may quickly attack the precisely machined threads, which then cannot provide a satisfactory threaded connection. Pipe thread corrosion may be ordinary oxidation, or rust, or maybe aggravated by micro-organisms which feed on various materials on the surface of the thread, producing an acid which causes pitting of the threads.
[0005] The exposed threaded ends of tubular metal goods are conventionally protected by some sort of supplemental means in order to extend their storage life. For example, physical thread protectors in the form of plastic or elastomeric end caps or end caps made from metals such as steel, brass or copper have been placed on the threaded ends of tubular goods to provide protection from physical abuse and from corrosion. Chemical compositions which act as running compounds and/or corrosion inhibitors are also applied to the thread surface regions of the tubulars, which combined with thread protectors serve to function as a system to prevent impact and corrosion damage to the valuable and vital thread areas. For example, API (American Petroleum Institute) pipe dope (thread compound) is utilized, although it is generally low in corrosion inhibiting properties. Pipe dope is intended to be used as a running thread compound with lubricating and sealing properties. It is a thick grease based material which may contain lead, other heavy metals and filler materials to seal the thread passageways found in the threaded connection of oil field tubular goods. An example of a storage compound as opposed to a thread compound is a product sold under the trademark KENDEX that is a wax based material which is only applied to prevent or inhibit corrosion. Other lighter materials, such as a light oil might be utilized as well if the pipe is to be used within a day or two of the time it is threaded.
[0006] While in some cases the applied compounds and solids are captured and recycled, they are sometimes allowed to be discharged into the environment, presenting the problems of hazardous waste containment and removal. Once the tubulars are threaded the manufacturer must apply either a pipe dope or storage compound then apply a thread protector to prevent corrosion and/or impact damage. OCTG threads are frequently subjected to a series of inspections once shipped from the manufacturer. These inspections require the removal of the thread protector and the applied compound. The compound on the thread protector and the threaded ends must be treated as hazardous waste and therefore present an expensive containment and removal problem.
[0007] Pipe dope compositions are less than an optimum solution as a storage compound since these products do not offer sufficient anti-corrosion properties and often contain hazardous materials such as lead, copper, zinc, and hydrocarbons. Storage compounds cannot be used as an API thread running compound as they do not exhibit sufficient lubricity properties, sealing properties and must be cleaned from the threaded connection thoroughly before the API thread compound and sealant is employed.
[0008] The mechanical end caps or thread protectors have traditionally functioned primarily to protect the threads against impact damage if the pipe is accidentally dropped or bumped. Many of the prior art thread protectors are loose fitting “dust covers” and are of little value in preventing impact damage or the intrusion of moisture into the thread region. Certain of the prior art designs are “cup-shaped” and thus offer a tighter fit and incorporate moisture seals, such an O-rings, in an effort to improve corrosion protection.
[0009] The prior art end caps are generally removed near the well site and often are contaminated with immersed crude oil, pipe dope, drilling mud and accumulated tars and lighter oils that are found on the drill site. As a result, recycling the plastic or elastomeric polymers making up the prior art end caps has been economically unfeasible in many instances due to the cost of cleaning the waste polymer pieces for recycle processing.
[0010] A need exists for an improved end cap for protecting the threaded ends of oil field tubular goods from physical damage and corrosion which eliminates the need for pipe dopes, greases, heavy metal constituents, or hazardous materials used in the past.
[0011] A need also exists for such an end cap which has incorporated therein a corrosion inhibiting compound, the compound being integrally molded within the polymeric body.
[0012] A need also exists for an improved end protector composition which can be easily and economically recycled by eliminating the need of much of the cost of cleaning waste polymer pieces before recycle processing.
SUMMARY OF THE INVENTION
[0013] An improved thread protector is provided for tubular goods having threaded ends such as oil field tubular goods. The improved thread protector is formed of a polymeric body having cylindrical wall portions which engage the threaded ends of the tubular goods in order to protect the threaded ends from physical abuse as well as isolating the threaded ends from environmental corrosion. The polymeric body has incorporated therein a corrosion inhibiting compound, the compound being integrally molded within the polymeric body.
[0014] The polymeric body can be formed of a variety of conveniently available materials commonly used in the industry including polyethylene, polypropylene, high density polyethylene, polyurethane, polyvinylchloride, styrene-butadiene copolymers, acrylics and polycarbonates. The corrosion inhibitor which is incorporated within the polymeric body has a characteristic flash point which is selected to be above a mold temperature used to mold the polymeric body. Preferably, the polymeric body has incorporated therein from about 1 to 20% corrosion inhibitor by weight, based upon the total weight of the polymeric body.
[0015] In a typical application, a sealant composition is first applied to the threaded ends of the tubular. The thread protector, in the form of a physical end protector, is then installed on the threaded end of the tubular. The end protector is a polymeric body having a corrosion inhibitor integrally molded within the polymeric body and having cylindrical wall portions which engage the threaded ends of the tubular goods in order to protect the threaded ends from physical abuse as well as isolating the threaded ends from environmental corrosion.
[0016] A method of recycling used end caps used to protect threaded ends of oil field tubular goods is also described. A source of used end caps is first collected at a central location. The used end caps will typically have field residue remaining on the end caps. The used end caps are first shredded and ground to a desired particle size. The particles are then conveyed to a thermokinetic blender which mixes the particles at elevated temperatures to form a polymeric product. The polymeric product is discharged into a suitable mold which forms a molded polymeric product having cylindrical walls. The molded polymeric product is discharged from the mold and selected portions of the cylindrical walls thereof are threaded, whereby the threaded selected portions of the cylindrical walls matingly engage a selected end of the oil field tubular goods. The mold temperature used to mold the polymeric bodies is typically in the range from about 300-400° F. The polymeric bodies will have incorporated therein from about 1 to 20% corrosion inhibitor by weight, based upon the total weight of the polymeric body.
[0017] Additional objects, features and advantages will be apparent in the written description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a partial, end view of the pin end of an oil field tubular showing an end protector of the invention in place thereon.
[0019] [0019]FIG. 2 is a view similar to FIG. 1 but showing a corresponding box end of an oil field tubular showing the end protector of the invention in place.
[0020] [0020]FIG. 3 is a simplified, schematic view of a method for recycling used end caps into the corrosion resistant protectors of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring now to FIG. 1 of the drawings, there is shown an improved thread protector 11 for a section of oilfield tubular goods, in this case, pin end 13 of a section of oil field casing. The tubular 13 has an externally threaded outer extent 15 . The thread protector 11 includes a polymeric body 17 having cylindrical wall portions 19 which engage the threaded outer extent 15 of the tubular 13 in order to protect the threaded end from physical abuse as well as isolating the threaded end from environmental corrosion. In the discussion which follows, the term “polymeric body” is intended to encompass plastic, elastomeric and synthetic polymeric materials of the type typically utilized in the industry for end caps. The preferred polymeric body is formed from a material selected from the group consisting of polyethylene, polypropylene, high density polyethylene, polyurethane, polyvinylchloride, styrene-butadiene copolymers, acrylics and polycarbonates. A particularly preferred material for the polymeric body is high density polyethylene.
[0022] The end cap or thread protector 11 illustrated in FIG. 1 has internally threaded cylindrical sidewalls which engage the externally threaded pin end of the tubular 13 . FIG. 2 shows a cup-shaped thread protector 21 which has externally threaded sidewalls for engaging the internally threaded, box end 25 of the tubular. The polymeric end cap protectors illustrated in FIGS. 1 and 2, which are examples of the Hunting Composite Gold Series protectors for API tubing, are typical of the prior art thread protectors in shape and overall function. Other typical examples of thread protectors commercially available from Hunting Composite of Houston, Tex., are the Hunting Composite Thread Protectors for API Casing and Tubing that are molded from high-density polyethylene, are covered by a protective steel shell, and are designed to cover the full thread length. The Hunting Composite Platinum Series Thread Protectors are also molded from high density polyethylene and compliment premium threads and sealing surfaces.
[0023] The thread protectors of the invention differ from the prior art in that the polymeric body 17 has incorporated therein a corrosion inhibiting compound which is integrally dispersed and molded within the polymeric body 17 . In one preferred embodiment to be described, the improved thread protectors of the invention are formed by recycling used end caps. A number of commercially available corrosion inhibitors can be utilized in the method of the invention. The preferred corrosion inhibitor has a characteristic flash point with the flash point being selected to be above a mold temperature to mold the polymeric body. For example, one commercially available inhibitor is sold under the trade name NaSul 729 by King Industries of Norwalk, Conn. This inhibitor has a sulfonate percentage of 51.2% as measured by ASTM D 3049; a viscosity of 81.6 CPS as measured by ASTM D 445; a flash point of 160° C. (320° F.) and a specific gravity of 0.980 as measured by ASTM's D 4052.
[0024] The corrosion inhibitor is typically present in the range from about 1 to 20% by weight, preferably about 5 to 15% by weight based on the total weight of the polymeric components. FIG. 3 is a simplified schematic which illustrates a preferred method of forming the thread protectors of the invention. In a particularly preferred embodiment, the thread protectors are manufactured by recycling used end caps which have been collected in a step 27 . The end caps can then be fed to a shredding and grinding step or steps 29 in which the end caps are reduced in size. The size of the shredded and ground particles is not critical but is typically on the order of 0.25-0.5 inches and may be pulverized to about 35 mesh or even to 100 mesh or finer. The ground up material is then fed to a thermokinetic mixer in step 31 . The corrosion inhibitor (and other materials) can conveniently be blended during the thermokinetic mixing step 31 . Since the compounder heats the materials in the range from about 300-400° F., the corrosion inhibitor should have a flash point above the expected compounding temperature.
[0025] Thermokinetic compounders are described, for example, in issued U.S. Pat. No. 5,895,790 to Good, issued Apr. 20, 1999. This reference describes a thermokinetic compounder which can be used for melt blending. The device economically recovers polymer blends and waste thermoset material into useful products by first preforming a thermoset material from disparate polymers and then melt blending the thermoset material with a thermoplastic material into useful products. The same type apparatus can be utilized in melt blending the used end caps of the invention, even where contaminated with oils and other oil field materials.
[0026] In the thermokinetic mixing process, polymer is loaded within a chamber where a shaft with widely spaced projections spins at speeds on the order of 4000 rpm, shearing and fracturing pieces of polymer and impinging them upon the inside wall of the chamber. While some thermokinetic mixers raise the temperature of polymers from ambient to as much as 620° F. in 20 to 25 seconds or less, the present method contemplates operating at temperatures on the order of about 320° F. or lower in order to prevent flashing of the corrosion inhibitor. This temperature will vary with the flash point of the selected inhibitor compound.
[0027] In the next step in the method, the molten batch is released from the chamber of the thermokinetic mixer 31 , preferably into a mold shown at step 33 in FIG. 3. The mold can conveniently be a two part mold operated by a hydraulic press provided with a water coolant cycle. Typical dwell time is on the order of five minutes at which point the mold halves are pulled apart and the pieces are removed. The molded end caps are then threaded on a lathe to the appropriate thread form in a step illustrated as 35 in FIG. 3.
[0028] Once manufactured, the thread protectors of the invention can be utilized in the customary fashion in the industry with the exception that a thread dope or heavy grease is not generally required. A light sealant composition may be applied to the threaded ends of the tubular, if desired. In a typical operation, the cut part is first inspected and accepted. A water displacement composition such as CRC 336, WD-40 or bactericide may be utilized in the cutting fluid. The product may then have a slight sealant applied such as the PRESERVE-A-THREAD product from Hunting Composite of Houston, Tex. The PRESERVE-A-THREAD compound is a corrosion inhibitor which can be sprayed or brushed onto the threads. The formulation contains no phosphates and is non-toxic, anti-microbial and biodegradable and recleaning prior to running the tubular is not generally necessary. The thread protectors of the invention can then be screwed into engagement on the pipe ends.
[0029] An invention has been provided with several advantages. The thread protectors of the invention do not require typical thread dope compounds to provide moisture and corrosion protection. Because thread dope compounds containing hazardous materials are not required, the used end protectors can be more easily recycled and pose less danger of environmental contamination. The thread protectors of the invention can be used with a light sealing composition and do not require harsh solvents of the type used to clean traditional dope compounds. The thread protectors of the invention offer the same degree of corrosion protection while utilizing more environmentally friendly materials. The thread protectors can be recycled for reuse even with field residue present. Because of the thermokinetic mixing process, heavy metals or other contaminants are encapsulated within the polymeric body and do not tend to leach into the environment.
[0030] While the invention has been shown in one of its forms, it is not thus limited and is susceptible to various changes and modifications without departing from the spirit thereof
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A method and system are shown for protecting the threaded ends of tubular goods such as oil field tubulars from physical damage and corrosion due to environmental factors. A thread protector is formed of a polymeric body having cylindrical wall portions which engage the threaded ends of the tubular goods. Instead of relying upon a separate thread compound or corrosion inhibitor applied to the exposed threads, the polymeric body has incorporated therein a corrosion inhibiting compound, which is integrally molded within the polymeric body as a part of the manufacturing process used to mold the polymeric body. The method also allows used end caps to be recycled into the corrosion resistant end caps of the invention.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. § 120 from the commonly owned and co-pending U.S. patent application Ser. No. 10/842,192 filed May 10, 2004, which claims the benefit under 35 U.S.C. § 119(e) from U.S. Provisional Patent Application Ser. Nos. 60/468,981, filed May 8, 2003, and 60/530,427, filed Dec. 17, 2003, the entire contents of which are each hereby expressly incorporated by reference into this disclosure as if set forth fully herein.
FIELD OF THE INVENTION
[0002] This invention relates to neurophysiological techniques and, in particular, to improved instruments and procedures to ensure accurate, real-time, temporary or permanent placement of surgically implanted devices.
BACKGROUND OF THE INVENTION
[0003] Pedicle instrumentation is often used to facilitate spinal fusion. Pedicle screws extend through the pedicles of vertebrae and into the body of the vertebrae. The screws are connected by rods or plates to eliminate motion between the vertebrae that are fused together.
[0004] Misplaced pedicle screws can injury the nerves and blood vessels that surround the vertebrae. Numerous techniques are used to help surgeons guide screws into the pedicles of the vertebrae. For example, surgeons often use x-rays including fluoroscopy to confirm the position of pedicle screws.
[0005] Nerve compression by pedicle screws can also be determined through electrical stimulation of the pedicle screws. Prior-art techniques involve recording electrical impulses in the legs or arms after electrical stimulation of the pedicles. High conductivity of the electrical impulses suggests the pedicle screws are too close to spinal nerves. High conductivity is determined by recording electrical impulses in the legs or arms of a patient after applying electrical impulses of relatively low amplitude to the pedicle screws.
[0006] Prior art “neurophysiology” techniques have several deficiencies. First, existing systems rely on the conductivity through a patient's body from the pedicle screw to electrodes in extremities or electrodes on the skin of the extremities. False negative values, low conductivity, can occur if the nerves or the skin do not conduct electricity well. Damaged nerves can be relatively poor conductors of electricity. Second, electrical impulses of relatively high magnitudes must be used to overcome the resistance of the skin, muscles, and nerves. Stimulation by electrical impulses of large amplitude can damage nerves. Third, the variable resistance of patient's bodies leads to a relatively wide range of “normal” values recorded from the extremities. The wide range of normal values decreases the sensitivity and the specificity of the prior art technologies.
[0007] NuVasive, Inc. of San Diego, Calif. offers a product that uses “screw test” technology to determine if a screw or similar device is being positioned close to a nerve during a surgical procedure. Surgeons typically use NuVasive's system to stimulate screws, guidewires, and taps placed into the pedicles of vertebrae. Recording surface electrodes are placed over the legs of the patient. Nerves conduct electricity very efficiently, such that electrical stimulation of the metal objects placed into the vertebrae can be recorded in the legs.
[0008] Using the NuVasive system, an electrical charge is sent through the screw, and a circle lights up on a computer screen giving a simple number to indicate the amount of charge reaching sensors placed on the patient's leg muscles. A high number, such as a 20, suggests the screw is clear of the nerve. A lower reading, like a 3, indicates the nerve is being stimulated and the surgeon needs to consider moving the screw. Thus, the lower the amplitude needed to record activity in the legs, the closer the metal objects are to the spinal nerves.
[0009] Research has shown that if the surface electrodes record electrical activity with stimulation of less than 8 milliamps, the metal objects are too close to the spinal nerves. The system can also be used in the cervical spine. The surface electrodes are placed on the arms for recording stimulation of devices placed into the cervical spine.
[0010] The NuVasive system has a several shortcomings. For one, the system does not yield real-time data. Nor does the system allow for efficient, repeated stimulation of instruments that are turned. This is due to the fact that the NuVasive system uses a ball-tipped stimulating probe, and the ball of the probe slips off the circular shaft of the instruments. In addition, while the system helps surgeons identify holes in the pedicle, it does not identify the location of the hole in the pedicle. Also, the instruments and screws that are placed into the spine cannot touch the skin, muscles, and subcutaneous tissues surrounding the spine during electrical stimulation. If the metal instruments touch the surrounding tissues during stimulation, the electricity can be shunted from the vertebrae. Shunting of electricity can lead to false recordings in the legs or arms (during stimulation in the cervical spine). Furthermore, the existing NuVasive system requires two different probes; one to stimulate screws and a second probe to stimulate wires.
SUMMARY OF THE INVENTION
[0011] This invention improves upon neurophysiological techniques through provision of several enhancement features. According to one aspect of this invention, stimulation of an instrument is possible while it is advancing into the spine or elsewhere, alerting the surgeon to the first sign the instrument or device (screw) may be too near a nerve. Early identification of misdirected instruments or screws may thus help prevent nerve damage.
[0012] A different aspect involves a directional probe that helps surgeons determine the location of the hole in the pedicle. Yet a further aspect provides an insulation sleeves to prevent shunting into the soft tissues. According to a different improvement, the same probe to be used to stimulate different devices, such as screws and wires.
[0013] One embodiment of the invention involves a clip that allows the use of continuous monitoring during curette, pedicle probe, tap, pedicle screw, and/or lateral mass screw insertion. The clip fits around the cylindrical shafts of these and instruments used to insert devices, including screws. The clip allows the shafts of the instruments to rotate without rotating the probe that sends electrical impulses for the testing. The surgeon may rotate an instrument to insert a tap, for instance, while an assistant repeatedly fires the probe. Thus, the surgeon can detect a breach of the pedicle wall as soon as it occurs rather than after the tap, etc. is fully inserted. Theoretically, early detection of a breach in the pedicle may prevent nerve injury and prevent enlarging a mal-aligned hole.
[0014] Other apparatus and methods of this invention improve upon existing neurophysiology technology in that electrical impulses are recorded from the spine rather than the extremities. Recording the impulses closer to the stimulated pedicle screws overcomes the deficiencies of prior-art techniques as outlined above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a lateral view of the side of the current probe and a novel clip of the present invention;
[0016] FIG. 2 is an exploded view of the invention of FIG. 1 ;
[0017] FIG. 3A is a lateral view of a curette to “sound” the pedicle and the probe with a clip attachment;
[0018] FIG. 3B is a lateral view of the probe of FIG. 1 attached to the curette of FIG. 3A ;
[0019] FIG. 3C is a cross section of the shaft of an instrument surrounded by the novel clip of the present invention;
[0020] FIG. 4 is a lateral view of an alternative embodiment instrument shaft;
[0021] FIG. 5 is a lateral view of the embodiment of the instrument drawn in FIG. 4 ;
[0022] FIG. 6 is the lateral view of an instrument to retract the soft tissues during pedicle screw or instrument stimulation;
[0023] FIG. 7 shows the insulated soft tissue retractor drawn in FIG. 6 ;
[0024] FIG. 8A is a lateral view of the probe and the novel tip;
[0025] FIG. 8B is an axial cross section of a vertebra and probes with the novel tips;
[0026] FIG. 9A is a lateral view of a screw driver, pedicle screw, and a novel insulating sleeve;
[0027] FIG. 9B is a lateral view of apparatus drawn in FIG. 9A ;
[0028] FIG. 9C is a cross section of the apparatus drawn in FIG. 9B ;
[0029] FIG. 9D is a lateral view of the apparatus drawn in FIG. 9B ;
[0030] FIG. 10A is a lateral view of an alternative embodiment of the insulation sleeve, pedicle screw, and sleeve expander;
[0031] FIG. 10B is a lateral view of the apparatus drawn in FIG. 10A ;
[0032] FIG. 10C is an axial cross section of the sleeve, screw, and sleeve expander drawn in FIG. 10A ;
[0033] FIG. 10D is an axial cross section of an alternative embodiment of the sleeve expander drawn in FIG. 10C ;
[0034] FIG. 11A is a lateral view of an alternative embodiment of the insulating sleeve;
[0035] FIG. 11B is an exploded view of the embodiment of the invention drawn in FIG. 11A ;
[0036] FIG. 11C is a cross section of the apparatus drawn in FIG. 11A ;
[0037] FIG. 12A is a lateral view of an alternative embodiment of the novel sleeve, a screw, and a screwdriver;
[0038] FIG. 12B is a lateral view of the apparatus drawn in FIG. 12A ;
[0039] FIG. 13A is a sagittal cross section through an alternative embodiment of that drawn in FIG. 3 ;
[0040] FIG. 13B is a sagittal cross section through an alternative embodiment of that drawn in FIG. 13A ;
[0041] FIG. 14A is a sagittal cross section of an alternative embodiment of invention drawn in FIG. 13B ;
[0042] FIG. 14B is an exploded lateral view of the embodiment of the invention 25 drawn in FIG. 14A ;
[0043] FIG. 14C is a sagittal cross section of an alternative embodiment of the invention drawn in FIG. 14A ;
[0044] FIG. 14D is an exploded lateral view of the embodiment of the invention drawn in FIG. 14C ;
[0045] FIG. 15A is a sagittal cross section of an alternative embodiment of the invention drawn in FIG. 14C ;
[0046] FIG. 15B is an exploded lateral view of the embodiment of the invention drawn in FIG. 15A ;
[0047] FIG. 16A is a lateral view of an alternative embodiment of the invention drawn in FIG. 14A ;
[0048] FIG. 16B is an oblique view of an alternative embodiment of the invention drawn in FIG. 16A ;
[0049] FIG. 17A is a lateral view of an alternative embodiment of the invention drawn in FIG. 14A ;
[0050] FIG. 17B is an exploded lateral view of the embodiment of the invention drawn in FIG. 17A ;
[0051] FIG. 18 is an oblique view of a portion of a vertebra and the preferred apparatus;
[0052] FIG. 19A is a view of the dorsal aspect of a portion of a vertebra and a recording electrode;
[0053] FIG. 19B is a view of the dorsal aspect of a portion of a vertebra and a recording electrode;
[0054] FIG. 20A is a view of the dorsal aspect of a portion of a vertebra and a 20 recording electrode on the inferior lateral surface of a pedicle;
[0055] FIG. 20B is a view of the dorsal aspect of a portion of a vertebra and a recording electrode;
[0056] FIG. 21A is an oblique view of the apparatus drawn in FIG. 18 ;
[0057] FIG. 21B is an exploded view of the apparatus drawn in FIG. 21A ;
[0058] FIG. 21C is a view of the top of the connecting component, the recording and stimulating electrodes;
[0059] FIG. 22 is an oblique view of a portion of a vertebra, a pedicle instrument or screw, and the recording electrode;
[0060] FIG. 23 is an oblique view of a portion of a vertebra, a pedicle screw, recording and stimulating electrodes use in an alternative embodiment of the apparatus;
[0061] FIG. 24 is a view of apparatus according to the invention including a stimulating probe;
[0062] FIG. 25 is a view of the posterior aspect of the spine;
[0063] FIG. 26 is the view of the front of an alternative embodiment of the device drawn in FIG. 24 ;
[0064] FIG. 27A is a posterior view of the spine similar to the view described in FIG. 25 ;
[0065] FIG. 27B is a posterior view of the spine as described in FIG. 27A ;
[0066] FIG. 28 is a posterior view of the spine, similar to the view drawn in FIG. 27B ;
[0067] FIG. 29 is a posterior view of the spine similar to the view drawn in FIG. 28 ;
[0068] FIG. 30 is a posterior view of the spine, similar to the view drawn in FIG. 29 , showing the alternative use of a reference electrode;
[0069] FIG. 31 is an axial view of a pedicle;
[0070] FIG. 32A is a lateral view of a needle-tipped stimulating or recording electrode;
[0071] FIG. 32B is a lateral view of an alternative embodiment of the tip of the electrode drawn in FIG. 32A ;
[0072] FIG. 32C is a lateral view of an alternative embodiment of the tip of the electrode drawn in FIG. 32A ;
[0073] FIG. 33 is an oblique view of an alternative embodiment of the invention;
[0074] FIG. 34A is a lateral view of another embodiment of the invention drawn in FIG. 33 ;
[0075] FIG. 34B is an anterior view of the embodiment of the device drawn in FIG. 34A ;
[0076] FIG. 34C is an oblique view of the embodiment of the device drawn in FIG. 34A ;
[0077] FIG. 35 is an anterior view of another embodiment of the device drawn in FIG. 33 ;
[0078] FIG. 36 is a posterior view of a peripheral nerve and another embodiment of the invention; and
[0079] FIG. 37 is a lateral view of a nerve root retractor that stimulates the spinal nerves.
DETAILED DESCRIPTION OF THE INVENTION
[0080] FIG. 1 is a lateral view of the side of the current probe 102 and a novel clip 104 according to this invention. One end of the clip snaps around instruments. The second end of the clip snaps over the tip of the probe. Alternatively, a second probe tip could be manufactured that incorporates the novel tip end. FIG. 2 is a detached view of the probe and tip of FIG. 1 .
[0081] FIG. 3A is a lateral view of a curette 302 used to “sound” the pedicle and the probe 102 with a clip attachment 104 . The shaft of the instrument 302 may be machined with a groove 310 to cooperate with the clip. FIG. 3B is a lateral view of the probe of FIG. 1 attached to the curette of FIG. 3A . FIG. 3C is a cross section.
[0082] FIG. 4 is a lateral view of an alternative embodiment, wherein the shaft of the 20 tap has a raised portion 402 to cooperate with a clip 404 . The raised portion 402 avoids the stress riser created by a groove in the shaft. FIG. 5 is a lateral view of the embodiment of the instrument drawn in FIG. 4 . The clip of the probe surrounds the shaft of the pedicle screw insertion tool. The clip rides on the enlargement of the shaft.
[0083] FIG. 6 is the lateral view of an instrument 602 used to retract the soft tissues during pedicle screw or instrument stimulation. The retraction instrument is made of plastic or other material that does not conduct electricity in the preferred embodiment.
[0084] As an alternative to the insulated soft tissue retractor of FIG. 6 , an insulated sleeve drawn in FIG. 7 may be used. FIG. 7 is an axial cross section through a vertebra and the surrounding muscles, skin, and subcutaneous tissues. A plastic sleeve would be particularly useful when stimulating percutaneous guide pins inserted into the pedicles. The insulating sleeve 706 prevents the transmission of electricity from the guide pin to the muscles or surrounding soft tissue. A similar apparatus could be used for testing modular taps. For example, the handle of a tap could be removed, thus allowing the insulating sheath to be placed over the tap.
[0085] Although the NuVasive monitoring system helps surgeons identify breaches of the walls of the pedicles, the system does not suggest where the pedicle wall has been breached. According to this invention, however, since the probe tip may be insulated circumferentially around the majority of the tip of the probe, the non-insulated portion of the tip can be rotated within the pedicle to determine the direction that requires the least amount of stimulation to record activity in the lower extremity.
[0086] FIG. 8A is a lateral view of the probe and a tip according to the invention. The dark area of the tip conducts electricity. The remainder of the tip 806 is insulated to prevent the conduction of electricity.
[0087] FIG. 8B is an axial cross section of a vertebra and probes using these tips. The medial walls of the pedicles have been breached. The probe on the left side of the drawing has the non-insulted portion of the tip directed toward the hole in the pedicle. The probe on the right side of the drawing has the insulated portion of the tip facing the hole in the pedicle. Less current will be required to stimulate the nerves on the left side of the drawing. For example, the surface electrodes could record activity in the lower extremity with stimulation of the probe at 4 milliamps with the exposed (conducting) area of the probe directed toward the medial wall of the pedicle (probe on the left side of the drawing) and the surface electrodes could record electrical activity in the lower extremities with stimulation of the probe at 10 milliamps with the exposed (conducting) area of the probe directed toward the lateral wall of the pedicle (probe on the right side of the drawing). Thus, the surgeon knows the medial wall of the pedicle has been breached. Consequently, the surgeon knows to redirect the pedicle screw more laterally, away from the holes in the pedicle.
[0088] FIG. 9A is a lateral view of a screwdriver 902 , pedicle screw 904 , and an insulating sleeve 906 . The insulating sleeve is preferably constructed of a flexible material that does not conduct electricity. For example, the sleeve could be made of plastic or natural or synthetic rubber. The sleeve can be seen folded back over itself at 908 just above the pedicle screw.
[0089] FIG. 9B is a lateral view of apparatus drawn in FIG. 9A . The insulating sleeve 906 has been unfolded and placed over the head of the pedicle screw. The insulating sleeve prevents the transmission of electricity into the tissues that surround the spine. Electricity from stimulating the shaft of the screwdriver exits through the threads of the screw. The sleeve enables the screwdriver to lie against the muscles of the spine without stimulating the muscles of the spine.
[0090] FIG. 9C is a cross section of the apparatus drawn in FIG. 9B . The flexible insulation sleeve can be stretched to fit tightly against the shaft of the screwdriver and the pedicle screw.
[0091] FIG. 9D is a lateral view of the apparatus drawn in FIG. 9B . The insulation sleeve may be removed by pulling on a cord 980 which tears the sleeve. Alternative mechanisms can be used to remove the sleeve from the screw. For example, the sleeve could be pulled from the screw while exerting counter pressure on the screw by the screwdriver. The sleeve could also be folded on itself as the sleeve is removed from the screw.
[0092] FIG. 10A is a lateral view of an alternative embodiment of an insulating sleeve 1002 , pedicle screw 1004 , and screwdriver with a sleeve expander 1006 . The sleeve is drawn in its expanded shape. The tip of the sleeve expander fits into the pedicle screw. In the preferred embodiment, the sleeve expander is flush with the top of the pedicle screw. The sleeve in this embodiment of the device is made of material that plastically deforms at its tip. The sleeve does not transmit electricity.
[0093] FIG. 10B is a lateral view of the apparatus drawn in FIG. 10A with the sleeve in its contracted shape. The tip of the sleeve contracts to surround the head of the pedicle screw. Ideally the sleeve is more rigid than sleeve drawn in FIG. 9A . The rigidity of the sleeve enables it to be forced over the screw by pushing on the top of the sleeve. This embodiment of the device would be easier to use after the screw has been placed into the spine.
[0094] FIG. 10C is an axial cross section of the sleeve 1002 , screw 1004 , and sleeve expander 1006 in FIG. 10A . The sleeve expander 1006 fits into the opening in the pedicle screw. FIG. 10D is an axial cross section of an alternative embodiment of the sleeve expander 1016 , a screw 1014 , and the sleeve 1012 . The tip of the sleeve expander in this case is round to fit in the circular opening in the pedicle screw.
[0095] FIG. 11A is a lateral view of an alternative embodiment of the insulating sleeve 1108 assembled over a pedicle screw 1110 . FIG. 11B is an exploded cross-sectional view of the embodiment of the invention drawn in FIG. 11A . FIG. 11C is a cross section of the apparatus drawn in FIG. 11A . FIG. 12A is a lateral view of an alternative embodiment of the novel sleeve 1202 , a screw 1204 , and a screwdriver 1206 . The insulating sleeve is placed over the pedicle screw and screwdriver prior to insertion of the pedicle screw into the spine.
[0096] FIG. 12B is a lateral view of the apparatus drawn in FIG. 12A . The sleeve has been pulled off of the pedicle screw. Longitudinal force on the sleeve may be used to split the sleeve along a pre-stressed area in the sleeve.
[0097] FIG. 13A is a sagittal cross section through an alternative embodiment of the invention, wherein a probe 1302 is placed into the center of an instrument 1304 . The illustration shows application of the probe to a tap. Placing the instrument onto or into the center of the instrument allows rotation of the instrument during repeated stimulation of the instrument.
[0098] FIG. 13B is a sagittal cross section through an alternative embodiment of that drawn in FIG. 13A . The probe connects to an intermediate piece 1330 that connects to the center of the instrument.
[0099] FIG. 14A is a sagittal cross section of an alternative embodiment of invention drawn in FIG. 13B . The spherical end of an electrode 1404 is captured in the instrument by a cannulated, threaded cap 1406 . The shaft of the instrument 1410 conducts electricity. The joint between the tip of the electrode allows movement between the electrode and the instrument, while maintaining continuous contact between the two components. FIG. 14B is an exploded lateral view of the embodiment of the invention drawn in FIG. 14A .
[0100] FIG. 14C is a sagittal cross section of an alternative embodiment of the invention utilizing a flat-tipped electrode 1440 captured by a threaded component 1444 . The joint between the electrode and the instrument allows rotation. FIG. 14D is an exploded lateral view of the embodiment of the invention drawn in FIG. 14C . Connections between electrodes of alternative shaped tips and instruments of alternative shapes are contemplated so long as the joints between the components permit rotation and keep the two components in contact.
[0101] FIG. 15A is a sagittal cross section of an alternative embodiment of the invention, wherein an electrode 1550 is threaded over the shaft of the instrument 1552 . The threaded connection between the electrode and the instrument holds the two components together. Rotation may occur across the flat surfaces of the two components. FIG. 15B is an exploded lateral view of the embodiment of the invention drawn in FIG. 15A .
[0102] FIG. 16A is a lateral view of an alternative embodiment of the invention drawn in FIG. 14A . A wire 1660 for the electrode is connected to a ratcheting component 1664 on the shaft of the instrument. The ratcheting component permits advancement of screws and taps with small rotations of the handle of the instrument forward and backward. The electrode does not wrap around the instrument because the handle of the instrument does not require rotation through 360 degrees.
[0103] FIG. 16B is an oblique view of an alternative embodiment of the invention drawn in FIG. 16A . The electrode is connected to a conducting component within the handle of the instrument. The conducting component transmits electrical impulses between the electrode and the shaft of the instrument. The ratcheting mechanism prevents wrapping the cord of the electrode around the instrument as the instrument is rotated.
[0104] FIG. 17A is a lateral view of an alternative embodiment of the invention including an electrode 1780 connected to a collar that rotates around the shaft of the instrument. The collar is held between projections from the shaft of the instrument. The collar remains in contact with the shaft of the instrument. Rotation between the shaft of the instrument and the collar prevents wrapping the cord of the electrode around the instrument as a screw or tap is advanced. FIG. 17B is an exploded lateral view of the embodiment of the invention drawn in FIG. 17A . The rotating collar is held on the shaft of the instrument by a removable threaded component 1788 .
[0105] FIG. 18 is an oblique view of a portion of a vertebra and preferred apparatus including a recording electrode 1802 placed around a portion of the pedicle of a vertebra 1800 . The recording electrode is connected to a monitor 1804 . The area 1806 represents a pedicle probe, tap, screw, or other instrument that will be placed into the pedicle. The pedicle instrument or screw is connected to a stimulating electrode. The recording and stimulating electrodes can be connected by third component 1810 . The connecting 15 component is represented by the area of the drawing with diagonal lines. In the preferred embodiment, the connecting component 1810 is radiolucent and made of a material that conducts electricity poorly.
[0106] FIG. 19A is a view of the dorsal aspect of a portion of a vertebra and a recording electrode 1802 . The lamina of the vertebra has been removed to better illustrate the pedicles of the vertebra. The arms of the recording electrode can be seen surrounding the inferior, medial, and lateral surfaces of the pedicle. The recording electrode was inserted from the inferior and/or lateral side of the vertebra.
[0107] FIG. 19B is a view of the dorsal aspect of a portion of a vertebra and a recording electrode 1802 . The recording electrode can be seen over the medial, superior, and inferior surfaces of a pedicle. The recording electrode was inserted from the medial side of the pedicle. A laminectomy could be performed to aid placement of the electrode.
[0108] FIG. 20A is a view of the dorsal aspect of a portion of a vertebra and a recording electrode 1802 on the inferior lateral surface of a pedicle. FIG. 20B is a view of the dorsal aspect of a portion of a vertebra and a recording electrode. The recording electrode has been advanced over the pedicle. The arms of the recording electrode can be spring loaded to ease insertion of the electrode over the pedicle.
[0109] FIG. 21A is an oblique view of the apparatus drawn in FIG. 18 . The connector 1810 aligns the instrument or screw to be inserted into the pedicle with the arms of the recording electrode. For example, pedicle screws can be directed into the center of the arms of the recording electrode. Thus, if the arms of the recording electrode surround a portion of the pedicle, the pedicle screw or instrument can be directed into the center of the pedicle.
[0110] FIG. 21B is an exploded view of the apparatus drawn in FIG. 21A . A removable handle is also illustrated. The removable handle can be placed over the recording electrode after placement of the connecting component over the recording component.
[0111] FIG. 21C is a view of the top of the connecting component, the recording and stimulating electrodes. The radiolucent connecting component allows surgeons to view insertion of the stimulating electrode between the arms of the recording electrodes with fluoroscopy. The arms of the recording electrode surround a portion of the pedicle.
[0112] FIG. 22 is an oblique view of a portion of a vertebra, a pedicle instrument or screw, and the recording electrode. The pedicle instrument can be seen penetrating the wall of the pedicle. The recording electrode can be moved up and down or around the pedicle to aid detection of the electrical impulse.
[0113] FIG. 23 is an oblique view of a portion of a vertebra, a pedicle screw, recording and stimulating electrodes use in an alternative embodiment of the apparatus. The recording electrode detects impulses in the spinal canal, nerves, muscles, vertebrae, and other spinal tissues or tissues that surround the spine. For example, the recording electrode could be placed on a spinal nerve, or the thecal sac. Penetration of the pedicle screw or instrument would be predicted by recording electrical impulses from the spinal nerve or thecal sac after stimulating the pedicle instrument with electrical impulses with relatively low amplitudes. The recording electrode could also be placed in other spinal tissues such as the paraspinal muscles. Fluid or other material could be placed around the pedicle to aid the conduction of electrical impulses. For example, saline could be placed into the spinal canal during the stimulation and recording of the electrical impulses.
[0114] The invention also anticipates reversing the stimulating and the recording electrodes. That is, electrical impulses could be recorded from pedicle screws or instruments after stimulating a portion of the spine. For example, the outer wall of the pedicle could be stimulated. Additionally, the sensitivity and specificity of the apparatus, as well as prior art apparatus, could be improved by measuring the time between stimulation and recording the electrical impulses. Relatively high rates of electrical conduction suggest the pedicle screw or instrument lies on or too near a nerve.
[0115] FIG. 24 is a view of apparatus according to the invention including a stimulating probe 2406 used to stimulate the spinal nerves (or other nerves). The stimulating probe is inserted into a port on the device marked “Stimulus”. A recording cable 2408 is inserted into a port on the device marked “Instrument”. The recording cable attaches to an instrument placed in the pedicle. For example, the “instrument” recording cable could be attached to the ratcheting instrument described in FIG. 16A . The ratcheting instrument is used to insert screws or taps into the vertebrae.
[0116] A second recording cable 2410 is inserted into a port on the device marked “Muscle”. The “Muscle” recording cable may include a bundle of wires. The wires within the “Muscle” recording cable attach to leads placed over muscles. For example, the “muscle” leads could be placed over the myotomes of both lower extremities or both upper extremities. Alternatively, the “Muscle” cable could be attached to leads over the gluteal muscles, the paraspinal muscles, or tissues of the body.
[0117] A green indicator light indicates safe placement of the pedicle instrument. The green light illuminates if the “Muscle” recording cable sends an electrical impulse into the device after stimulation of a spinal nerve (alternatively other nerves could be stimulated) and the “Instrument” recording cable does not send an electrical impulse into the device after stimulation of the spinal nerve. A 6 mA stimulus could be delivered to the stimulus probe. Alternative stimuli between 0.01 mA to 40 mA could be delivered.
[0118] A red indicator light indicates a potentially misplaced pedicle instrument. The red light illuminates if the “Instrument” recording cable sends an electrical impulse into the device after stimulation of the spinal nerve or the “Muscle” recording cable fails to send an electrical impulse into the device. Two additional lights are used to determine why the red light illuminated. A “Muscle” light illuminates if the “Muscle” recording cable fails to send an electrical impulse into the device. Failure of the “muscle” recording cable to send an electrical impulse into the device suggests the nerve was not properly stimulated. An “Instrument” light illuminates if the “Instrument” cable sends an electrical impulse into the device. Illumination of the “Instrument” light alerts the surgeon the pedicle instrument has received an electrical impulse. The pedicle instrument receives an electrical impulse, if the instrument has breached the walls of the pedicle and the instrument is lying against the stimulated nerve. The device may also have ports that receive ground and reference electrodes.
[0119] Existing systems monitor all of the myotomes of both extremities. An electrical stimulus is delivered to the instrument within the pedicle. Detection of the electrical impulse after low levels of stimulation, for example 8 mA, in any myotome is indication of a potentially misplaced pedicle instrument. A preferred embodiment of this invention records from the instrument or screw within the pedicle rather than stimulating the instrument or screw within the pedicle. Recording leads over the muscles are used to confirm an electrical impulse has been applied to a spinal nerve (or other nerve). As such, recording a stimulus from any muscle in the extremities or potentially other muscles such as the gluteal or paraspinal muscles indicates the stimulus has been properly delivered. Recording from fewer, multiply innervated muscles, simplifies the device. Recording from fewer muscles and recording from the gluteal or paraspinal muscles also assists the surgeon. The present invention decreases the amount of time surgeons must spend applying the recording leads over multiple myotomes of both extremities while using prior art systems. The simplicity of the device enables surgeons to test and monitor their patients. The device does not require a highly compensated Neurophysiologist to interpret the data. Other embodiments of the invention eliminate the need to monitor any of the muscles.
[0120] FIG. 25 is a view of the posterior aspect of the spine. The lamina have been removed to better illustrate the pedicles 2502 and the nerves 2504 . The black circle in the center of one of the white circles indicates the cross section of an instrument within the pedicle (for example) a screw, tap, or curette.
[0121] In the embodiment of the invention depicted in FIG. 24 , an electrical stimulus is delivered to the lower spinal nerve at point S. A recording electrode is attached at R to the instrument within pedicle. One or more additional recording electrodes are placed over muscles. A second stimulus is delivered to the spinal nerve at S′, or, alternatively at S″. If the pedicle instrument breaches the medial wall (spinal canal side) or the inferior wall of the pedicle, and the instrument lies against the spinal nerve, stimulation of the lower spinal nerve will stimulate the instrument in the pedicle. If the pedicle instrument breaches the lateral or superior wall of the pedicle, and the instrument lies against the spinal nerve, stimulation of the upper spinal nerve will stimulate the instrument within the pedicle. Instruments in adjacent pedicles on the same side of the spine may be tested simultaneously by stimulating a single spinal nerve. For example, stimulation of the L 4 nerve simultaneously tests the integrity of the medial and inferior walls of the L 4 pedicle and the superior and lateral walls of the L 5 pedicle. Simultaneous testing of instruments within the pedicles requires a multi-channel device.
[0122] Prior art systems may detect a hole or a crack in a pedicle, but they do not indicate the location of the crack or hole in the pedicle. If surgeons know the location of the hole in the pedicle, then they can reposition a screw and safely direct the screw away from the hole in the pedicle. This invention helps surgeons determine if the misplaced pedicle instrument was placed through the inferior and/or the medial surface of the pedicle or through the superior and/or lateral wall of the pedicle.
[0123] FIG. 26 is the view of the front of an alternative embodiment of the device drawn in FIG. 24 . The multi-channel device can be used to simultaneously test instruments in more than one pedicle. The cables extending from ports on right side of the device marked “Instrument 1 ” and “Instrument 2 ” can be attached to instruments in different pedicles. The stimulus probe can be used to deliver electrical impulses to a spinal nerve. The cables extending from the ports marked “Muscle 1 & Muscle 2 ” can be attached to surface electrodes over muscles supplied by the stimulated nerve. A single recording electrode may also be used when testing the instruments in two pedicle screws. For example, the cable attached to “Instrument 1 ” could be attached to a tap in the left L 4 pedicle.
[0124] The cable attached to “Instrument 2 ” could be attached to a screwdriver attached to a pedicle screw in the left L 5 pedicle. The cables extending from the “Muscle 1 ” and/or “Muscle 2 ” ports could be attached to needle electrodes placed into the Gluteus Medius and the Gluteus Maximus Muscles of the left buttock. The Gluteus Medius is innervated by the superior gluteal nerve. The superior gluteal nerve arises from the L 4 , L 5 , & S 1 nerves. The Gluteus Maximus is innervated by the inferior gluteal nerve. The inferior gluteal nerve arises from the L 5 , S 1 , and S 2 nerves. Surface electrodes could be used rather than needle electrodes. A stimulus could be applied to the left L 4 nerve root. The L 4 nerve root courses along the inferior and medial surfaces of the L 4 pedicle, and the superior and lateral portion of the L 5 pedicle.
[0125] The indicator lights are similar to the indicator lights drawn in FIG. 24 . If both green lights illuminate, then device did not detect electrical impulses from either instrument in the pedicles, and the device detected an electrical impulse from the recorded muscles. The device may use a reference recording lead to compare to the muscle recording lead. The device may contain a microprocessor. If the muscle recording lead receives a much stronger impulse than the reference electrode receives, then the nerve has likely been stimulated properly. Alternatively, the microprocessor may compare the impulses received by the recording electrodes to reference values. The reference values enable the device to indicate if the nerve has been properly stimulated or the soft tissues around the nerve were mistakenly stimulated. The device may use a ground lead.
[0126] The red light by the large number one will illuminate if the instrument attached to the cable from the “Instrument 1 ” port receives an electrical impulse or the device fails to receive an impulse from both or either “Muscle” recording electrodes. Similarly, the red light by the large number two will illuminate if the instrument attached to the cable from the “Instrument 2 ” port receives an electrical impulse or the device fails to receive an impulse from both or either “Muscle” recording electrodes. The “Instrument 1 & 2 ” and the “Muscle 1 & 2 ” lights are used as described in the text of FIG. 24 , to indicate if the instruments have been stimulated or the muscles were not stimulated.
[0127] FIG. 27A is a posterior view of the spine similar to the view described in FIG. 25 . The dark circles represent instruments in the pedicles. R 1 and R 2 represent recording electrodes that are attached to the instruments in the pedicles. S 1 , S 2 , & S 3 represent a few of the possible stimulation sites. The figure illustrates a nerve may be stimulated below the pedicle, at the level of the pedicle, or above the pedicle. Stimulation of the nerve below the pedicle relies on transmission of the impulse in a caudal direction to test the superior and lateral aspects of the pedicle below the stimulated nerve and transmission of the impulse in a caudal direction to stimulate the muscle. Stimulation of the nerve below the pedicle relies on transmission of the impulse in a cephalic direction to test the inferior and medial surfaces of the pedicle above the stimulated nerve. Spinal nerves carry electrical impulses in both cephalic and caudal directions. Motor portions of the nerves transmit impulses away from the spinal cord to the muscles (caudal direction). Sensory portions of the nerves transmit impulses from the sensation receptors to the spinal cord (cephalic direction). The device drawn in FIG. 26 could be used to test the instruments in the adjacent pedicles drawn in FIG. 27A . A single stimulus delivered at S 3 would test the instruments in both pedicles. Additional stimulus sites could be used to complete the testing. For example, stimulus sites S 4 and S 2 could be used to complete the testing.
[0128] FIG. 27B is a posterior view of the spine as described in FIG. 27A . The cross sections of pedicle instruments are seen in all of the pedicles. The drawing illustrates other embodiments of the invention. The embodiments drawn in FIG. 27B do not require monitoring the muscles in the extremities. In one embodiment of the invention the recording electrodes are placed in or over the nerves. Techniques well know to those specialists who perform EMG testing could be used to locate the nerves. Alternatively, the electrodes could be placed on or in the nerves under direct observation.
[0129] A stimulus is applied at S 1 . The recording electrodes are attached to the instrument in the pedicle (R 1 ) and another portion of the stimulated nerve. If the R 2 electrode detects the stimulated impulse and the R 1 electrode does not detect the impulse, then it is unlikely the pedicle instrument is contacting the stimulated nerve. A multi-channel device could be used to test the instruments in more than one pedicle simultaneously. The R 2 electrode could be placed in a spinal nerve or a peripheral nerve that has components that arise from the stimulated nerve. For example, for testing the pedicles in the lumbar spine, the R 2 electrode could be placed in the sciatic nerve (L 4 , L 5 , S 1 , S 2 , & S 3 ) or branches from the sciatic nerve, the femoral nerve (L 2 , L 3 , & L 4 ) or branches from the femoral nerve, or other nerves. The spinal nerve components that form the sciatic and femoral nerves are listed in parentheses behind the words sciatic nerve and femoral nerve respectively. Naturally other nerves would be stimulated and recorded when testing instruments in the cervical and thoracic spine.
[0130] The invention is more sensitive and more accurate than prior-art devices. Prior-art devices may record a false positive if electrical impulses are delivered through a crack in the pedicle, but the instrument is contained within the pedicle. The present invention allows testing with smaller electrical impulses. The smaller impulses are less likely to stimulate a pedicle instrument through cracks in the pedicle. Prior art devices may record a false negative if the recording electrodes over the muscles in the extremities fail to detect an impulse. As noted previously, nerves that conduct impulses poorly, poor conduction through the surface electrodes, etc., may falsely indicate the instrument is safely contained in the pedicle.
[0131] Prior-art systems generally send multiple stimuli of increasing amplitude into the instrument within the pedicle. Prior art systems attempt to record the amount of stimuli necessary to record the impulse over the lower extremities. Recording an impulse over the lower extremities decreases the probability of a false negative result. Stimulating pedicle instruments with multiple stimuli with increasing amplitude is time consuming and requires sophisticated software. The present invention improves upon prior art devices by generally only requiring the application of a single stimulus per pedicle instrument undergoing testing. Some embodiments of the invention allow testing pedicle instruments in multiple vertebrae with the application of a single stimulus.
[0132] Note that the invention may also be used to test nerves while retracting nerves or performing other spinal procedures. The distance between S 1 and R 2 could be predetermined. In fact, S 1 and R 2 could extend from the same instrument. Electrical impulses could be periodically delivered to the nerve at S 1 during surgery. For example, the electrical impulses could be delivered at a frequency of one per minute. The microprocessor within the monitor could signal an alarm, for example, illuminate a light bulb, if the amplitude of the impulse detected at R 2 decreased when compared to a reference amplitude obtained by stimulating the nerve before manipulating the nerve during the operation. The microprocessor could also cause an alarm to signal if the time between the stimulus delivered at S 1 and recorded at R 2 increased when compared to a reference time obtained for the nerve before manipulating the nerve during the operation.
[0133] Standard reference amplitudes and velocities may also be preprogrammed into the microprocessor. Standard reference velocities require fixed distances between S 1 and R 2 . The S 1 impulse could be delivered through a nerve root retractor or a stimulus probe. A stimulus delivering retractor is drawn in FIG. 37 . As noted above, R 2 may lie anywhere along the course of the spinal nerve, nerves supplied by the spinal nerve, or muscles supplied by the spinal nerve. The device alerts surgeons of potential nerve injury before the nerve injury occurs. For example, excessive retraction of a nerve root may injure the nerve root. The device detects diminished nerve function within seconds or minutes of the excessive retraction. Embodiments of the invention for use with peripheral nerves are described in FIG. 36 .
[0134] In the drawings, R 4 represents an alternative recording position. One or more R 4 electrodes could be placed over or in muscles of the body including muscles in the extremities, the muscles in the buttock, the muscles about the shoulder, or muscles about the spine. In contrast to prior-art devices, the R 4 electrode may be used to confirm the nerve has been properly stimulated. Any muscle innervated by the stimulated muscle may be monitored. A single muscle that is supplied by multiple nerve roots may be monitored while testing instruments in pedicles at different levels of the spine. For example, the Gluteus Medius muscle could be monitored to confirm the L 4 , L 5 , or S 1 nerves have been successfully stimulated. The gluteal muscles and the skin over the muscles are easily reached during surgeries on the lumbar spine. Prior-art systems require monitoring of many muscles of the body. Failure to detect stimulation of one of the muscles may lead to a false negative reading. A false negative reading fails to properly detect an instrument, such as a pedicle screw, is compressing or injuring a nerve. Prior-art systems typically require monitoring over four separate locations over each extremity. Preparing the skin over multiple sites and placing the electrodes over multiple sites is time consuming.
[0135] The present invention alerts surgeons if the R 4 electrode is improperly placed or if the R 4 electrode/electrodes has/have shifted during the operation. The red light on the device and the muscle light on the device illuminate if the R 4 electrode does not record an impulse. The novel invention enables surgeons to monitor the paraspinal muscles. The paraspinal muscles area easily accessible in the surgical field. Prior art devices do not use the paraspinal muscles. Surgical exposure of the spine may injure the paraspinal muscles or the nerves to the muscles. Injury to the nerves to the paraspinal muscles or injury of the paraspinal muscles may cause prior art devices and methods to yield a false negative result, if the devices fail to record an impulse. Failure of prior art methods and devices to detect stimulation of the paraspinal muscles could indicate: (a) that the pedicle instrument is contained within the pedicle, (b) the nerve to the paraspinal muscle is not functioning properly, (c) the paraspinal muscles are not functioning properly or, (d) the stimulated muscle has not been recorded. Explanations (b), (c), and (d) lead to false negative results. Thus, prior-art systems do not monitor the paraspinal muscles. The present invention alerts the surgeon if injury to the nerves to the paraspinal muscles or the paraspinal muscles precludes monitoring the muscles, If the surgeon is unable to detect recordings from the paraspinal muscles after delivering a stimulus to the nerves, then the surgeon is alerted to monitor other muscles, such as the gluteal muscles. The ventrally, segmentally, innervated intertransversalis muscles are monitored in one embodiment of the invention. Other paraspinal muscles may be monitored.
[0136] FIG. 28 is a posterior view of the spine, similar to the view drawn in FIG. 27B . An alternative embodiment of the invention is illustrated in the drawing. S 1 represents stimulation of a peripheral nerve such as the sciatic nerve, femoral nerve, branches the sciatic nerve, branches of the femoral nerve, or other peripheral nerve. R 3 & R 4 represent recording sites on or in the spinal nerves. Alternative R 3 & R 4 sites include nerves within the thecal sac, the spinal cord, or the brain. The R 3 & R 4 sites are monitored to confirm the nerve has been stimulated correctly. The R 1 & R 2 are monitored to detect stimulation of the instruments within the pedicles. A single electrical stimulus from S 1 could be used to test multiple pedicles simultaneously. Stimulation of the sciatic nerve may allow simultaneous testing of the pedicles near the L 4 , L 5 , S 1 , S 2 , & S 3 nerves. Stimulation of the femoral nerve may allow testing of the pedicles near the L 2 , L 3 , and L 4 nerves. A multi-channel device allows simultaneous testing of multiple pedicles.
[0137] FIG. 29 is a posterior view of the spine similar to the view drawn in FIG. 28 . The alternative embodiment of the invention stimulates multiple spinal nerves simultaneously. S 1 represents a stimulus delivered over the nerves in the thecal sac, the spinal cord, or the brain. An electrical or magnetic stimulus may be used. R 1 B, R 2 B, R 3 B, & R 4 B are recording sites to confirm the spinal nerves near the pedicles undergoing testing are properly stimulated. R 1 A, R 2 A, R 3 A, & R 4 A are recording sites from the instruments that lie within the pedicles. If R 1 B, R 2 B, R 3 B, or R 4 B fail to detect an impulse, the device will alert the surgeon that the pedicle instruments at the R 1 A, R 2 A, R 3 A, or R 4 A sites respectively, has not been adequately tested. Failure to detect an impulse at a RnB site signals the stimulus was not applied to the surface of the pedicle by the nerve monitored by the RnB electrode. A S 1 needle electrode may be placed through the dura. The S 1 site may be cephalad or caudal to the tested pedicles. If all RB sites record impulses and none of the RA sites record impulses, then all of the instruments are likely contained within the pedicles. A multi-channel device, with at least four groups of alarm lights like those illustrated in FIG. 24 , could be used in this embodiment of the invention.
[0138] FIG. 30 is a posterior view of the spine, similar to the view drawn in FIG. 29 , showing the alternative use of a reference electrode. A microprocessor within the device compares the impulse detected by the R 2 electrode to the impulse detected by the reference (R 3 ) electrode. The microprocessor triggers an alarm, such as illuminating a light bulb, if the stimulus received by R 2 is below a preset value or the stimulus received by R 2 is near or below that received by R 3 . The alarm alerts the surgeon that the electrodes at the R 2 or S 1 sites are not properly contacting the spinal nerve.
[0139] FIG. 31 is an axial view of a pedicle. The drawing illustrates an alternative embodiment of the invention. The black circle represents the cross section of an instrument in the pedicle. S 1 represents a stimulation site. R 1 represents a recording site on the instrument in the pedicle. R 2 represent a recording site on the pedicle. If the R 1 electrode detects a smaller signal than the R 2 electrode the instrument is likely contained in the pedicle.
[0140] FIG. 32A is a lateral view of a needle-tipped stimulating or recording electrode. The area of the drawing with diagonal lines represents insulating material. The needle tipped electrode is generally placed in nerves or muscles. FIG. 32B is a lateral view of an alternative embodiment of the tip of the electrode drawn in FIG. 32A . The balled tipped probe is generally placed on nerves or muscles. FIG. 32C is a lateral view of an alternative embodiment of the tip of the electrode drawn in FIG. 32A . The curved tip is easier to insert through the neuroforamina. The tip may help the surgeon direct the electrode to the S 1 position drawn in FIG. 30 .
[0141] FIG. 33 is an oblique view of an alternative embodiment of the invention. This embodiment of the invention demonstrates the use of stimulating (S 1 ) and recording (R 1 ) electrodes in an instrument. For example the instrument may be a cannula as drawn in FIG. 33 . Other than the electrodes, the instrument is made of a non-electrical conducting material in the preferred embodiment of the device. A monitor with microprocessor measures the amplitude and velocity of an impulse delivered from S 1 to R 1 . Rapid transfer of a high amplitude impulse suggests the cannula is against a tissue that readily transfers impulses. Nerves transmit impulses better than muscles transmit impulses. The novel cannula could be used to alert surgeons when the instrument is against a nerve. Surgeons could use the novel cannula to navigate between the nerves in muscles. For example, surgeons could use the device for trans-psoas approaches to the spine.
[0142] FIG. 34A is a lateral view of another embodiment of the invention drawn in FIG. 33 . Recording and stimulating electrodes are used in the walls of a stylet or a blunt dissector. Other than the electrodes, the stylet or dissector is made of a material that conducts electricity poorly. The stylet can be used within a cannula. The blunt tip helps surgeons separate the fibers of muscles. The electrodes and the monitor alert surgeons when the instrument lies against a nerve. FIG. 34B is an anterior view of the embodiment of the device drawn in FIG. 34A . FIG. 34C is an oblique view of the embodiment of the device drawn in FIG. 34A . FIG. 35 is an anterior view of another embodiment of the device drawn in FIG. 33 . The electrodes are incorporated into the ends of a retractor.
[0143] FIG. 36 is a posterior view of a peripheral nerve and another embodiment of the invention. This embodiment of the invention may be used to protect peripheral nerves during non-spinal operations. The nerve is stimulated at one location S 1 . Recording electrodes/electrode are placed in another location along the nerve or a branch of the nerve (R 1 ). Alternatively recording electrodes/electrode may be placed in muscles that are supplied by the stimulated nerve (R 2 ). A device, with a microprocessor, delivers electrical impulses at S 1 periodically during the operation. For example, the device may deliver one impulse per minute. The device measures the amplitude of the impulses recorded at R 1 and/or R 2 and the time between the delivery of the stimulus and recording of the stimulus. The device triggers an alarm, for example illuminates a light bulb, if the amplitude or velocity of the transmitted stimulus deteriorates during the surgical procedure.
[0144] The microprocessor may also be programmed to compare the recorded values for the stimulus to standard values. The distance between S 1 and R 1 or R 2 could be fixed or measured to enable the microprocessor to calculate velocity figures. For example, this embodiment of the device could be used during hip replacement surgery. A needle electrode (S 1 ) could be placed into the sciatic nerve at the level of the sciatic notch. The SI electrode could be sutured into place. Alternatively, the mechanisms use to hold pacemaker electrodes in position could be used to hold the S 1 electrode in the tissues near the sciatic nerve while the tip of the S 1 electrode lies in the nerve. The device would quickly alarm the surgeon if sciatic nerve function deteriorated during surgery. The device would alert the surgeon to diminish traction on the sciatic nerve before the injury became permanent. This embodiment may be used on other peripheral nerves in the body. It may also be used to detect additional causes of nerve injury such as pressure on the nerve or surgical dissection around the nerve.
[0145] FIG. 37 is a lateral view of a nerve root retractor that stimulates the spinal nerves. The retractor can be used to deliver the stimulus at the S 1 site as described in FIG. 30 .
[0146] According to this invention, electric impulses may be recorded from an instrument placed into and possibly through the pedicle of a vertebra. Peripheral nerves, spinal nerves, the sciatic nerve, the femoral nerve, or a plexus of nerves may be stimulated. Recording electrodes are also placed over spinal nerves. A recording electrode may be placed through the dura. If the recording electrode over, or within, a nerve detects an impulse transmitted through the nerve and the recording electrode on an instrument placed into a pedicle does not detect an impulse, then it is likely the instrument within the pedicle does not breach the walls of the pedicle. Alternatively, the spinal nerves could be stimulated with recording electrodes placed over or in peripheral nerves, the nerves in the thecal sac, and the instrument/instruments in the pedicles.
[0147] Stimulation and/or recording electrodes can be used over the dura or through the dura cephald and/or caudal to the level the pedicle screw or screws are inserted. Multiple pedicle screws could be tested simultaneously by a single stimulating impulse. For example, a trans-dural stimulating electrode could be placed cephald to the pedicle screws. A second trans-dural recording electrode could be placed caudal to the pedicle screws. Alternatively, multiple recording electrodes could be placed over or in the spinal nerves near the pedicle screws. The recording electrodes listed above could be changed to stimulating electrodes and the stimulating electrodes listed above could be changed to recording electrodes. If recording electrodes placed on instruments within the pedicles do not detect an electrical impulse, but the recording electrodes over or within the nerves detect an impulse, then the screws, curettes, or taps are likely within the pedicles. Testing of the invention will likely determine thresholds (for stimulation and recording) at which penetration of the pedicle wall by an instrument is unlikely. Techniques well known to those who perform EMG testing could be used to help locate spinal and peripheral nerves.
[0148] An electrode placed over or within a myotome may be used to confirm stimulation of a nerve. For example, if an electrode over the L 5 myotome detects a impulse applied to the L 5 nerve and a recording electrode from an instrument in a pedicle near the L 5 nerve does not record an impulse, it is unlikely the instrument within the pedicle near the L 5 nerve penetrates the wall of the pedicle. The invention eliminates the need for repeated stimulation at successively higher impulses as used in prior art systems. Prior art systems use successively higher impulses to record a value in the extremities in an effort to avoid a false negative. Failure to record a stimulus over the myotome in prior art systems may confirm the instrument does not penetrate the walls of the pedicle. Alternatively, failure to record a stimulus over the myotome in prior art systems may indicate a problem with the conductivity of the nerve, the junction between skin and the electrode, or other technical problem.
[0149] Recording and/or stimulating electrodes can be placed in or over the tissues about the spine including the disc, the gluteal muscles, muscles about the hip or shoulder girdle, or the extremities.
[0150] Velocity calculations and measurements (of transmittance of the electrical impulse) may also be used. A single monitor or instrument may have recording and stimulating electrodes. A fixed distance between the recording and stimulating electrodes would ease velocity calculations. For example, a non-conducting cannula with one or more stimulating electrodes and one or more recording electrodes may be used in transpsoas approaches. An impulse that travels with high velocity from the stimulating electrode to the recording electrode suggests the cannula is near or against a nerve. Stimulation may be in the range of 0.01 mA-50 mA.
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Neurophysiological instruments and techniques are improved through various enhancements. Stimulation of an instrument is possible while it is advancing into the spine or elsewhere, alerting the surgeon to the first sign the instrument or device (screw) may be too near a nerve. A directional probe helps surgeons determine the location of the hole in the pedicle. Electrically insulating sleeves prevent shunting into the soft tissues. According to a different improvement, the same probe to be used to stimulate different devices, such as screws and wires. Electrical impulses may be recorded from non-muscle regions of the body, including the spine and other portions of the central nervous system as opposed to just the extremities.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a nonprovisional application claiming priority to U.S. patent application Ser. No. 62/312,924 filed on Mar. 24, 2016, entitled “Iterative Blind Detection Method for Phase Shift Keying Modulations” the entire content of which is fully incorporated by reference herein.
FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT
[0002] The United States Government has ownership rights in this invention. Licensing inquiries may be directed to Office of Research and Technical Applications, Space and Naval Warfare Systems Center, Pacific, Code 72120, San Diego, Calif., 92152; telephone (619) 553-5118; email: ssc pac t2@navy.mil, referencing NC 103394.
FIELD OF THE INVENTION
[0003] The present invention pertains generally to the identification of a data signal without the benefit of knowing how the signal was modulated. More particularly, the present invention pertains to efficiently determining whether or not a PSK modulation is present on a received signal and if so what type of PSK modulation is present.
BACKGROUND OF THE INVENTION
[0004] One of the primary goals of wireless communication is to maximize the data rate while simultaneously making efficient use of the available spectrum. There are three primary methods of modulating a sine wave radio carrier; one of which is referred to as phase shift keying. Phase shift keying is a type of digital modulation which translates digital binary data (1's and 0's) into phase shifts on a carrier wave. For example a binary phase shift keyed (BPSK) system will transmit a particular sinusoidal signal to indicate a binary 1 and transmit the same sinusoid 180 degrees out of phase to indicate a binary 0. These two modulated waves would be referred to as the two BPSK “symbols”. This type of modulation can transmit more information during every symbol by allowing more discrete phase states (e.g. 0, 90, 180, and 270 degree phase shifts instead of just 0 and 180). For instance, having four possible phase shifts in the transmitted sinusoid provides four different symbols; transmitting twice as much information per symbol (i.e. can transmit two bits per symbol as there are now 4 different symbols to transmit). Phase shift keying is a very common type of modulation that is used in many applications including cellular phones, wireless modems, military systems, satellite communications, and many more applications.
[0005] With the introduction of cognitive radios, software defined radios, and other similar systems; it is desirable to detect the modulation of a received signal without having prior knowledge of the signal. Current cognitive radios either detect modulation based on brute force methods of trying various demodulations schemes until one works or by using a lookup table to determine what the signal should or might be at a certain frequency. The first method is not computationally efficient and the second method is not dynamic and adaptable to new signals. Methods that accomplish the same result as this invention are computationally inefficient and require knowledge of the signal's data rate to create a signal to compare it to.
[0006] This new innovative solution allows for any PSK signal to be quickly categorized by the type of PSK modulation or determined to not be PSK modulated. This is done in a computationally efficient manner. Traditional methods use covariance or correlation to detect against a known signal, but these methods are limited by the stored signals used for comparison and require knowledge about the data rate of the signal. This new innovative method can successfully detect PSK signals with any data or symbol rate without prior signal knowledge in a computationally efficient means.
[0007] In view of the above, there is a need for simplified, efficient method for determining if a signal is a PSK type signal and if so its respective characterization.
SUMMARY OF THE INVENTION
[0008] This invention provides a technique for efficiently and quickly detecting whether an arbitrary signal is a PSK signal and if so what type of PSK modulated signal is present. A PSK signal could be a BPSK (binary phase shift keying, two symbols with 1 bit communicated per symbol), QPSK (quadrature phase shift keying, four possible symbols with 2 bits communicated per symbol), 8PSK (8 symbol phase shift keying, eight possible symbols with 3 bits communicated per symbol), or higher order M-PSK (M symbol phase shift keying, M possible symbols with log 2 (M) bits communicated per symbol). This invention utilizes a trigonometric property of squaring cosines or sinusoids to force any PSK modulated signal to eventually converge to a single sinusoid. Unlike traditional correlation methods, this innovative method requires no information about the symbol or data rate of the signal.
[0009] These, as well as other objects, features and benefits will now become clear from a review of the following detailed description, the illustrative embodiments, and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The novel features of the present invention will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similarly-referenced characters refer to similarly-referenced parts, and in which:
[0011] FIGS. 1A and 1B illustrates an example graphical depiction of BPSK sinusoidal and out of phase sinusoid signal plotted with respect to amplitude over time.
[0012] FIG. 2A and 2B illustrates the graphical depiction of the example signal of FIGS. 1A and 1B after squaring their values.
[0013] FIG. 3A and 3B illustrates the graphical depiction of the example signal of FIGS. 2A and 2B after applying high pass filtering to the signal.
[0014] FIG. 4 illustrates a graphical representation of a generic BPSK signal with a 1GHz center frequency and a 20 Mbps data rate.
[0015] FIG. 5 illustrates a graphical depiction of the signal of FIG. 4 after it has been squared and high pass filtered.
[0016] FIGS. 6A, 6B and 6C illustrates a graphical representation of a generic modulated sinusoid QPSK signal that is then squared and filtered yielding a single sinusoid signal.
[0017] FIG. 7 illustrates one method of processing a signal in accordance with the teachings of the present disclosure.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0018] This invention provides a method for efficiently and quickly detecting the specific modulation type on an arbitrary PSK signal. PSK can be BPSK (binary phase shift keying, two symbols with 1 bit communicated per symbols), QPSK (quadrature phase shift keying, four possible symbols with 2 bits communicated per symbol), 8PSK (8 symbol phase shift keying, eight possible symbols with 3 bits communicated per symbol), or higher order M-PSK (M symbol phase shift keying, M possible symbols with log 2 (M) bits communicated per symbol). This invention utilizes a trigonometric property of squaring cosines or sinusoids to force any PSK modulated signal to eventually converge to a single sinusoid. Unlike traditional correlation methods, this innovative method requires no information about the symbol or data rate of the signal.
[0019] FIGS. 1 thorugh 3 illustrate in graphical form the basic principle of the disclosed method for detecting PSK signal. For example purposes only the figures depict a BPSK signal. FIGS. 1A and 1B depict the two possible BPSK symbols, sinusoid and out of phase sinusoid (1, 0) of a hypothetical signal. These two symbols then squared as shown in FIGS. 2A and 2B . After squaring the signal values, the DC offset is removed via high pass filtering with the results illustrated in FIGS. 3A and 3B . As illustrated in FIGS. 1-3 the result of the squaring and high pass filtering converts all BPSK symbols into a single identical sinusoid.
[0020] The resulting single sinusoid is most easily detected spectrally. FIG. 4 shows the spectrum of a generic BPSK signal with a 1GHz center frequency and a 20Mbps data rate with no filtering. This signal is made up of two sinusoid symbols that are 180 degrees out of phase.
[0021] FIG. 5 shows the result of squaring the BPSK signal and high pass filtering. Here it can be seen that the BPSK signal collapses to a single sinusoid after one iteration of squaring and DC removal. This is the basis of the invention method. The signal is put through an iterative loop of squaring and DC removal until the spectrum collapses to a single sinusoid. The number of iterations required to collapse the spectrum into a single sinusoid indicates the order of the modulation (M-ary, with M being 2, 4, 8, etc.) Conversely, if the signal spectrum does not collapse after a reasonable number of iterations it indicates that the signal is not PSK. This collapse to a single sinusoid happens in one iteration for BPSK, in two iterations for QPSK, in 3 iterations for 8PSK, in 4 iterations for 16PSK, and so on.
[0022] FIG. 6 shows this same method being used on a QPSK signal. The initial untouched spectrum is shown on the left indicating that the signal is a modulated sinusoid. The squared and filtered spectrum is shown in the middle indicating that the signal is a still a modulated sinusoid. As expected by the result of this invention, the spectrum collapses to a single sinusoid on the far right after two iterations, indicating that the signal is QPSK. The frequency scale on the bottom indicates the result of squaring. The center frequency doubles with each iteration.
[0023] The equations below indicate the exploited trigonometric properties that allow this innovative method to detect PSK signals without prior knowledge about the signals. Equation (1) shows the trigonometric identity for squaring a sinusoidal wave. Squaring the wave results in a sinusoid at twice the original carrier frequency with a constant addition to the wave (i.e. a DC offset). BPSK symbols consist of a sinusoid with 0 degrees of offset (×+0) and a sinusoid with 180 degrees of offset (×+180 deg). If the first sinusoid is squared, the resulting argument of the sinusoid is (2×), if the second sinusoid is squared the resulting argument of the sinusoid is (2×+360 deg) which is equivalent to (2×) since 0 deg=360 deg in phase shift (once complete revolution). This shows why both BPSK symbols turn into the same sinusoid after squaring and high pass filtering (to remove ½ DC term in equation (1)). This indicates that any BPSK signal will collapse to a single sinusoid (regardless of data rate) when squared with itself and high-pass filtered since both of the symbols that make up the signal result in the same sinusoid.
[0000]
Trigonometric
identity
cos
2
(
x
)
=
1
2
+
1
2
cos
(
2
x
)
(
1
)
[0024] Equation 2 below shows how QPSK collapses to a single sinusoid. The four QPSK symbols are sinusoids with 45 (×+45 deg), 135 (×+135 deg), 225 (×+225 deg), and 315 (×+315 deg) degree offsets. If these symbols are squared the resulting sinusoid arguments are (2×+90 deg), (2×+270 deg), (2×+450 deg), and (2×+630 deg) respectively. When these sinusoids are simplified (i.e. remove 360 degrees) the argument are (2×+90 deg), (2×+270 deg), (2×+90 deg), and (2×+270 deg). This shows that one iteration of squaring and high pass filtering (to remove ½ DC term) turns QPSK into a two symbol PSK modulation (i.e. BPSK). One more iteration will turn the two symbol PSK (BPSK) into a single sinusoid. Therefore, any QPSK signal, regardless of data rate, will collapse to a single sinusoid after two iterations of squaring with itself and high-pass filtering. This same method works for higher order PSK by continuing the process.
[0000]
Squaring
twice
:
cos
2
(
x
)
=
1
2
+
1
2
cos
(
2
x
)
→
HPF
,
rescale
cos
2
(
2
x
)
=
1
2
+
1
2
cos
(
4
x
)
(
2
)
[0025] This method runs iterations of squaring and high pass filtering an incoming signal to determine whether it eventually collapses into a single sinusoid. If the signal eventually collapses to a single sinusoid in its spectrum, it is a PSK signal and the number of iterations required before it collapses indicate the type of PSK modulation used (i.e. BPSK, QPSK, 8PSK, etc.). If the signal does not collapse spectrally it is not PSK. This method will efficiently check unknown signals to see if they are PSK while indicating the type of modulation without any prior knowledge of the signal's data rate.
[0026] FIG. 7 illustrates the steps associated with one method 700 of practicing the teachings of this disclosure. The method begins when one receives a data signal, step 702 . After receipt of a data signal its value is recorded, Step 704 . The recorded data signal is then evaluated to determine if the signal frequency is recognized, step 706 . If the signal is not recognizable then the next step in the process, step 708 is to square the value of the signal. The squared signal value is then filtered to remove DC content, step 710 . At this point the original received signal that has been squared and filtered is evaluated to determine if a single sinusoidal component remains, step 712 ; if yes the signal is a PSK type signal, if no steps 708 , squaring and 710 filtering are repeated and the resulting signal evaluated to determine if a single sinusoid remains. This process is repeated as many times as necessary if a single sinusoid is not the resulting component. If repeating the process results in a single sinusoid remaining, then the number of iterations directly correlates to the type of PSK signal, step 714 , where the type of M-ary M-PSK modulation (M=2, 4, 8, 16, 32, etc) is found from M being equal to 2 raised to the exponential power of the number of iterations (i.e. M=2 number —of of _ iterations ) If completing ten iterations of squaring, filtering and evaluating (steps 708 , 710 , and 712 ) fails to yield a single sinusoid as the resulting signal, then a determination is made that the original received data signal (step 702 ) is not a PSK signal or that the M-ary value is greater than 1024 (2 10 ).
[0027] This new innovative detection method allows any PSK signal to be efficiently detected without any prior knowledge of the signal's modulation or data rate. Only the signal's approximate center frequency must be known. This method differs from prior art methods for detecting PSK signal that are performed by comparing the incoming signal to known signals until a match is identified which is computationally inefficient and only works when the incoming signal is very close in frequency and data rate to the expected signal. The detection method disclosed herein is efficient and requires no prior knowledge of the data rate. This method is new in that it does not required comparison to know signals or any correlation. The method squares the incoming signal with itself, filters the signal, and evaluates the resulting spectrum.
[0028] It will be understood that changes in the details and steps arrangement of parts, which have been herein described and illustrated to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims.
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A signal detection method that allows characterization of a modulated signal to be efficiently determined. The method comprises the steps of receiving a data signal, processing the data signal to determine its value squaring the value of the signal; filtering the squared signal value to remove DC content; evaluating the resulting signal to determine if a single sinusoidal value remains; and determining that the presence of a single sinusoidal value as the resulting signal from the squaring and filtering steps indicates that the received data signal is a phase-shift key signal or conversely that the absence of such after a given number of cycle of squaring and filtering indicates a different modulation technique is present in the signal.
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BACKGROUND OF THE INVENTION
This invention relates in general to sealing arrangements for a bearing and shaft combination and, more particularly, to dynamoelectric machines, e.g., electric motors having bearing sealing arrangements.
In many applications of electric motors, generators, or alternators the environment is laden with dust, dirt, powder from material processing, moisture or vapors of various fluids, and mixtures of these and other contaminants which if not excluded reduce the performance and operating life of a bearing. The entrainment of these contaminants in the greases and oils used to lubricate bearings causes wear of the bearing materials by abrasion and corrosion, loss of lubricant by displacing or syphoning the lubricant from the reservoirs, and destruction of the lubricating properties of the greases and oils through dilution, thickening, or chemical attack.
Typical electric motor applications where severe environments are found include, for example, motors and generators used in railway cars, dairies, grain and feed mills, chemical processing plants, chickenhouses, air conditioning systems, construction equipment, and commercial and domestic appliances.
In the past, flexible seals of rubber or similar material have been used; however, these flexible seals have had certain shortcomings that have resulted in excessive wear and premature failure, or failure to be adaptable to excessive shaft misalignment and thus permitting leakage of the lubricant. To overcome these shortcomings labyrinth type seals which normally rquire a metal casing to retain their form and shape (which in turn increases the cost of the seal) have been used. Labyrinth seals of this type are shown, for example, in FIG. 6 of Scott's U.S. Pat. No. 3,794,392; and in FIG. 3 of Lower's U.S. Pat. No. 3,499,654. Face type seals have also been used to seal or prevent the leakage of a fluid or gas around a rotatable member like a motor shaft. Face type seals usually include a spring, bellows, and sealing ring. In order to work properly for any period of time, face type seals need to be supplied with some kind of lubrication at the sealing surfaces. The fluid being contained often provides this lubrication. Without lubrication a face type seal will fail rapidly because of seal surface wear. One example of a carbon ring having a sealing face is shown in FIG. 1 of Place's U.S. Pat. No. 3,788,650.
There is a definite advantage in forming a resilient seal that does not require a metal casing and that does not require the addition of lubricant to the fluids being contained thereby. Solutions of the above problems will be discussed in more detail hereinafter and it will be seen that the resolution of these and other problems would be particularly desirable.
Accordingly, it is an object of the present invention to provide a sealing arrangement having a resilient seal.
Another object of the invention is to provide an improved dynamoelectric machine having a bearing sealing arrangement wherein a seal is essentially self-lubricating and of long life.
Yet another object of the invention is to provide a bearing sealing arrangement wherein a seal is of a sinuous shape so that the seal may deflect under pressure and conform to variations in shaft alignment, and so that such pressure does not materially increase the engagement pressure on the contact surfaces of the seal.
SUMMARY OF THE INVENTION
In carrying out the above and other objects in one preferred form, I provide a dynamoelectric machine having a bearing system, shaft, and improved sealing arrangement. The sealing arrangement prevents contaminants like water and dirt from entering the bearing and also prevents the loss of lubricant from the bearing system through an opening for a rotatable shaft.
The sealing arrangement includes a seal; and a seal engaging member that may be in the form of a collar or disc which fits on, and rotates with, the shaft next to the bearing. The collar or disc may be part of a thrust runner. This disc is made of a non-corroding material and may be ceramic, carbon, nickel-iron alloy, or a plastic material which can be ground or lapped to a very flat finish on the sealing surface. A self-loading sinuous shaped seal made of a resilient material is positioned so as to contact a sliding surface of the disc (or any suitable part of a thrust system) and a stationary portion of the bearing housing. Bearing lubricant is utilized to provide a small amount of lubrication for the sliding interface of the rotating disc and the stationary self-loading resilient seal. The sinuous design of the resilient seal provides a spring effect and thus reduces or limits the load on the sealing surface. This results in minimum wear and lowers the stress levels on the resilient material to a value below the resilient material flow range, and yet maintains suitable contact between the sealing surfaces should a small amount of sear occur. At least part of the rotatable structure (which may include a shaft, spacer or disc, or collar) is accommodated with a radial clearance in a circumferentially extending opening in the seal.
The subject matter which I regard as my invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention itself, however, together with further objects and advantages thereof, may be best understood by reference to the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view, with parts in section, parts removed, and parts broken away, of an embodiment of the invention in the form of an electric motor having a improved sealing arrangement;
FIG. 2 is a perspective view of one form of seal with a portion removed, that may be used in embodiments of my invention;
FIG. 3 is a perspective view, with a portion removed; of another form of seal that may be used in sealing arrangements embodying the invention;
FIG. 4 is an elevational view, with parts in section, parts removed, and parts broken away, of an electric motor illustrating another sealing arrangement and embodying my invention in still another form; and
FIG. 5 is a view in elevation of parts of an electric motor with parts in section and parts broken away showing yet another sealing arrangement and embodying the invention in another form.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, for purposes of illustration, I have shown an electric motor for the purpose of describing one preferred exemplification of the invention. The motor includes a movable assembly comprising rotor 13, and shaft 12; and a stationary assembly comprising a stator assembly 16. The stator assembly includes a magnetic core, winding, and frames, and housing means. This type of construction is shown for example, in U.S. Pat. Nos. 2,905,267 and 3,243,617 the disclosures of which are incorporated herein by reference, it being understood that other types and forms of motors may embody the invention.
An impeller 11 is mounted on shaft 12, and a spacer 17 is provided between impeller 11 and rotating seal engaging member or disc. 23. Cup 18 fits around shaft 12 and mates tightly with motor end shield 19 while retaining and protecting the seal 22 in place. Seal 22 has opening 29 (see FIG. 2) which accommodates spacer 17 mounted on shaft 12. The opening wall which surrounds part of spacer 17 is spaced therefrom so as to provide a circumferentially extending radial clearance therebetween, as clearly revealed in FIG. 1. The surface of seal 22 that defines seal opening 29 mates with seal engaging member or disc 23 to establish a sliding interface 25. Sliding interface 25 receives a small but sufficient amount of lubricant from lubricating grease which is provided with bearing assembly 27. Besides the lubricant which is normally supplied with a bearing, additional grease 24 can be added at the time of assembly which will increase the supply of bearing grease lubrication. Outer periphery wall 28 (see FIG. 2) of the seal 22 is in contact with stationary cup 18 and stationary motor end shield 19. The seal is initially positioned so as to be preloaded and thus exert an axial preloading force on disc 23 at sliding interface 25. The wavy or sinuous design of seal 22 provides a spring effect which serves to limit the resultant contact force for small deflections of seal 22 along the sealing interface 25. This contributes to minimum wear and lowers the stress levels in lip 34 (see FIG. 2) of seal 22 to a value below the plastic flow range of the seal material. The resiliency of seal 22 helps maintain the contact between seal 22 and disc 23 at sealing interface 25 should a small amount of wear occur. The one piece resilient seal 22 eliminates the need for separate springs, bellows, and sealing rings that would be rquired if face type seals were to be used.
FIG. 3 shows a seal similar to the one shown in FIGS. 1 and 2. The only difference in seal 22 shown in FIG. 2 and seal 122 shown in FIG. 3 is that seal 122 has more undulations than seal 22. Thus, the description of seal 22 will also apply to seal 122. Seal 22 (or 122) is formed with an opening 29 (or 129) which will accommodate, with a circumferentially extending radial clearance, a shaft or other rotating member mounted on the shaft. The outer periphery of seal 22 (or 122) is formed by wall 28 (or 128) and the shape or design of the seal from outer wall 28 (or 128) to opening 29 (or 129) is wavy or sinuous. The waves form troughs 33 or 133, as the case may be. Opening 29 (or 129) is surrounded by wall 32 (or 132) which establishes the previously mentioned radial clearance. The material between wall 28 (or 128) and wall 32 (or 132) is formed to a uniform thickness. The portion or crest 31 (or crests 131) does not extend to the same height as lip 34 (or 134). Or more explicitly, crest 31 as seen in FIG. 1 is at a higher vertical level than interface 25. This will allow for greater deflection of the seal without having the portion of the seal between wall 28 and wall 32 come in contact with a rotating member. Wall 32 has a lip 34 that defines opening 29. Lip 34 establishes a flat smooth contact surface that mates with a smooth rotatable disc to form a sliding interface shown as 25 in FIG. 1. The contact surface of lip 34 maintains effective contact with the rotatable disc.
The seal can be made from a pliant plastic sealing material such as "Nylatron GS", a composition of nylon and molybdium disulfide (MoS 2 ). This is a well known low friction wear resistance material used widely for thrust bearings in electric motors. This material is sold under the tradename "Nylatron G.S." by the Polymer Corp. In my preferred embodiment I injection molded "Nylatron G.S." to form the seal. But it will be understood that any suitable long wearing, pliant plastic, moldable material could be used.
FIG. 4 shows still another embodiment of my invention. Shaft 37 is rotated by rotor 38 and has disc 39 mounted to shaft 37. Bearing lubricant retaining material 42 (for example grease, absorbent fibrous material such as felt, or any other suitable type of oil retaining material including extrudable materials) is contained by seal 43. At the time of assembly additional lubricant 41 (such as oil or grease) may be added. This additional lubricant can reach bearing 40 by capillary action as described in U.S. Pat. No. 3,250,579, which patent is assigned to the assignee of this invention and is incorporated herein by reference. Seal 43 is in rotatable contact with disc 39 and in stationary contact with motor end shield 44. Seal 43 is self-lubricating, just as seal 22 in FIG. 1. Lubricant 41 along with oil exuding from the end of porous bearing 40 provides sufficient lubrication to keep the sliding surfaces of the materials chosen from wearing and at the same time helps seal the contact of the surfaces to exclude contaminants from the bearing.
FIG. 5 illustrates another use of my sealing arrangement. Here the sealing arrangement is used on both ends of a bearing assembly. Motor shaft 47 rotates in bearing 48 which is mounted in hub 49. Hub 49 is formed as part of motor end shield 50. Bearing 48 is lubricated by oil from free oil reservoir 51 which can be filled by removal of threaded fill plug 55. Since the shaft 47 might be operated in various orientations, capillary feed passages 52, 53, 54 are provided to conduct oil to bearing 48 and to thrust washer 57. Capillary feed passage 54, which is located adjacent bearing 48, is formed by grooves spaced around hub 49. Annular plate 64 cooperates with end shield 50 to provide another capillary feed passage 53. Yet another passage 52 is formed on the opposite end of bearing 48 by annular thrust plate 56. One end of plate 56 is in rotatable contact with thrust washer 57 which is made of a low friction material. Washer 57 mates with thrust collar or disc 58 mounted on shaft 47. Collar 58 performs a dual function as a thrust collar and as a seal engaging member. Usually collar 58 is press fitted on shaft 47, as is collar or disc 66. It will be recognized that a thrust washer may be added between collar 66 and annular plate 64 to provide thrust capability in either direction of axial movement of shaft 47. Discs 58 and 66 are formed with a flat smooth surface to mate with resilient seals 61 and 67, respectively forming sliding interfaces 62. Seals 61 and 67 also mate with end shield 50 and are held in place and protected by annular caps 63 and 68 respectively. As will be noted, the portions of seals 61 and 67 that mate with end shield 50 are chosen to be of configurations that mate with an end shield that is selected for a given application.
The disc or seal engaging member (e.g., runner 39 in FIG. 4 or runner 23 in FIG. 1) is usually made from a non-corroding material such as ceramic, carbon, nickel-iron alloy, or plastic materials which can be ground or lapped to a very flat finish on the sealing surface. In one actual construction, a disc was made of an alloy marketed by the International Nickel Co., under the tradename of "Niresist" and often used in corrosive environments. The disc is made to fit tightly on the shaft, thereby providing an effective seal around the circumference of the shaft.
In a reduction to practice of my invention, four direct drive centrifugal blowers were made with the seal assembly shown in FIG. 1 to seal the blower from the motor where the shaft enters the blower case. The four devices were cycled 58 minutes "on" at 9200 rpm and were "off" 2 minutes while tap water was fed into the blower intake continuously. During the two minute "off" period the water supplied filled the horizontally mounted blower to the level of the intake before spilling over. After 6000 hours of operation for two of the units the test was arbitarily terminated. The tests on the third and fourth units were terminated after 5300 and 3600 hours respectively because of failure of components other than the sealed bearing.
It will be appreciated, after comparing the preferred embodiments illustrated herein, that the smooth surfaces of the seals and the seal engaging members which form part of a sliding interface (e.g., interface 25 in FIG. 1) are oriented relative to a shaft so as to be oriented crosswise relative to the longitudinal direction of such shaft. Moreover, the sinuous shape of the preferred forms of seals illustrated herein is such that the surface or face of the seals along the sliding interface are movable in the longitudinal direction of the shaft. The sinuous shape of the seals, as spelled out hereinabove, influences the movement of the interface defining portions of the seals.
While the present invention has been described with reference to particular embodiments and exemplifications thereof in accordance with the Patent Statutes, it is to be understood that modifications may be made by those skilled in the art without actually departing from the invention. Therefore, I intend in the appended claims to cover all such equivalent variations as come within the true spirit and scope of the invention.
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Seal arrangement to be used with dynamoelectric machines having a bearing and shaft combination. Seal is formed from resilient material in a sinuous shape providing a radial clearance for the rotatable shaft. Portion of seal mates with rotating seal engaging member and provides a sliding surface which is self-lubricating. Sinuous shape of seal allows deflection under pressure to lessen sliding surface pressure and conforms to variations in shaft alignment.
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This application is a continuation of application Ser. No. 703,441 (now abandoned), filed Feb. 19, 1985 which, in turn, is a continuation of application Ser. No. 248,596 (now abandoned), filed Mar. 27, 1981.
BACKGROUND OF THE INVENTION
This invention relates to a steam processing apparatus and, more particularly, to an apparatus for receiving a mixture of liquid and vapor, separating the vapor from the liquid and discharging the vapor and the liquid from separate outlets.
In natural circulation vapor generators, mixtures of water and steam rise in heated steam-generating tubes and discharge into one or more large steam drums disposed in an elevated position above the tubes. The drums include means to separate the water from the steam with the latter being removed through openings of the upper portions of the drum and the former being recirculated through downcomers to the boiler and back to the steam generating tubes to complete the natural circulation loop.
In relatively large installations employing natural circulation vapor generators, it is essential that an efficient separation of the steam from the water be effected in the drum with minimal pressure loss in order to furnish steam of the required purity to the point of use, and steam-free water to the circulation system. In these arrangements, the expansion of the water-steam mixture through the separator results in a substantial pressure drop which, if too large, can adversely effect the circulation system. Also at low must have sufficient flow area to minimize pressure loss and still achieve separation.
Many of the prior art arrangements designed to minimize the pressure drop and maximize the flow area have included a drum with an extraordinarily large length which is incompatible from a fabrication standpoint with the furnace width dimension for a given capacity unit. As a result, the drum often overhangs relative to the furnace which tends to increase material and erection costs.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a steam processing apparatus in which liquid is separated from vapor at a relatively low pressure loss.
It is a further object of the present invention to provide an apparatus of the above type which is of a simple, efficient and inexpensive design.
It is a still further object of the present invention to provide an apparatus of the above type in which a drum is provided, the length of which is relatively short for a given capacity unit and, therefore, can be fabricated in a relatively inexpensive manner.
It is a still further object of the present invention to provide an apparatus of the above type which permits a relatively high loading per foot of drum length.
Toward the fulfillment of these and other objects, the steam processing apparatus of the present invention comprises a cylindrical drum having at least one inlet for receiving a mixture of liquid and vapor from an external source, a first outlet for discharging the liquid, and a second outlet for discharging the vapor. A plurality of rows of separators are disposed along the length of the drum to other side of the axis of the drum. Each separator includes spiral discharge arms and a baffle arrangement for separating the mixture into a liquid and a vapor. The liquid is directed to the first drum outlet and the vapor to the second drum outlet. A portion of each separator of a particular row extends partially into the space between adjacent separators of the adjacent row.
BRIEF DESCRIPTION OF THE DRAWINGS
The above brief description, as well as further objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of the presently preferred but nonetheless illustrative embodiment in accordance with the present invention when taken in conjunction with the accompanying drawings in which:
FIG. 1 is a vertical cross-sectional view of the steam processing apparatus of the present invention;
FIG. 2 is a cross-sectional view taken along the line 2--2 of FIG. 1;
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2; and
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring specifically to FIG. 1 of the drawing, the reference numeral 10 refers in general to the steam processing apparatus of the present invention which includes a steam drum 12 which forms a portion of a natural circulation steam-water system. The drum 12 is of an elongated cylindrical shape and is disposed with its axis parallel to the horizontal. The upper end portions of two groups of steam generating risers or tubes 14 extend through the drum 12 and communicate with the interior of the drum to introduce a mixture of water and steam into the drum. A plurality of downcomers (one of which is shown by the reference numeral 16) extend from the lower portion of the drum to discharge the separated water (along with a quantity of feed water) to a furnace (not shown) where the water is heated and recycled back through the drum 12. Dried steam is removed from the drum 12 through a plurality of discharge tubes 17 disposed at the upper portion of the drum.
An elongated girth baffle 18 is provided within the drum immediately above the end portions of the tubes 14 to define a chamber 20 for receiving the mixture of water and steam from the tubes 14. A plurality of separators 22 are disposed in the drum 12 and are arranged in four horizontally extending rows, tow extending to either side of the axis of the drum. Each separator 22 includes a riser pipe 24, the lower end portion of which is bolted to the girth baffle 18. The riser pipes 24 are adapted to receive the water-steam mixture from their respective chambers 20 and separate the mixture into steam and water as will be described in detail later. Although not clear from the drawings, it is noted that the chamber 20 takes the form of a concentric annulus inside the drum 12 that permits flow from one side of the drum to the other. This annulus is interrupted only by the openings in the drum 12 for the downcomers 16 and by the support structure shown. Therefore, water can flow through an open girth area in between the latter openings and support structure.
Two horizontally extending feed pipes 26 are disposed in the chamber 20 and are adapted to introduce water into the drum 12 which flows through the separators 22 with the mixture of water and steam to replenish the supply of steam that is discharged from the separators and, thus, maintain a constant water level, shown by the reference letter L. This water passes downwardly through a vortex eliminator 28 to the downcomer 16 for discharge back into the natural circulation loop. The vortex eliminator 28 operates in a conventional manner to prevent swirling of the water as it discharges from the drum 12 into the downcomer 16, and thus reduces the entrance loss to the downcomer 16. In addition, the vortex eliminator 28 also prevents the steam from being drawn from the upper portion of the drum into the downcomer. Since the vortex eliminator 28 is of a conventional design, it will not be described in any further detail.
A plurality of steam dryers are disposed in the upper portion of the drum 12 with one being shown by the reference numeral 30 in FIG. 1. The dryers 30 are supported by a conventional support structure in a position immediately above the separators 22 and immediately below a dry box 32, also of a conventional design. The dryers 30 include a plurality of plates (not shown) which are in a nested, but spaced, relationship and may be of the chevron type disclosed in U.S. Pat. No. 2,472,101, issued on Jun. 7, 1949. The dryers 30 function to dry the steam discharging from the upper portion of the separators 22 and separate any entrained water particles carried over with the steam as it flows through the space between the nested plates and through the dry box for discharge from the tubes 17.
As shown in FIG. 2, which depicts the two adjacent rows of separators 22 disposed on one side of the axis of the drum 12, the separators in each row are spaced slightly apart in a horizontal direction with a portion of each separator of a particular row extending partially into the space between adjacent separators of the adjacent row. Of course, this minimizes the space taken up by the separators 22 and contributes to the advantages set forth herein.
Referring specifically to FIGS. 3 and 4 which depict the details of a separator 22, the reference numeral 36 refers to an upright cylindrical shell through which the riser pipe 24 extends in coaxial relationship. The riser pipe 24 has a flanged end portion 24a which is bolted to the girth baffle 18 (FIG. 1) and receives a mixture of a water and steam from the tubes 14.
A cap 38 extends over the upper end of the pipe 24 and a plurality of slots 40 (FIG. 4) are formed through the upper wall portion of the pipe 24. A plurality of substantially spiral shaped arms 42 are connected to the pipe 24 in registry with the slots 40 with the free ends of the arms being open to permit the water-steam mixture to discharge therefrom in a substantially tangential direction relative to the shell 36.
A support structure is provided within the shell 36 for supporting the riser pipe 24 within the shell in the coaxial position shown. As a non-limitive example, the support structure can include a plurality of upper support struts 46 and/or a plurality of lower support struts 48.
A wire mesh unit 50 is disposed at the upper end portion of the shell 36 for filtering any entrained water particles from the steam exiting from the separator and is retained by a cross assembly 52 (FIG. 2). The unit 50 is supported in the position shown by a bolt assembly 54 extending in threaded engagement with the cap 38 of the riser pipe 24.
As a result of the above, the mixture of water and steam entering the end portion 24a of the riser pipe 24 rises upwardly in the riser pipe and then passes radially outwardly from the pipe through the slots 40 and into the arms 42 where it is directed tangentially against the inner wall of the shell 36. This creates a vortex, or swirling stream of fluid with the resulting centrifugal forces causing the vapor portion of the mixture to travel away from the inner wall of the shell 36 and towards the center of the swirling stream and pass upwardly, by virtue of its buoyance, into the upper portion of the shell 36 and through the wire mesh unit 50. The water portion of the mixture collects on, and flows down, the inner wall of the shell 36 until it falls into the reservoir of water disposed above the girth baffle 18 (FIG. 1), before passing through the vortex eliminator 28 and into the downcomer 16 for recirculation.
Referring again to FIG. 1, the steam from the separators 22 passes upwardly through the chevron driers 30 into the dry box 32 whereby the steam is dried and separated from any entrained water particles before passing outwardly from the drum 12 through the discharge tubes 17 as shown by the dashed flow arrows in FIGS. 1 and 3.
In view of the foregoing, an efficient and compact steam processing apparatus is provided which enables the drum length to be decreased relative to the furnace width dimension for a given capacity unit, and thus permits an increase in loading per foot of drum length. In addition, the decreased drum length reduces material and erection costs for the drum, and the number of riser circuits to, and drum steam discharge tubes from, the drum.
A latitude of modification, change and substitution is intended in the foregoing disclosure and in some instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention therein.
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A steam processing apparatus and method in which a plurality of separators are disposed along the length of a cylindrical drum having inlet means for receiving a mixture of liquid and vapor and outlet means for discharging the separated liquid and vapor. The mixture is discharged against a baffle after which the separated liquid is passed to the drum liquid outlet and the separated vapor is passed upwardly by natural buoyant forces to the drum vapor outlet. The separators are disposed in a plurality of rows--two to each side of the axis of the drum along the length thereof.
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BACKGROUND OF THE INVENTION
The invention relates to an arc extinguishing chamber whose side walls are made of composite material, and to a switchgear device comprising such a chamber.
Low-voltage circuit breakers of high ratings more often than not comprise separable contacts arranged at the entry of an arc extinguishing chamber. When separation of the contacts takes place caused by a trip device following an overcurrent, an electrical arc arises between the contacts and is propagated in an arc extinguishing chamber designed to absorb the energy of the arc while maintaining its voltage. The chamber comprises a plurality of separators arranged transversely to the arc and designed to break the arc down into fractions. This fractioning enables the voltage of the arc to be increased and the arc to be cooled by heat exchange with the separators. The separators are supported by two side walls of the chamber, arranged facing one another perpendicularly to the separators. These side walls essentially have to perform mechanical securing of the separators and electrical insulation.
The chamber is subjected to very high thermal, mechanical and electrical stresses: to give a good idea thereof, a current of 200,000 amperes maintained for 4 ms at an arcing voltage of 500 Volts gives off an energy of 400 kJ. The plasma column forming the arc can reach a temperature situated between 4,000 and 20,000 Kelvins. The separators are subjected to electrodynamic forces during breaking tending to separate them from one another. The pressure in the arc extinguishing chamber can at the same time reach 1.4 MPa.
The side walls have to withstand these stresses without becoming conducting themselves and without giving off a low dielectric strength gas.
Traditionally, the walls are formed by a stratified material composed of successive layers of thermosetting resin reinforced by fiber glass. The glass fibers give the walls their mechanical strength. However glass fibers contain low ionization potential elements. Experience shows that when these glass fibers are subjected to high temperatures, the elements having a low ionization potential inside the fibers ionize and hamper the arc extinguishing process, in particular for voltages in excess of 400 Volts. In addition, molten glass beads appear at the surface due to ablation of the resin and foster adhesion of metallic particles given off in the chamber by melting of the separators. The surface resistance of the walls, taken between two points both of which are close to one of the separated contacts, therefore decreases during breaking. For these reasons, the risk of breaking failure is high.
To overcome this problem, the document FR-2,616,009 proposes a three-layer composite stratified structure. The external layers are formed by a multitude of linen fibers impregnated with melamine resin whereas the internal layer is constituted by a multitude of woven glass fibers impregnated with melamine resin. The layer comprising the glass fibers gives the structure its rigidity whereas the superficial layer comprising linen fibers remains non-conducting even during and after exposure to the arc. This stratified material proves satisfactory in applications where it is only exposed to the arc on the side where its layer comprising linen fibers is situated. The material does on the other hand present some problems in an architecture requiring that an edge of the side wall be exposed to the arc. Such an architecture is for example encountered in the case of a circuit breaker comprising, for a given phase, two poles connected in parallel, each pole being provided with an arc extinguishing chamber, the arc extinguishing chambers being connected to one another by a communication orifice made in the adjacent side walls of the two chambers and enabling circulation of the gases. A circuit breaker of this type is described in the French Patent Application bearing the national registration number 98/06206. With such a cutting of the stratified material plate, the layer comprising glass fibers is flush with the surface of the edge, resulting in a certain vulnerablity in this zone. It is naturally possible to deposit an additional layer comprising linen fiber to specifically protect this zone, but this solution is costly.
It has moreover been proposed in the document DE-A-43 22 351 to replace the melamine-based thermosetting resins reinforced with cotton or linen cellulose fibers by a polyamide thermoplastic polymer matrix containing a cellulose material coated with a hardened melamine-formaldehyde resin, in which the polyamide and coated cellulose material are present in a ratio of 6:1 to 1:1. The material used is supposed to give dielectric properties at least equal to those of thermosetting materials, and better mechanical properties. However, experience shows that the thermoplastic nature of the material gives rise to problems from the temperature withstand point of view, in particular when progressive diffusion of the heat stored by the metallic separators takes place, during and after breaking, i.e. in practice about 30% of the breaking energy. As the polyamide of the walls tends to soften when the temperature rises, it undergoes deformations rapidly making the chamber unusable. This is why this solution is not applicable to circuit breakers with high ratings.
SUMMARY OF THE INVENTION
The object of the invention is therefore to overcome the shortcomings of the state of the technique in order to propose a high-performance structure of an arc extinguishing chamber side wall for low-voltage circuit breakers of high ratings producing arcing energies in the region of 400 kJ. Its object is in particular to determine such a structure whose edges are also resistant to breaking.
According to a first feature of the invention, this object is achieved by means of an electrical arc extinguishing chamber designed to be placed facing separable contact means of a switchgear apparatus and to extinguish the arc generated by separation of said contact means, comprising: two side walls facing one another, each side wall comprising a stratified composite structure with at least two layers, and a plurality of spaced apart plates arranged between the side walls and secured by the side walls, one of said layers comprising a polyamide fabric impregnated with a thermosetting resin. The resin is not simply disposed between two layers of fabric, but at least partially coats the fibers or wires constituting the fabric.
Each of the layers of the stratified composite structure preferably comprises a fabric of polyamide fibers at least partially coated with a thermosetting resin. The structure obtained is thus produced at low cost.
According to one embodiment the thermosetting resin is of the type obtained by condensation of formaldehyde with melamine.
Advantageously, the thermosetting resin contains fire-proofing elements. Such a structure provides even better performances.
A second feature of the invention relates to a switchgear apparatus comprising a chamber as defined previously.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages and features of the invention will become more clearly apparent from the following description of different embodiments of the invention, given as non-restrictive examples only and represented in the accompanying drawings in which:
FIG. 1 represents an exploded perspective view of a circuit breaker according to the invention;
FIG. 2 represents a longitudinal cross-section of the circuit breaker of FIG. 1, along a mid-plane of the twinned pole of the circuit breaker;
FIG. 3 represents an exploded view of an arc extinguishing chamber of a pole of the circuit breaker according to the invention;
FIG. 4 represents a partially exploded perspective view of a rear compartment of the circuit breaker of FIG. 1, showing more particularly a communication orifice between two twinned poles according to the invention;
FIG. 5 represents a transverse cross-section showing two twinned poles;
FIG. 6 represents a transverse cross-section of a side wall of a chamber according to FIG. 3;
FIG. 7 schematically represents a manufacturing process of a side wall of a chamber according to FIG. 3;
FIG. 8 schematically represents a transverse cross-section of a side wall according to a second embodiment of a chamber according to FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIGS. 1 and 2, a six-pole circuit breaker 10 comprises an insulating case formed by assembly of a rear base 12 , an intermediate frame 14 with open ends and a front panel 16 , which confine a rear compartment and a front compartment on each side of a front partition 18 of the intermediate frame 14 . In the front compartment there is housed an operating mechanism 20 of the circuit breaker 10 which acts on a switching shaft 22 common to all the poles of the circuit breaker. This mechanism 20 is fitted on the front partition 18 of the intermediate frame 14 . The rear compartment is itself subdivided into elementary compartments by intermediate partitions 24 , 25 (cf. FIG. 4) of the intermediate frame 14 . A pole of the circuit breaker is housed in each elementary compartment. Each pole comprises a separable contact device and an arc extinguishing chamber 26 .
The separable contact device comprises a stationary contact means 28 directly supported by a first connection terminal 30 of the circuit breaker passing through the base 12 of the insulating case, and a movable contact means 32 . The movable contact means 32 is provided with a plurality of parallel-mounted contact fingers 34 pivotally mounted on a first transverse spindle 36 of a support cage 38 . The heel of each finger is connected to a second connection terminal 40 passing through the base 12 , by means of a braided strip 42 of conducting material. The connection terminals 30 , 40 are designed to be connected to the line-side and load-side power system, for example via a busbar. The end of the cage 38 situated near to the second connection terminal 40 is equipped with a spindle housed in a bearing securedly united to the insulating case, so as to allow pivoting of the cage 38 between an open position and a closed position of the pole around a geometric axis 44 materialized in FIG. 2. A contact pressure spring device 46 is arranged in a notch of the cage 38 and urges the contact fingers 34 to pivot counterclockwise around the first spindle 36 . Each contact finger 34 comprises a contact pad 47 which, in the position represented in FIG. 2, is in contact with a single pad 49 arranged on the stationary contact means 28 . The cage 38 is coupled to the switching shaft 22 by a transmission rod in such a way that rotation of the shaft 22 induces pivoting of the cage 38 around the spindle 44 .
The structure of the arc extinguishing chamber 26 can be seen more particularly in FIG. 3 . The chamber comprises a juxtaposition of separators formed by metallic strips 50 for deionization of the electrical arc. The separators are assembled on an insulating support comprising two lateral cheeks 52 . The internal face of each cheek 52 is provided with notches operating in conjunction with complementary asperities of the strips for positioning of the latter. Positioning of an upper arcing horn 54 is achieved in the same way. A composite external wall 56 is arranged appreciably perpendicularly to the lateral cheeks and to the deionization strips. This wall forms a frame for assembly of the lateral cheeks. It comprises exhaust orifices for outlet of the breaking gases and a stacking of intermediate filters 58 designed to limit pollution of the outside environment.
It can be seen in FIG. 4 how the arc extinguishing chamber 26 is inserted in one of the elementary compartments of the circuit breaker, here a lateral compartment bounded by an intermediate partition 24 and one of the external lateral partitions 60 of the intermediate frame 14 . This construction enables the state of the circuit breaker poles to be checked and the arc extinguishing chamber 26 to be replaced with a reduced number of handling operations.
The extinguishing device is completed by a lower arc guiding horn 62 fixed to the base 12 and electrically connected to the stationary contact means 28 of the pole, which confines the inlet of the arc extinguishing chamber 26 in the downwards direction. The stationary contact 28 has, in the zone directly facing the front end of the fingers 34 of the movable contact means 32 , a profiled edge 64 approximately complementary to the profile of the fingers 34 , extending upwards to the protuberance of the lower horn 62 to globally form with the latter a profile without a notable break in the slope. This stationary contact zone, called spark arrester, enables the risks of damage to the contact pads 47 and 49 to be eliminated. When opening of the contact parts takes place, the initial pivoting movement of the cage 38 around its spindle 44 —clockwise in FIG. 2 —in fact causes pivoting of the movable fingers 34 around their spindle 36 in the opposite direction. In this initial phase, this combined movement results in the front part of the fingers and the spark arrester moving towards one another and coming into contact, before the contact pads 47 , 49 separate. When separation of the pads 47 , 49 takes place, the fingers 34 are in a position such that the distance between the pads 47 , 49 increases more quickly than the distance between the lower horn 62 and the fingers 34 of the movable contact 32 . Consequently the arc is initially drawn between the spark arrester and the front end of the fingers 34 and migrates immediately to establish itself between the protuberance of the horn 62 and the front part of the fingers 34 , preventing any movement of the arc towards the pads 47 , 49 or any striking at the level of the latter. When opening is pursued, the arc extends in front of the chamber and enters therein in the usual manner.
The poles of the circuit breaker 10 are twinned two by two so as to form three groups of two adjacent poles. By twinning we mean electrical connection in parallel of the stationary contact means 28 of the two poles and of the movable contact means 32 of the two poles. In practice, this twinning is performed outside the case, at the level of the free ends of the connection terminals 30 , 40 of the contacts to be connected, by interposing two connection strips 66 which can be seen for one of the poles in FIG. 4, these two strips being fixed by each of their ends to a corresponding part of each connection terminal 30 , 40 protruding out from the case.
The three intermediate partitions 24 separating two twinned compartments differ from the other two intermediate partitions 25 in that they comprise a communication aperture 68 of appreciably rectangular cross-section, as can be seen in FIGS. 2, 4 and 5 . This aperture is situated close to the contact zone, at the level of the inlet to the arc extinguishing chamber. It is arranged in such a way that the lower arcing horns 62 of the two twinned poles are facing one another on each side of the aperture. In the heightwise direction, measured along an axis perpendicular to the base 12 , the aperture 68 extends appreciably up to the height of the upper horns 54 . In the lengthwise direction, measured along an axis perpendicular to the previous axis and to the pivoting spindle 44 of the movable contact means 32 , the aperture extends on both sides of the inlet of the chamber 26 . Finally, the inlets of the two arc extinguishing chambers 26 are practically not separated by the intermediate partition 24 . An inlet opening common to the two arc extinguishing chambers 26 can thus be defined, which is materialized, in a straight cross-section perpendicular to the longitudinal axis, by an appreciably rectangular common orifice whose edge is defined following the edge of the upper horn 54 of one of the poles, the edge of the upper horn 54 of the twinned pole, a part of the wall of the intermediate partition 25 without aperture of this twinned pole, the protuberant upper edge of the lower horn 62 of the twinned pole, the corresponding edge of the lower horn 62 of the first pole and a part of the wall of the intermediate partition 25 without aperture—or of the external lateral partition 60 , depending on the case—of the first pole. As can be seen particularly in FIGS. 2 to 4 , the lateral cheeks 52 of the arc extinguishing chambers 26 have a cutout 70 corresponding to the aperture 68 of the intermediate wall 24 separating the twinned poles. The face of the lateral cheeks 52 of each arc extinguishing chamber 26 facing the adjacent intermediate partition 24 , 25 is adjoined over its whole surface to the partition.
Each lateral cheek 52 of the chamber 26 is formed by a structure 100 made of stratified composite material comprising three superposed layers 102 , 104 , 106 , represented in FIG. 6 . In this example, all the layers are identical and each composed of a polyamide fabric composed of weft wires or fibers 108 or warp wires or fibers 109 forming a cloth armor coated with a thermosetting resin 110 obtained by condensation of formaldehyde with melamine with a formula C 3 N 6 H 6 . The fabric gives the structure its tensile strength. The resin gives the material its coherence and its compression resistance. It occupies not only the space between the different layers of cloth, but also the space between the wires of each layer of cloth, so that each wire is more or less coated with resin. In other words, each layer 102 , 104 , 106 is composed of a cloth impregnated with resin. The polyamide used can be a Pa 6 or Pa 6.6 polyamide. A stratified structure corresponding to these criteria is marketed by ITEN Industries (Ashtabula, Ohio, USA) under the reference “Resiten N-9”.
The composite structure 100 can be obtained according to a process schematically represented in FIG. 7. A strip 120 of polyamide fabric coming from a roll 122 runs in a continuous flow in a resin bath 124 fed by a tank 126 , then in a heating tunnel 128 connected to a boiler 130 . Due to the effect of the heat, the resin melts then hardens by a reticulated polymerization process. On output from the tunnel 128 , the coated fabric is cut into sheets 132 by a cutting press 134 . On output, the sheets 132 are stacked. The stack 136 is run through a press 138 under high pressure, at a temperature of about 140° C. to 210° C., so as to cause interlaminary flow of the resin enabling adhesion between the sheets 132 to take place. The plates 140 obtained are then cut in a second cutting press 142 in order to give them the final shape in accordance with their use.
The results obtained with this type of structure are very advantageous. When a break occurs on a short-circuit, the melamine formaldehyde resin erodes and lets the polyamide strengthening fabric become apparent. This fabric gives off in particular hydrogen which allows formation of a gaseous film protecting the surface directly exposed to the arc. Consequently, the adherence of the molten particles is very greatly reduced. The electrical withstand properties remain optimal throughout the exposure phase of the walls to the arc.
After the arc has been extinguished, the heat stored in the metallic strips, i.e. about one third of the breaking energy, is dissipated, in particular by diffusion through the side walls, thus increasing their temperature. In this phase, the thermosetting resin ensures the mechanical strength of the wall, as the polyamide is for its part a thermoplastic material, reversible in liquid above 300° C.
Due to the simultaneous volatilization of the polyamide and of the melamine, there is no dielectric weak point creation, in particular at the level of the cutouts 70 of the structure.
FIG. 8 represents a transverse cross-section of a cheek according to a second embodiment of the invention, which only differs from the previous embodiment in the smaller thickness of the resin layer 100 separating two successive layers of cloth. The mechanical and dielectric characteristics of this cheek are more homogeneous. The performance obtained is of the same order as that of the previous example. This illustrates the doubtlessly preponderant importance of the resin coating the wires of the polyamide fabric and impregnating the fabric with respect to that situated farther away from the polyamide wires between two layers of fabric.
The invention is naturally not limited to the above embodiment. The armor of the fabric can be simple (cloth armor) or complex. The different sheets constituting the different layers of the structure can be stacked in the same direction or alternatively in different directions, so as to obtain particular mechanical characteristics. The structure can, in addition to one or more layers composed of melamine reinforced with polyamide fabric, also comprise layers of different natures. Coating of the polyamide fabric fibers can be partial or full. The thermosetting resin can usefully contain fire-proofing elements such as inorganic charge generating material which may be hydrated or not (magnesium hydroxides, zinc borate . . . ), nitrogenous compounds, phosphoreted compounds, organo-halogenated compounds or organo-phosphoreted compounds. The number of layers is variable according to requirements. Good results are obtained with a structure with an overall thickness of 1 to 3 mm comprising 2 to 20 layers.
Likewise the invention is not limited to the particular type of chamber described in the embodiment. In particular, the separators may be of any shape and arrangement. The chamber may or may not be removable with respect to the case which contains said chamber.
Finally, although the invention has been described with reference to a particular circuit breaker with two pole compartments per phase connected to one another by an opening, the invention is not limited to this type of switchgear apparatus. It is naturally applicable to any type switchgear apparatus using arc extinguishing chambers. The breaking resistance characteristics of the side walls of the chambers according to the invention, in particular at the level of the edges exposed to the arc, avoid any particular treatment of these edges from being required. However, the vocation of the invention is also to apply to chambers whose walls do not necessarily have edges exposed to the arc.
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An electrical arc extinguishing chamber designed to be placed facing separable contacts of a switchgear apparatus and to extinguish the arc generated by separation of the contacts comprises two side walls facing one another and a plurality of spaced apart plates arranged between the side walls and secured by the side walls. The side walls have a stratified composite structure with at least two layers. The layers comprise a polyamide fabric impregnated with thermosetting resin. The chamber thus obtained has advantageous breaking strength properties. The edges of the side walls do not present any dielectric weakness points. The chamber is particularly suitable for low-voltage switchgear of high power ratings.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to improved sol-gel barrier films. More particularly, the invention pertains to sol-gel coated polymer films which do not require thermal or electron beam densification to obtain useful oxygen barrier films.
2. Description of the Prior Art
It is known in the art that SiOx barrier coatings may be produced on substrates either by thermal evaporation of silica dioxide or plasma enhanced chemical vapor deposition of organo silicones. Both of these processes are expensive due to materials costs or processing costs. However they are the only currently available methods available to glass coat polymer films because these processes do not destroy the integrity of the films. U.S. Pat. No. 5,084,356 illustrates vapor depositing SiO 2 onto a substrate. An alternate method of producing silica films is by the sol gel method. This process requires densifying the sol gel coating to SiO2 by increasing the Si-O-Si bond content and eliminating water in the process. Two methods are available to accomplish this. One requires that the monomeric sol-gel coating be heated to over 800° C. and the other requires the sol-gel coating to be exposed to an electron beam. U.S. Pat. Nos. 5,318,857; 5,186,745; 5,091,009; 5,013,588; 4,997,482; 4,385,086; 4,361,598; 5,096,738; 5,091,224; 4,614,673 illustrate the coating of a monomer followed by in-situ cure by heating. These methods have disadvantages that effect the choice of substrate and the economics of the coating process.
The process of the present invention produces a glass-like coated polymer film by the sol-gel method without thermal or electron beam densification to obtain a useful oxygen barrier film. According to the process, a relaxed sol-gel composition is formed by hydrolyzing a tetrafunctional alkoxide silicate in an aqueous solution including a Lewis acid or metal chelate catalyst to produce a pre-crosslinked polymer having a viscosity of about 2600-3200 cps. The crosslinked polymer is then relaxed without depolymerizing it by diluting to a viscosity of about 1 cps. This is then coated on a substrate and dried without undergoing a curing. None of the aforementioned patents show coating of a polymer. Rather they coat monomers and then cure in-situ.
U.S. Pat. No. 4,842,901 precondenses tetraethyl ortho silicate, water, acid and a C 4 or higher alcohol, deposition on a substrate and drying, however there is no redilution to relax the polymer. U.S. Pat. No. 4,966,812 shows a reliquification by an ultrasonic breaking of polymer bonds with subsequent dilution, however, there is no dilution of a fully condensed polymer composition and this disclosure does not show use of a Lewis acid. U.S. Pat. No. 4,842,837 discloses hydrolyzing alkoxysilane with an alkaline catalyst and U.S. Pat. Nos. 5,328,645; 4,741,778; and 4,789,563 show the use of an alkaline hydrolysis or condensation. However, alkaline catalysts form polymer particles which produce a non-uniform coating. None of the foregoing patents disclose preformation of a cured polymer using a Lewis acid, relaxing the polymer by redilution and coating a cured polymer with subsequent drying. This invention produces a high oxygen barrier film on the substrate that is stable to heat and moisture while being extremely thin film (preferably <0.1 micron) and thus eases the recycling of the material.
SUMMARY OF THE INVENTION
The invention provides a method of producing a relaxed sol-gel composition which comprises hydrolyzing a tetrafunctional alkoxide silicate in an aqueous solution comprising water or water plus a C 1 to C 4 alcohol and a catalyst. The catalyst is selected from the group consisting of a protic acid, Lewis acid, a metal chelate, a Lewis acid plus a protic acid, and metal chelate plus a protic acid. The reaction is conducted at a pH of from about 1 to about 3. Hydrolysis is conducted until a viscosity of 2600-3200 cps is obtained to thereby produce a crosslinked sol-gel polymer composition. The latter is then relaxed and substantially complete hydrolysed of any residual alkoxyl groups thereof by diluting it with water or water plus a C 1 to C 4 alcohol, optionally containing a Lewis acid or metal chelate until a viscosity of about 0.5 to about 5 cps is obtained to produce a relaxed sol-gel polymer composition while substantially not depolymerizing the polymer. The relaxed sol-gel polymer composition has substantially no visible polymer particles therein. It is an important feature of the invention that at least one of the foregoing steps is conducted with a Lewis acid or metal chelate. In a subsequent step the relaxed sol-gel polymer composition is substantially dried without additional curing. The invention also provides a coated substrate article produced by coating the relaxed sol-gel polymer composition onto a substrate with subsequent drying.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows the change in viscosity with time for the compositions of Examples 1 and 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The process will be illustrated by reference to the preferred embodiment. A relaxed sol-gel composition is formed by hydrolyzing and crosslinking a tetrafunctional alkoxide silicate. Tetrafunctional alkoxide silicates useful for this invention include tetra-C 1 to C 9 alkyl ortho silicate although the most preferred are tetraethyl orthosilicate (TEOS) and tetramethyl orthosilicate. The hydrolysis is conducted in an aqueous solution comprising water or water plus a C 1 to C 4 alcohol. The intermediate hydrolysis converts the alkoxy group to a hydroxy group and this latter then polymerizes and crosslinks. The hydrolysis is conducted with a catalyst which can be a Lewis acid, a metal chelate, a Lewis acid plus a protic acid or a metal chelate plus a protic acid. Lewis acids non-exclusively include aluminum chloride, iron chloride and zinc chloride. Protic acids include hydrochloric acid, nitric acid and acetic acid among others. Metal chelates include beta diketones such as aluminum, chromium and zirconium acetylacetonate. The hydrolysis may be conducted in two stages by first hydrolyzing with the protic acid and then with the Lewis acid or metal chelate. The Lewis acid or metal chelate is important for the invention since it allows the tetrafunctional alkoxide silicate to condense and crosslink more completely than would be obtained if a protic acid alone is used. The condensation or ripening is conducted until a viscosity of 2600-3200 cps is obtained to produce a crosslinked sol-gel polymer composition. This usually takes from about three to about five days. The catalyst is present in that amount sufficient to catalyze the condensation and crosslinking. The Lewis acid or metal chelate is preferably present in an amount of from about 1% to about 10% by weight of the tetrafunctional alkoxide silicate, more preferably from about 2% to about 6%. The protic acid, when one is used, is preferably present in an amount of from about 0.5% to about 10% by weight of the tetrafunctional alkoxide silicate, more preferably from about 1% to about 4%.
After the TEOS gel has ripened it is then diluted with water or a 50/50 mixture of water/ethanol one to four times. In one embodiment of the invention, this solution may contain the Lewis acid or metal chelate to bring the condensation reaction to completion. However, at least of one the hydrolysis and dilution steps must be conducted with a sufficient amount of a Lewis acid or metal chelate to bring the condensation reaction to substantial completion. The dilution serves to relax the condensed polymer without causing a depolymerization. The preferred viscosity ranges from about 0.5 cps to about 5 cps, preferably about 0.5 to about 1.5 cps and most preferably about 1 cps. The relaxed sol-gel polymer composition has substantially no visible polymer particles. This process improves on prior art processes which merely condense until a low viscosity of about 10 cps is obtained. The prior processes inherently produce coatings with visible polymer particles and no significant improvement in oxygen transmission rate. The relaxed sol-gel composition may additionally comprising a colorant such as a uv or infrared absorbing dye.
Then the solution is coated down onto a substrate which is preferably substantially non-porous. Typical substrates non-exclusively include glass, metals, polyesters such as polyethylene terephthalate, polyethylene, polyolefins such as polypropylene, cellulosic polymers such as cellulose acetate butyrate, among many others. These articles afford oxygen barrier, abrasion resistance and rust and corrosion proofing. Thereafter, the solution is dried. The drying is effective to evaporate and substantially remove the water and alcohol solvents, however, there is substantially no additional condensation or curing of the crosslinked polymer. In the preferred embodiment, the drying is conducted in the absence of applied heat. The temperature is not critical and may range from about 10° C. to about 130° C. depending on economical drying times, but preferably drying is conducted at about room temperature.
The coated substrate article preferably has an oxygen transmission rate of less than about 20% that of the uncoated substrate. Preferably the coated substrate has an oxygen transmission rate of less than about 10 cm 3 /M 2 /day as calculated by ASTM D-3985. The substrate is coated with a substantially uniform coating of the relaxed sol-gel polymer composition at a thickness not in excess of that which would provide a substantially crack-free layer on the substrate when dried. One then dries the relaxed sol-gel polymer composition to provide a substantially crack-free layer on the substrate. The dried, substantially uniform coating on the substrate is one which is substantially crack free and has a preferred thickness of about 0.5 micron or less, preferably 0.2 micron or less and may optionally comprises more than one layer of the relaxed polymer composition. This invention is capable of affording an effective oxygen barrier coating at room temperature.
The following non-limiting examples serve to illustrate the invention.
EXPERIMENTAL PROCEDURE
In the following examples, metal alkoxide, tetraethoxy orthosilicate (TEOS) is dissolved in a ethanol/water solution, the molar ratio of TEOS to ethanol to water was varied from 1/2/5, 1/3/5, 1/4/5 and 1/3/7. The solution is hydrolyzed with concentrated HCl, or a Lewis acid, or HCl and a Lewis acid, or HCl and a metal chelate compound. Then the solution is allow to age from 3 to 7 days depending on the initial reactants molar ratios to a viscosity of 2600 to 3200 cP (Brookfield #4 spindle @50 rpm). At that time the gel is diluted with a water/ethanol mixture or ethanol to a viscosity of 1-5cP. FIG. 1 shows the change in viscosity with time before dilution for the sols of Examples 1 and 2. Before coating down on 48 gauge PET a Lewis acid or a metal acetoacetonate (AcAc) is added. The coatings are laid down using either a #7, or #32 wire wound rod or dip coated. The samples are air dried.
EXAMPLE 1
A hydrolysis was carried out by mixing 92 grams of ethanol, 208 grams of tetraethoxy orthosilicate, 90 grams of water and 2.5 grams of concentrated hydrochloric acid. The solution was stirred and aged until the Brookfield viscosity (#4 spindle @50 rpm) of the solution was 2600-3200 cp, approximately 72 hours. There were no visible signs of any particles in solution. At this point the viscous solution was diluted four fold with a 50:50 solution of water/ethanol which contained 2% (by weight) of a Lewis acid, FeCl 3 . The solution was visibly clear and had a viscosity of 5 cp. The solution was coated down onto 48 gauge PET film with a #7 wire wound rod and air dried. The thickness of the dried film is estimated to be 0.1 microns and SEM photomicrographs show no cracking of the film. The resultant oxygen transmission (OTR) rate at 0% Relative Humidity (RH) was 22 cm 3 /m 2 /day.
EXAMPLE 2
A hydrolysis was carried out by mixing 138 grams of ethanol, 20 g grams of tetraethoxy orthosilicate, 90 grams of water and 1.2 grams of concentrated hydrochloric acid. The solution was stirred and aged until the Brookfield viscosity (#4 spindle @50 rpm) of the solution was 2600-3200 cp, approximately 120 hours. There were no visible signs of any particles in solution. At this point the viscous solution was diluted four fold with a 50:50 solution of water/ethanol which contained 1% (by weight) of a metal chelate, Al acetoacetonate (Al AcAc). The solution was visibly clear and had a viscosity of 1 cp. The solution was coated onto 48 gauge PET film with a #32 wire wound rod and air dried. The resultant oxygen transmission (OTR) rate at 0% Relative Humidity was 15 cm 3 /m 2 /day. The thickness of the dried film is estimated to be 0.2 microns and SEM photomicrographs show no cracking of the film.
EXAMPLE 3
A hydrolysis was carried out by mixing 92 grams of ethanol, 208 grams of tetraethoxy orthosilicate, 90 grams of water and 3.4 grams of AlCl 3 and 1.2 grams of concentrated hydrochloric acid. The solution was stirred and aged till the Brookfield viscosity (#4 spindle @50 rpm) of the solution was 2600-3200 cp. There were no visible signs of any particles in solution. At this point the viscous solution was diluted four fold with a 7:3 solution of water/ethanol which contained 2% (by weight) of a Lewis acid, CrCl 3 The solution was visibly clear and had a viscosity of 1 cp. The solution was coated down onto 48 gauge PET film with a #7 wire wound rod and air dried. The resultant oxygen transmission (OTR) rate at 0% Relative Humidity (RH) was 31 cm 3 /m 2 /day.
EXAMPLE 4
A hydrolysis was carried out by mixing 92 grams of ethanol, 208 grams of tetraethoxy orthosilicate, 90 grams of water and 2.5 grams of concentrated hydrochloric acid. The solution was stirred and aged until the Brookfield viscosity (#4 spindle @50 rpm) of the solution was 2600-3200 cp, approximately 72 hours. There were no visible signs of any particles in solution. At this point the viscous solution was diluted three fold with ethanol which contained 2% (by weight) of a Lewis acid, AlCl 3 . The solution was visibly clear and had a viscosity of 5 cp. The solution was coated down onto 48 gauge PET film using a dip coating method and then air dried. The resultant oxygen transmission (OTR) rate at 75% Relative Humidity was 13 cm 3 /m 2 /day.
EXAMPLE 5
A hydrolysis was carried out by mixing 92 grams of ethanol, 208 grants of tetraethoxy orthosilicate, 126 grams of water, 2.5 grams of concentrated hydrochloric acid and 2.2 of AlAcAc. The solution was stirred and aged until the Brookfield viscosity (#4 spindle @50 rpm) of the solution was 2600-3200 cp. There were no visible signs of any particles in solution. At this point the viscous solution was diluted three fold with ethanol which contained 2% (by weight) of a Lewis acid, FeCl 3 . The solution was visibly clear and had a viscosity of 2 cp. The solution was coated down onto 48 gauge PET film using a dip coating method and then air dried. The resultant oxygen transmission (OTR) rate at 75% Relative Humidity was 80 cm 3 /m 2 /day.
EXAMPLE 6
Example 1 was repeated with the following conditions. A hydrolysis was carried out by mixing ethanol, tetraethoxy orthosilicate (TEOS), water and concentrated hydrochloric acid. The molar ratio of water to TEOS was 5, the molar ratio of ethanol to TEOS was 2 and the molar ratio of HCl to TEOS was 0.07. The viscous solution was diluted four fold with a 50:50 solution of water/ethanol which contained 2% (by weight) of a Lewis acid, AlCl 3 . The solution was coated down onto 48 gauge PET film with a #7 wire wound rod and air dried. The resultant oxygen transmission rate was 20 cm 3 /m 2 /day.
EXAMPLE 7
Example 1 was repeated with the following conditions. A hydrolysis was carried out by mixing ethanol, tetraethoxy orthosilicate (TEOS), water and concentrated hydrochloric acid. The molar ratio of water to TEOS was 5, the molar ratio of ethanol to TEOS was 2 and the molar ratio of acids to TEOS was 0.07. The viscous solution was diluted four fold with a 1:1 solution of water/ethanol which contained 6% (by weight) of a Lewis acid, AlCl 3 . The solution was coated down onto 48 gauge PET film with a #7 wire wound rod and air dried. The resultant oxygen transmission rate was 51 cm 3 /m 2 /day.
EXAMPLE 8
Example 1 was repeated with the following conditions. A hydrolysis was carried out by mixing ethanol, tetraethoxy orthosilicate (TEOS), water and concentrated hydrochloric acid. The molar ratio of water to TEOS was 5, the molar ratio of ethanol to TEOS was 2 and the molar ratio of HCl to TEOS was 0.07. The viscous solution was diluted four fold with a 1.1 solution of water/ethanol which contained 6% (by weight) of a Lewis acid, AlCl 3 . The solution dip coated onto 48 gauge PET film and air dried. The resultant oxygen transmission rate at 75% Relative Humidity was 21 cm 3 /m 2 /day.
EXAMPLE 9
Example 1 was repeated with the following conditions. A hydrolysis was carried out by mixing ethanol, tetraethoxy orthosilicate (TEOS), water and concentrated hydrochloric acid. The molar ratio of water to TEOS was 5, the molar ratio of ethanol to TEOS was 4 and the molar ratio of HCl to TEOS was 0.035. The viscous solution was diluted three fold with ethanol which contained 2% (by weight) of a Lewis acid, ZrAcAc. The solution was dip coated onto 48 gauge PET film and air dried. The resultant oxygen transmission rate at 75% Relative Humidity was 80 cm 3 /m 2 /day.
EXAMPLE 10
Example 1 was repeated with the following conditions. A hydrolysis was carried out by mixing ethanol, tetraethoxy orthosilicate (TEOS), water, concentrated hydrochloric acid and AlAcAC. The molar ratio of water to TEOS was 7, the molar ratio of ethanol to TEOS was 3 and the molar ratio of acid to TEOS was 0.07. The viscous solution was diluted three fold with ethanol which contained 2% (by weight) of a Lewis acid, AlCl 3 . The solution was dip coated onto 48 gauge PET film and air dried. The resultant oxygen transmission rate at 75% Relative Humidity was 93 cm 3 /m 2 /day.
COMPARATIVE EXAMPLE 11
A hydrolysis was carried out by mixing 92 grams of ethanol, 208 grams of tetraethoxy orthosilicate (TEOS), 90 grams of water, 2.5 grams of concentrated hydrochloric acid. The solution was stirred and aged until the Brookfield viscosity (#4 spindle @50 rpm) of the solution was 2600-3200 cp, approximately 72 hours. There were no visible signs of any particles in solution. At this point the viscous solution was diluted two fold with water which contained 2% (by weight) of a Lewis Acid AlCl 3 . The solution was visibly clear and had a viscosity of 5 cp. The solution was coated onto 48 gauge PET film with a #7 wire wound rod and air dried. The resultant oxygen transmission (OTR) rate at 0% Relative Humidity was 122 cm 3 /m 2 /day. The thickness of the dried film was estimated to be 6.5 microns and SEM photomicrographs show extensive cracking of the film.
COMPARATIVE EXAMPLE 12
A hydrolysis was carried out by mixing 92 grams of ethanol, 208 grams of tetraethoxy orthosilicate (TEOS), 90 grams of water, 2.5 grams of concentrated hydrochloric acid. The solution was stirred and aged until the Brookfield viscosity (#4 spindle @50 rpm) of the solution was 2600-3200 cp, approximately 72 hours. There were no visible signs of any particles in solution. At this point the viscous solution was diluted four fold with a 1:1 ethanol-water which contained 2% (by weight) of a Lewis Acid FeCl 3 . The solution was visibly clear and had a viscosity of 5 cp. The solution was coated onto 48 gauge PET film with a #7 wire wound rod and air dried. The resultant oxygen transmission (OTR) rate at 0% Relative Humidity was 124 cm 3 /m 2 /day. The thickness of the dried film was estimated to be 0.5 microns. The coating is noticed to be non-uniform since it has particles of about 0.5 microns in diameter. SEM photomicrographs show extensive cracking of the film.
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A relaxed sol-gel composition and a coated substrate article which is produced therefrom. A tetrafunctional alkoxide silicate is hydrolyzed in an aqueous solution together with a Lewis acid or metal chelate catalyst with optional protic acid until a viscosity of 2600-3200 cps is obtained to form a crosslinked sol-gel polymer composition. The polymer is relaxed by diluting it with water or water plus alcohol optionally containing a Lewis acid or metal chelate until a viscosity of about 1 cps is obtained while not depolymerizing the polymer. The relaxed polymer has substantially no visible polymer particles. The relaxed polymer composition is uniformly coating a substrate and dried without requiring an in-situ curing.
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BACKGROUND OF THE INVENTION
The present invention relates to computers and, more particularly, to testing computer systems fabricated on an integrated circuit. A major objective of the present invention is to provide computer-system-on-a-chip designs with enhanced built-in testability.
Much of modern progress is associated with the increasing prevalence of computers, including embedded controllers as well as general-purpose computers. A typical computer includes a processor, memory, and peripherals that communicate with each other over a system bus. In many computers, the processor, memory, and some peripherals are embodied in separate integrated circuits. However, with advances in integrated-circuit manufacturing technology allowing millions of transistors on an integrated circuit, it is now practical to build computer systems on an integrated circuit (chip). Instead of assembling separate integrated circuits on a printed-circuit board, computers can be designed by assembling functional blocks on an integrated-circuit layout.
Testing of complex integrated circuits, such as single-chip computers is an essential and formidable task. While the functional block designs are often well characterized, they are subject to manufacturing defects. In addition, each circuit design represents a novel arrangement of functional blocks that requires testing both for design integrity and for defects in the connections between function blocks.
The prior art provides a default method for testing a computer system. A test program can be run on the computer processor, which can write to peripherals coupled to the system bus and then read from the system bus to determine if the expected results occur. While much can be accomplished with this approach, it is typically not effective at testing non-system-bus connections between on-chip peripherals or between on-chip peripherals and off-chip devices. Likewise, on-chip functions that rely on non-system-bus inputs, e.g., communications from a modem, can be hard to evaluate. Accordingly, several approaches to augmenting this processor-based testing approach have been considered.
One prior-art “multiplex-to-pins” approach is to multiplex the input-output ports of functional blocks to provide controllability of input and observability of outputs. This allows for external test equipment to test the non-system bus connections. A major problem with this multiplex-to-pins approach is that it precludes many possible test combinations. Tests requiring more than one use of a pin at a time cannot be performed. If a pin is used to access an internal connection, its normal use is precluded. Likewise, if a pin is multiplexed to more than one internal connection, only one of these may be accessed at a time. Even with careful assignment of pins to internal connections, the restrictions on test combinations can be prohibitive. Typically, only a single peripheral is tested, not its connections to the rest of the system, thus degrading a key goal of the test. In addition, the multiplex-to-pins approach requires flexible test hardware to map peripheral test patterns to pins—since that mapping varies from device to device.
In addition, this multiplex-to-pins approach becomes less practical as the number of internal connections increases relative to the number of pins. Multiplexing internal connections to pins consumes routing resources, and the inter-blocks routes tend to be very costly in terms of area. Moreover, non-test application performance can be adversely affected not only by the additional multiplexers, but also by the parasitic capacitances along the paths between the input-output ports and the pins.
Scanning approaches introduce data serially and read out the results serially, thus avoiding much of the routing complexity of the multiplex-to-pins approach. JTAG (“Joint Test Action Group”) is a standardized test-interface specification for the scanning. The JTAG specification requires a five-pin interface to test equipment. These pins are “serial test-data in” (TDI), “serial test-data out” (TDO), “test clock” (TCK), “test reset” (TRST), and “test-mode select” (TMS). Thus, the number of pins required for testing using the prevailing scan approaches is small and fixed. Thus, problems with routing and test-pin count are vastly reduced compared to the multiplex-to-pins approach.
The vast majority of complex chips use a “fulls scan” approach to test for manufacturing faults. In the full-scan approach, all registers, including those internal to functional blocks, are arranged in a serial shift chain. Typically, the order of registers in a full-scan serial-shift chain is not determined as part of the design process, but as an automated post-design procedure. Due to the functionally arbitrary order and large number of registers involved, functional testing using the full-scan approach is impractical. Instead, functional testing is achieved by simulation, and the full scan is used to check for manufacturing faults. Furthermore, scan approaches are destructive in nature, since old state data will be shifted out as new data is shifted in.
The simulation used for design validation and the full scan used for finding manufacturing faults are performed before an integrated circuit is integrated into a system. Configurations not anticipated in the simulation are not tested. Latent manufacturing defects that become overt during use (e.g., due to gradual electro-migration) may not be detected by the full scan. In addition, in view of the large amount of shifting required, the full scan can be very time consuming.
The prior-art also reaches a more limited “peripheral-scan” (also known as “partial-scan” or “scan-wrapper”) approach. In the peripheral-scan approach, non-system-bus functional block ports are multiplexed to latches or registers arranged in a serial shift chain. Test data can be shifted in from external test equipment, a clock cycle run to clock data into the peripheral and capture outputs, and then the data can be shifted out to the external test equipment. Thus, the peripheral-scan approach can be used for functional testing. However, scanning data in and out is still quite time consuming.
The approaches discussed above all involve difficult tradeoffs. While the full-scan is relatively comprehensive in the components it can test, it is impractical to use it for functional testing. On the other hand, while a peripheral-scan allows for functional testing, the range of components that are tested is more limited than it is for the full-scan approach. The multiplex-to-pins approach is faster, but is costly in terms of routing resources.
A bus-access approach couples external testing equipment a system bus. Each module to be tested has a test harness with test registers. Each test register can be associated with a module input or outputs. During testing, these registers are coupled to the system bus so that they can be accessed by the external test equipment. Such a test approach is disclosed by Arm Limited in “AHB Example AMBA System Technical Reference Manual”. This document was obtained in the year 2000 the Arm, Limited website at www.arm.com. The document is copyrighted 1999, and no publication date is given.
The bus-access approach is faster than the scan approaches and consumes fewer routing resources than does the multiplex-to-pins approach. However, Arm's implementation still requires thirty-six dedicated pins, which is costly in terms of packages and board area.
The bus-access, scan and the multiplex-to-pin approaches share many limitations. A salient limitation is the requirement for dedicated testing equipment. The testing equipment is expensive. The requirement of the external testing makes it impractical to test circuits once they are in use, which, in turn, makes it difficult to test in the context of signals associated with normal use.
More generally, the bus-access, scan, and multiplex-to-pins approaches all require a test mode in which conditions are very difficult from normal operation. Functional modules are not performing their normal functions and none of the circuitry being tested is operating at normal speed. Thus, many problems that could occur during normal functioning at normal operating speed may not occur under test conditions. Thus, differences between test conditions and normal operating conditions limit test comprehensiveness.
Summarizing the known prior art, the multiplex-in-pins and scan approaches expand upon the default processor-based approach to testing integrated circuits generally, and system-on-a-chip computers specifically. The multiplex-to-pins approach allows relatively rapid testing; however, it imposes severe limits on combinations of inputs that can be applied during testing, and it can be expensive in terms of routing resources. The scan approaches allow data to be scanned or shifted to and from the non-system-bus ports; this approach is less taxing on routing resources and less restrictive of the test inputs. However, the serial scanning of data into and out of the integrated circuit is time consuming. Sophisticated test software is required to stimulate and observe specific areas of the design. All these approaches are limited by the requirement of dedicated test equipment and test conditions that are very different from normal operation.
What is needed is a novel approach to enhancing the default testing that does not require external testing equipment. Preferably, the novel approach would be less taxing on routing resources than is the pin-multiplexing approach. Also, preferably, the novel approach would be less time-consuming than the scan approaches. Finally, it is desired that testing under near-normal operating conditions be available after an integrated circuit is installed in an incorporating system.
SUMMARY OF THE INVENTION
The present invention provides for system self-testing in which a processor has access via a system bus both to bus and non-bus connections. The non-bus connections are made accessible through the bus during testing (but not during execution of normal application programs) via multiplexers. The invention is especially applicable to embedded controllers and system-on-a-chip computers. The computer system includes a processor, a system bus, and a set of peripherals, all of which can be fabricated on a single integrated circuit.
The system also includes test-driver multiplexers and test-driver registers. Each register has a data input coupled to the system bus and a control input coupled to an address decoder. The address decoder decodes addresses asserted by the processor to determine when to enable the register so that it can be written to.
One of the integrated peripherals is connected either to one of the multiplexer data inputs or to the multiplexer output. The other of these two multiplexer ports is coupled to another functional module. This other functional module can also be one of the integrated peripherals or it can be a non-peripheral on-chip functional module or it can be an external device. The remaining multiplexer data input is coupled to an output of said register.
Preferably, the multiplexer control input is also coupled to an output of said register, in this case, the control input and the second data input respond to different bit positions of a value stored in the register. Alternatively, another means can be used to control the multiplexer—e.g., the address decoder in response to a separate address assigned to control the multiplexer.
During execution of an application program, the test-driver multiplexer is set so that the peripheral and the functional module are connected. During execution of a test program, the test-driver multiplexer can be controlled so that the test-driver is selected as the active multiplexer input. In this case, the data value is provided to whichever functional module is connected to the test-driver multiplexer output.
The invention provides a method in which a test program is initiated, data is written to a test-driver register via the system bus, a test-driver multiplexer is switched to connect the test-driver register output to a non-system-bus connection, and then the result of the test is read by the processor via the system bus. The reading of a test result can take different forms. In some cases, the result can be read by the processor via a system bus connection that is normally in place during execution of an application program. For example, the test can involve conveying the test data to a non-system-bus input of a system-bus-peripheral that, as a matter of course, makes the result available via the system bus.
If the peripheral receiving the test data is not connected to the system bus or does not provide the result of interest to the system bus as a matter of course, a test sampler can be used. For signals that can be statically controlled or that change slowly enough that polling by the processor will not miss any important states, a test sampler can involve a tap from a non-system-bus connection to a multiplexer having an output to the system bus. To observe transient states, sample-and-hold circuitry, trigger logic, and/or edge-sensitive logic can be used. In response to a read request, the multiplexer can be controlled to select the test-sampler as a bus input so that the processor can read non-system-bus data.
The invention provides for incorporating test drivers and/or test samplers in module function blocks for optimal design convenience in providing enhanced testability of computers systems on a chip. However, for function blocks not including required test drivers or test samplers, these can be provided external to the function blocks as part of a dedicated test-mode controller peripheral. The required registers can be written to by addressing the test-mode controller peripheral, which also controls the associated test-driver multiplexers.
A major advantage of the present invention over the default processor-based testing scenario is that there is direct testability of ports not normally addressable by a processor over a system bus. The invention consumes fewer routing resources than does the multiplex-to-pins approach, and it much less time consuming than the scanning approach. In part because of its speed, the present invention makes comprehensive functional testing practical, in contrast to both the peripheral-scan approach and the full-scan approach.
A major advantage over the alternative enhancements to the default approach is that no external testing equipment is required. Moreover, tests can be run in context and at normal operating speeds so that test conditions more closely compare to normal operation. Accordingly, the validity of test results is enhanced.
Furthermore, test drivers and samplers can be selected individually; and unselected circuitry can functional normally and at full speed. The precision with which tests can be directed permits testing to go beyond merely determining whether or not an integrated circuit functions as intended; the present invention allows faults to be isolated. In other words, the present invention allows not only validation but also debugging of circuitry. These and other features and advantages of the invention are apparent from the description below with reference to the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a personal digital assistant (PDA) incorporating the present invention.
FIG. 2 is a block diagram of a keypad interface and some functional modules connected thereto of the PDA of FIG. 1 .
FIG. 3 is a block diagram of a mode selector of the PDA of FIG. 1 .
FIG. 4 is a flow chart of a method of the invention practiced in the context of the PDA of FIG. 1 .
In FIGS. 2 and 3, test-driver multiplexer data inputs selected during application program execution are labeled “D 1 ”, test-driver multiplexer data inputs that are selected only during test program execution are labeled “D 2 ”, test-driver multiplexer outputs are labeled “DQ”, and test-driver multiplexer control inputs are labeled “CI”.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the present invention, a personal digital assistant PDA 10 comprises a system-on-a-chip 12 , an LCD (liquid crystal display) panel 14 , a serial connector 16 , and a keypad 18 with five buttons, as shown in FIG. 1 . PDA 10 belongs to a familiar class of consumer products in which the main user interface is a touch-screen LCD panel 14 . Tactile buttons on keypad 18 provided for on/off and basic application mode control. A serial port allows for communication, e.g., with a desktop computer for data reconciliation and with the Internet via a modem.
Internally, system 12 includes a process (“central processing unit” or “CPU”) 20 , a system bus 21 , a memory subsystem 22 , and other peripherals. Memory 22 stores program instructions and user data. Processor 20 executes program instructions. System bus 21 provides for communication between processor 20 , memory 22 , and the various peripherals.
Memory 22 includes a memory interface 24 , nonvolatile flash RAM (random access memory) 26 , and volatile SRAM (static random-access-memory) 28 . Flash RAM 26 holds the operating system, as well as built-in application and test programs. SRAM 28 holds user data and serves as a scratch pad for data manipulations by processor 20 .
System 12 includes six normal-mode bus peripherals. Bus peripherals related to LCD panel 14 include an LCD controller 30 and a touch-screen interface 31 . An RS 232 serial controller 33 manages communications via serial connector 16 . A keypad interface 35 handles inputs from keypad 18 . A timer 37 provides internal timing for system 12 . An interrupt controller 39 handles interrupts from other peripherals and informs processor 20 of their assertions. In addition to these six bus normal-mode peripherals, system 12 includes a test-mode controller 40 configured as a bus peripheral.
System 12 also includes several test circuits, including test drivers D 00 -D 11 , and test samples S 00 -S 03 , S 05 , S 07 , S 10 , and S 12 . Some test circuits, e.g., D 00 , S 00 , D 04 , S 12 , are internal to bus peripherals. In other words, the designs of these function blocks provide for these test circuits.
Other test circuits are not included in a function block. For example, driver node D 09 is functionally associated with the output of off-chip keypad 18 , and so has a separate on-chip location. Test driver D 05 is similarly associated with an off-chip device, LCD panel 14 . Test sampler S 05 and test driver D 06 are associated with touch-screen interface 31 . In this case, a design module for a touch-screen interface with built-in test circuits was not available, accordingly, test circuits S 05 and D 06 are located external to touch-screen interface 31 .
The test-circuits can manage single line and multi-line connections. For example, test circuits D 00 , S 00 , S 01 , D 02 and S 02 , associated with memory transfers, involve 48-bit connections (including data, address, and control lines). Test-driver D 04 is connected to an 11-bit path for conveying graphical data to LCD panel 14 ; while test circuits D 05 and S 05 are coupled to 8-bit paths conveying touch-screen information from LCD panel 14 . Test circuits D 07 and S 07 are coupled to 5-bit paths involving serial interface 33 . Test circuits D 09 and S 10 are coupled to 5-bit paths from keypad 18 to keypad interface 35 . Test sampler S 12 of interrupt controller 39 is 4-bits wide to accommodate four single-bit wide inputs from test drivers D 06 , D 08 , D 10 , and D 11 .
The bit-width of each test sampler corresponds to the bit-width of the path it is connected to. Each test driver includes a register that is wider than the path it is connected to. The extra bit or bits are used to control a multiplexer that switches its output between an off-bus connection (selected during normal operation) and the test of the bits in the register. In the typical case of a two-input multiplexer, the driver register is one-bit wider than the data path at the multiplexer output.
In response to depression of a preset combination of the buttons on keypad 18 , processor 20 begins execution of a test program 50 , instead of an application program 51 , FIG. 2 . Among the instructions of test program 50 are instructions to write certain test values to test-mode controller 40 . Accordingly, processor 20 issues write requests with associated addresses and data. Test-mode controller 40 includes an address decoder 52 that responds to the address by enabling all three test-driver registers R 05 , R 06 , and R 09 so that can be written to in a single write operation. The different registers are connected to receive different bit positions of the data being written so that their contents can be independent.
Processor 20 can also read from registers R 05 , R 06 , and R 09 . To this end, processor 20 can issue a read request to the same address used for the write request. In response, decoder 52 controls multiplexer 54 so that its output is coupled to the outputs of registers R 05 , R 06 , and R 09 . Reading these registers can be used to confirm test settings or, in the context of a read-modify-write operation, to change the contents of one register without changing the contents of the others.
In this example, a 9-bit value is written to register R 05 . The most-significant bit is applied to a control input CI of multiplexer M 05 . When this control bit is zero, multiplexer M 05 couples its output DQ to its first input D 1 ; this input is coupled to the output of LCD panel 14 so that touch-screen data can be transmitted to touch-screen interface 8-bits at a time. The touch-screen data can be monitored by issuing a write command; the write command causes decoder 52 to couple a tap T 05 from output of LCD panel 14 to bus 21 . Note that the function of test sampler S 05 involves tap T 05 and multiplexer 54 .
The touch-screen data is simulated by the least-significant 8 bits stored in register R 05 . When the most-significant bit of register R 05 is one, multiplexer M 05 couples its output to its second data input D 2 ; this input is couple to the eight least-significant bits of registers R 05 . This provides simulation data to touch-screen interface R 06 for test purposes. It can thus be seen that the function of test-driver D 05 involves register R 05 and multiplexer M 05 .
The more-significant bit of 2-bit register R 06 controls multiplexer M 06 to determine whether interrupt controller 39 is coupled to touch-screen interface 31 or to register R 06 . In the latter case, test-mode controller 40 can simulate or preclude an interrupt from touch-screen interface 31 . Thus, the function of test driver D 06 involves register R 06 and multiplexer M 06 .
The most-significant bit of 6-bit register R 09 controls multiplexer M 09 to determine whether keypad interface 35 is coupled to receive from keypad 18 or from register R 09 . In the former case, keypad interface 35 receives five bits of data from keypad 18 . In the latter case, register R 09 can be used to simulate 5-bits of data from keypad 18 , while precluding actual button presses from being detected by keypad interface 35 . Thus, the function of test driver D 09 involves register R 09 and multiplexer M 09 .
Test-mode controller 40 directly controls test circuitry to simulate or monitor devices external to system-on-a-chip 12 , FIG. 1 . Test drivers D 05 and D 09 and test sampler S 05 are examples. Test-mode controller 40 also controls test circuitry for function blocks without built in test counterparts. An example of this is test driver D 06 for touch-screen interface 31 .
In general, however, designing for testability is simplified if test circuits are designed into the function blocks. When built into a peripheral, test registers can be addressed at a known offset from the peripheral's base address. The least-significant bits of a register's base address would not vary from device to device. Thus, a common test routine could be used for many different devices.
The modifications required to a conventional keypad interface to yield keypad interface 35 are detailed with reference to FIG. 3 . The modifications required for other functional blocks can be extrapolated by analogy with keypad interface 35 .
Keypad interface 35 includes a keypad interface function 60 , an address decoder 62 , a 2-bit register R 10 , a driver multiplexer M 10 , and a read multiplexer 64 . A precursor keypad interface 35 designed without the test enhancement of the present invention includes an identical keypad interface function and a similar address decoder. Keypad interface 35 modifies the address decoder to handle an additional address devoted to test functions. In addition, it adds register R 10 and multiplexer M 10 , and widens multiplexer 64 .
The outputs of keypad interface controller 60 are coupled to inputs of multiplexers M 10 and 64 , whereas the precursor keyboard interface controller has outputs coupled directly to interrupt controller 39 and system bus 21 , respectively. To provide for testability, these connections are controlled in keypad interface 35 .
Test driver D 10 includes 2-bit register R 10 and multiplexer M 10 . In addition, it provides a tap 66 from the outputs of register R 10 to an input of multiplexer 64 . Thus, processor 20 can issue a read request with the test address, causing tap 66 to be the selected input of multiplexer 64 so that processor 20 can read the contents of register R 10 .
Test sampler S 10 involves tap T 10 and multiplexer 64 to allow the keypad input to keypad interface function 60 to be monitored. Test sampler S 10 serves primarily for continuity testing.
More generally, system-bus peripherals having outputs that are not normally connected to the system bus are provided with test-driver circuits. The test-driver circuits include a test-driver multiplexer coupled to whatever communications path the peripheral output is connected to in normal operation. The peripheral output is one input to the test-driver multiplexer. The peripheral is also provided with a register that is addressable by the system processor via the system bus. This register is coupled to another input of the test-driver multiplexer. Optionally, one or more of the register bit positions can be coupled to the control output of the test-driver multiplexer to determine which of its inputs is selected. Preferably, the register output is coupled, e.g., through another multiplexer, to the system bus so that its contents can be read directly by the processor.
A test-mode selector is provided to control test circuitry associated with non-system-bus, e.g., off-chip, peripherals. The arrangement of registers and multiplexers can be essentially the same as for the test-driver circuitry for non-system-bus outputs of system-bus peripherals. However, in this case, it is the test-mode selector that is addressed rather than the peripheral itself. The test-mode selector can also be used to control test drivers for system bus peripherals that, for whatever reason, have not been modified to include test drivers.
Test-samplers can be included in system-bus-peripherals at their non-system-bus inputs. The invention provides for including registers in the test samples. However, it is generally sufficient to provide a tap at such an input. The processor can then monitor the tap by addressing it through a multiplexer coupled to the system bus.
Monitoring a non-system bus signal with a tap is sufficient for signals that can be statically controlled or change slowly enough that polling by the processor will not miss any important states. If transient behavior must be observed, some other sample-and-hold, trigger logic, and/or edge-sensitive logic must be added to synchronize the signals to the processor. Dynamic sampling logic is highly application specific.
A method ME 1 of the invention practiced in the context of PDA 10 is flow-charted in FIG. 4. A test program is initiated at step ST 1 . The initiation can occur in a number of ways. A test program can be initiated during system boot (power on). A test program can be initiated in response to a user action, such as depressing a particular combination of buttons concurrently. A test program can be initiated automatically as part of an exception handling routine in response to an error detected during operation of an application program. A test program can be used to assist in software debug.
Processor 20 writes data to test-drive registers at step ST 2 . This step involves writing data to registers built into system-bus peripherals or to registers in a test-mode selector or both.
Multiplexers are switched at step ST 3 so that peripheral ports normally coupled to non-system-bus data paths during execution of application programs are decoupled and the registers are coupled to the non-system-bus data paths instead. Step ST 3 can be essentially concurrent with step ST 2 , especially in the preferred case in which some bit positions of the register control the multiplexer. In other cases, the multiplexer can be switched after data is entered into the registers.
Test results are read at step ST 4 by addressing an appropriate test sampler point. This can simply involve reading a normal address associated with a bus peripheral. Alternatively, it can involve reading from a multiplexer that has been set so that it couples a test sampler (tap, sample-and-hold circuit, trigger logic, and/or edge-sensitive logic) from a non-system-bus port of a system-bus peripheral to the system bus. Also alternatively it can involve reading from a multiplexer that has been set so that is couples a test sampler from a non-system-bus node that is not connected to a system-bus peripheral. In this case, the multiplexer can be part of a test-mode selector.
While the modifications and method called for by the present invention are described in the context of a PDA, the invention applies generally to devices including integrated circuit systems that include processor, system bus, system-bus peripherals, and non-system bus connections. In addition for testing for problems with permanently attached devices, the method can be used for testing temporarily connected devices like PC cards, flash-memory cards, etc. These and other variations upon and modification to the described embodiments are provided for by the present invention, the scope of which is defined by the following claims.
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An embedded-controller-based system, such as a personal digital assistant (PDA), includes a system-on-a-chip with a processor, system bus, memory, and system-bus peripherals. The system-bus peripherals include connections to data paths that are not accessible from the system bus during execution of application programs. Associated with these connections are test drivers that include registers that can be written to by the processor via the system bus for software controllability. When the processor executes a test program, it writes test values to these registers. Some bits of the test values are used to control multiplexers so that they can decouple function block ports from the non-system-bus connections and then couple the remaining bits of the registers. In this way, a test program can write data directly to the non-system bus connections. The results of the test data being applied at the source of inter-block connections can be read from the destinations using test samplers. The test samplers can be taps to function block ports that are multiplexed to the system bus for reading during a test procedure for software observability. Thus, both bus connections and non-bus connections can be tested by a program running the system processor without requiring external test equipment.
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FIELD OF THE INVENTION
[0001] This invention relates to a method of conditioning a long horizontal open-hole water injection well in a tight formation prior to acid stimulation to improve the contact of the acid with the rock as well as the penetration of the acidic materials into the reservoir rock and thereby enhance the permeability of the formation and the flow rate of the injected water.
BACKGROUND OF THE INVENTION
[0002] It is a common practice to employ acid stimulation of low-permeability or damaged carbonate reservoir formations in order to enhance the flow and production of hydrocarbon fluids from the formation surrounding the wellbore. Acid treatment of water injection wells is similarly employed to enhance the permeability of the reservoir. However, the effectiveness of the acid treatment can be seriously reduced if the wellbore contains formation damage caused by incursions of drilling fluids, or mud, and other foreign matter. This problem is particularly pronounced in water injection wells through tight carbonate reservoir formations and results in acid treatments that are less successful than those carried out in relatively high permeability water injection wells.
[0003] The effectiveness of the acid treatment is directly proportional to the injection rate (e.g., barrels of water/minute) and inversely proportional to the injection pressure, i.e., a lower pressure is required for a given injection rate following an effective acid treatment.
[0004] It has been found that hydrochloric acid which can effectively dissolve the calcium carbonate minerals present in both the filter cake and the formation is not capable of dissolving or degrading some of the formation-damaging polymer components present in the drilling fluid, such as xanthan gum and starch. The xanthan gum is used to increase viscosity and the starch to control fluid loss. Three different damage mechanisms associated with drilling fluids are filtrate invasion, solid invasion (internal filtercake) and external filtercake. Other materials used in assembling the drilling pipe can also cause damage to the surrounding formation. Pipe dope applied to the couplings and other fittings used in assembling the drilling pipes and associated components can also cause damage to the surrounding formation.
[0005] As used herein, the term “undesirable materials” will be understood to refer to formation-damaging polymers, other chemical substances, debris and other materials which interfere with the flow of formation fluids from the walls and adjacent reservoir rock of the well bore and thereby reduce the productivity/injectivity of the well. The inherent formation pressure is the pressure of the fluids in the pores of a reservoir created by the weight of the overburden, water injection and any underground withdrawal.
[0006] As used herein, the term “wellbore” if not otherwise modified, will be understood to mean the combined vertical section and the open-hole horizontal section of the well.
[0007] It is therefore an object of the present invention to provide a method of substantially eliminating or greatly reducing the presence of formation-damaging materials, such as polymer components and pipe dope residue that interfere with the effectiveness of an acid stimulation treatment in an open-bore horizontal water injection well, to thereby render the subsequent acid treatment of the formation more efficient and effective.
SUMMARY OF THE INVENTION
[0008] The method of the present invention comprehends the inclusion of an additional step or pre-treatment stage prior to the introduction of the pressurized acid treatment of a water injection well in which the injection portion of the horizontal open-hole wellbore is subjected to flowback of the formation fluids for a period of time that is sufficient to remove a substantial portion of the undesired materials from the walls of the wellbore and from the adjacent formation. In some formations, the flowback stage can be achieved as a result of the inherent reservoir pressure and once the application of pressure on the drilling fluid is discontinued at the surface, the formation fluids will flow into the open-hole bore with sufficient force to displace the introduced wellbore fluids back up through the vertical wellbore and produce the formation fluids and the undesirable materials to the surface through the production/injection tubing.
[0009] The rate and time allowed for the flowback is controlled at the wellhead. In such a case, the flowback can be achieved by depressurizing the wellbore fluid to atmospheric and opening the wellhead valve to discharge the wellbore fluid.
[0010] The formation fluids produced during the flowback step can include brine, hydrocarbon liquids and/or gases and will initially include damaging mud-induced solids introduced under pressure into the wellbore during the drilling of the wellbore and the liquid that was forced into the pores of the reservoir rock. The portion of the reservoir occupied by solids faulted on the horizontal open-hole bore surface and the solids and liquid penetrating the formation around the bore are referred to herein as the infiltration zone.
[0011] In the event that the inherent reservoir pressure is not sufficient to raise the wellbore fluid, formation fluids, debris and undesirable materials to the wellhead at the earth's surface, the flowback is achieved by reducing the hydrostatic pressure of the completion fluid in the production zone to a pressure that is less than the inherent pressure of the formation fluids proximate to the production zone. The hydrostatic pressure of the fluid is reduced by displacing a portion of the fluid from the vertical section of the wellbore to the earth's surface.
[0012] In one preferred embodiment of this aspect of the method of the invention, the wellbore fluid is displaced by the use of a “nitrogen lift” process in which nitrogen gas is circulated through the production/injection conduit and into the wellbore to displace liquids and to thereby reduce the hydrostatic pressure created by the fluid column that extends to the wellhead at the earth's surface. Nitrogen lifting is well known and is a commonly used technique for initiating production in a well following acidizing treatments or over-balanced completions.
[0013] The quality of the completion fluid, debris and undesirable materials, along with any produced formation fluid(s) are monitored at the wellhead during the flowback stage. Samples of the formation fluids are subjected to periodic physical inspections. When the amount of undesirable materials is reduced to a predetermined acceptable level, the flowback stage is terminated.
[0014] Following termination of the flowback stage, the wellbore is prepared for the acidizing treatment stage in accordance with standard and customary procedures. This typically includes a preflush step which consists of water, a mutual solvent and water-borne wetting surfactant is next used to condition the wellbore for the acid treatment. The acidizing treatment stage of the process can include a 20% by weight emulsified HCl solution injected under pressure followed by a spacer of non-emulsified HCl and appropriate additives, which is then followed by a diverting agent.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0015] The invention will be described below in further detail and with reference to the attached drawings in which:
[0016] FIG. 1 schematically depicts a typical open-bore horizontal water injection well completion of the prior art in which the method of the invention can advantageously be practiced;
[0017] FIG. 2 is a detail of a representative portion of the open-bore well of FIG. 1 schematically illustrating the formation damage;
[0018] FIG. 3 is a detail similar to FIG. 2 schematically illustrating the effect following application of the method of the invention; and
[0019] FIG. 4 is a schematic diagram of a completion similar to FIG. 1 illustrating the positioning of apparatus for applying a nitrogen lift to raise the formation fluids to the wellhead.
DETAILED DESCRIPTION OF INVENTION
[0020] Referring to FIG. 1 , a water injection well completion in accordance with the prior art is illustrated that includes a vertical well bore section 10 extending from the earth's surface 9 that includes a series of casing elements, generally identified as 14 . As illustrated, the casing 14 includes section 14 A extending from the earth's surface having a diameter of about 24 inches. A representative series of concentric casing elements having the indicated diameters are also illustrated as follows: 14 B (18⅝″), 14 C (13⅝″), 14 D (9⅝″) and 14 E (7″). An injection tubing 12 terminates in supporting element 16 . It will be understood by one of ordinary skill in the art that the length of the vertical section 10 can be many thousands of feet.
[0021] The horizontal section 20 of the open-hole well bore is also of indeterminate length and is defined by the curved transitional heel portion 22 and the completion end, or toe, 24 . Note that the casing 14 terminates at region 15 which defines the beginning of the open-hole portion of the well in the carbonate formation 40 .
[0022] Also shown in FIG. 1 is sampling point 80 located at the earth's surface that includes control valve 82 and suitable sampling, inspection, testing, recording and alarm apparatus 84 . As noted above, the term “open-hole” refers to the fact that well casing 14 terminates at 15 and no well casing pipe is installed in the horizontal section, as it is in the vertical portion of the well bore 10 . As will be described in more detail below, the drilling fluid which is very dense to begin with contains undesirable materials, some of which infiltrate even a tight carbonate formation. Solid materials infiltrate beyond the surface of the horizontal bore hole and the liquid components penetrate the tight formation even further while displacing the reservoir fluids, due to the greater hydrostatic pressure of the drilling fluid in the vertical portion of the well. A layer of the solid undesirable materials also builds up in the surface of the bore hole and is referred to as the external filtercake.
[0023] The problem of mud damage mechanisms is illustrated in the enlarged cross-sectional schematic diagram of FIG. 2 which shows a portion of the tight carbonate formation 40 that is represented by the matrix of circular elements having small pores or passages between them. During the drilling operation, drilling fluid, or mud 50 , is introduced under pressure into the upper end of the vertical wellbore 10 for the purposes of lubricating the drill bit (not shown) that is attached to the downhole end of the drill pipe and also, of equal importance, to carry the fragmented formation rock away from the drill bit and up to the surface. Since the drilling fluid 50 is very dense and extends the entire length of the wellbore to the earth's surface, it produces a significant pressure on the open-hole bore in the horizontal drilling phase.
[0024] As a result of the over-balanced pressure, an internal filtercake 54 as represented by the small particles in FIG. 2 infiltrates the pores of the reservoir rock 40 . In addition, an external filtercake is formed and appears as a uniform dark coating 52 on the walls of the open-hole bore 20 . Also as shown in the illustration of FIG. 2 , the lighter area 56 extending from the external filtercake 52 represents drilling fluid liquid filtrate which displaces any reservoir fluids 42 which are represented by the darker area.
[0025] In accordance with the method of the invention, the reduction of the wellbore fluids overpressure, i.e., by the use of the nitrogen lift that is described in more detail below, will allow the inherent reservoir pressure on the reservoir fluids 42 in the injection zone to cause the reservoir fluids to flow-back into the open-hole bore 20 and thereby flush the filtrate 56 , and most, if not all of the internal filtercake 54 and external filtercake 52 from the surrounding reservoir rock.
[0026] The formation fluids produced during the flow-back stage of the process of the present invention can include brine, hydrocarbon liquids and/or gases, in addition to the drilling fluid filtrate. As schematically illustrated in FIG. 3 , following flow-back, substantially all of the external filtercake 52 and most of the internal filtercake 54 and filtrate 56 are flushed from the reservoir rock 40 by the reservoir fluids 42 flowing into the open-hole bore.
[0027] As previously noted, nitrogen lifting is an operation that is known and that has been commonly used to enable a well to flow initially or to bring a previously flowing well back into production. The nitrogen is introduced into the vertical section of the well bore at the desired location using coiled tubing. The nitrogen gas functions to “unload” or reduce the hydrostatic pressure upstream of the production zone to thereby under-balance the well so that it will flow naturally as a result of the inherent reservoir pressure.
[0028] Utilizing a simple calculation employing the known reservoir pressure at the production zone and along with the weight or density of the completion fluid in the well, the vertical depth of the well and its average diameter, the amount of overbalance can be estimated and the corresponding minimum depth for application of the nitrogen lift can be identified. The nitrogen can be introduced from a pressurized source at the earth's surface at a rate of from 300 to 900 SCF/bbl, the pressure being dependent upon the response achieved in the well during the nitrogen lift operation.
[0029] Referring now to FIG. 4 , the well completion of FIG. 1 is shown with the additional apparatus required for performing the nitrogen lift. A specialized vehicle 100 equipped with apparatus for transporting a length of coiled tubing 120 that is sufficient to reach the predetermined desired depth “D” in the vertical portion of the wellbore 10 is disposed adjacent the wellhead 80 . The coiled tubing 120 is poured into the well until the end of the tubing 122 reaches the desired predetermined depth “D” below the earth surface.
[0030] A source of liquefied nitrogen 130 is also disposed in the proximity of the wellhead and connected to pump 140 , which in turn is connected to the inlet end 124 of the coiled tubing which is typically retained on the vehicle 110 .
[0031] Once the apparatus has been positioned and secured, the liquefied nitrogen is pumped from its container 130 and through the coiled tubing 120 to be discharged into the vertical section 10 of the wellbore. When the liquefied nitrogen has been discharged from the open end 122 of the submerged tubing 120 , it rapidly expands to fill the wellbore and rises as an essentially continuous plug or block of gas towards the earth's surface, lifting the well completion fluid/mud out of the wellbore 10 . With this reduction in the hydrostatic pressure, the inherent formation pressure of the reservoir is able to displace the filtrate 56 and the reservoir fluids begin their backflow into the horizontal open-hole wellbore 20 . In addition to displacing the liquid filtrate 56 , the moving fluids also displace the internal filtercake 54 and the external filtercake 52 , respectively, from the adjacent formation and the surface of the open-hole bore. These materials will also be carried to the surface where they can be sampled and physically inspected for their content.
[0032] In some cases, the inherent reservoir pressure is sufficient to lift the reservoir fluids and any remaining undesired materials and completion fluid/mud to the surface and the injection of the liquefied nitrogen into the vertical wellbore 10 can be discontinued. In the event that the inherent reservoir pressure is not sufficient for this purpose, the nitrogen lift process can be continued while the fluids are inspected at the surface until the desired quality has been observed, after which the nitrogen injection is terminated and the coil tubing withdrawn. Thereafter, the acidizing treatment is initiated and completed as described above.
[0033] The method of the invention reduces polymer penetration of the tight carbonate formation 40 during the acid treatment, which is one of the main causes of injectivity loss, especially in tight carbonate formations. Laboratory tests have shown that the injection of a reacted solution of 20 wt % HCl acid and the components of a typical fluid used in the drilling of horizontal water injection wells resulted in a loss of more than 80% of the base core permeability.
EXAMPLES
[0034] Application of the method of the invention in three water injection wells produced a significant improvement in their injectivity. A field study was undertaken for the post treatment injection test results for six wells in the same formation in which three of the wells ( 1 , 2 , 3 ) were treated with the industry standard acid treatment and the other three wells ( 4 , 5 , 6 ) were treated using the method of the invention. The results of these comparative tests showed that the wells treated using the flowback method of the invention had a more than 2-fold increase in injectivity at lower injection pressure as compared to those subjected to the same acid treatment, but without the prior flowback stage.
[0035] The results of the tests on the six wells are set forth in the following tables, where Table 1 represents the post-acid stimulation treatment injection test without the flowback stage and Table 2 shows the improved results for the series of post-acid stimulation treatment injection tests with the prior flowback stage. In the tables, IWHP is the injection wellhead pressure.
[0000]
TABLE 1
Well No.
Well 1
Well 2
Well 3
Injection Rate,
27
30
20
bbls/min
IWHP, psi
1500
1100
1000
[0000]
TABLE 2
Well No.
Well-4
Well-5
Well-6
Injection Rate,
50.1
61.4
60
bbls/min
IWHP, psi
928
663
591
[0036] While the process of the invention has been described in detail above and illustrated in the accompanying drawings, modifications and variations will be apparent to those of ordinary skill in the art from this description and the scope of the protection to be accorded the invention is to be determined by the claims which follow.
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An open-hole horizontal water injection well in a tight formation is conditioned prior to an acidizing treatment by subjecting the injection zone to a flowback stage, optionally at reduced pressure, in order to remove undesirable materials such as formation-damaging polymers, chemical residues from pipe dope and the like, from the surface and adjacent formation pores, and producing the formation fluid to the wellhead at the earth's surface where it can be monitored for a reduction in the undesirable materials.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to metal beams used in a grid structure for a suspended ceiling, and more particularly, to a connection that joins together, end-to-end, main beams in the grid.
[0003] 2. Background Art
[0004] Suspended ceilings having metal beams called tees, or runners, that form grids to support panels, are well known. Such grids have main beams and intersecting cross beams. The beams are formed generally of flat sheet metal folded into an inverted T-shape, but in some instances are extruded metal, such as aluminum. The main beams are connected end-to-end and are suspended from a structural ceiling by wires. The cross beams are connected end-to-end through slots in the main beams and are supported by such main beams.
[0005] The main beams, which run parallel to one another, are generally spaced 48″ apart. Cross beams are connected to the main beams to form either 24″×24″ rectangular openings, or 24″×48″ openings, which receive the laid-in panels.
[0006] Such main beams in a suspended ceiling are subjected primarily to tension, compression, and bending stresses, and occasionally to twisting forces. The function of the connection, which joins the generally 12 foot lengths of main beams together longitudinally, is to resist these stresses and forces, and to maintain adequate strength and alignment between the beams.
[0007] Any compression forces on the connection exist longitudinally of the beams, which abut each other end-to-end, so that the connection has only to keep the ends of the beams aligned to resist these compressive forces. Fire relief notches are cut into the beam proper to provide for expansion relief from these compressive forces in case of fire, since there is no give at the beam end.
[0008] As to tension forces that pull apart one beam from another longitudinally, the connection is the sole means to resist such tension forces. With respect to bending, the connection, along with the beam-ends, must provide resistance to such bending. The connection must also resist the occasional twist.
[0009] Prior art connections on the ends of main beams were generally of two types.
[0010] In one type of connection, the connector elements were formed integrally with the beam itself; particularly out of the web portion of the beam. Such a construction caused loss of material from the cutting away to achieve the connecting elements. Furthermore, the process to make such connectors was a relatively slow one since, although the beam itself was made relatively rapidly in a roll forming operation, the connector itself was formed in one or more braking operations that generally required intricate forming of the relatively soft grid tee metal. Additionally, the soft metal of the tee had relatively little spring qualities that could be used to form the connection.
[0011] In another form of main beam, or tee, connection, clips alone are used to form the connection. A separate clip is attached to the end of each tee, which is squarely cut at the end. A clip is inset into a pan depressed in the tee, so that the clips can engage solely with one another, independent of the tee, along the central plane of the web. Clips permit the use of harder, springier steel than web metal where the connection is formed from the tee.
SUMMARY OF THE PRESENT INVENTION
[0012] The connection of the present invention combines a pair of clips, as well as a pair of configured grid tees, to form a connection. Each of the clips fastened on a beam end is identical to the other clip in the pair, as is the grid tee construction at each of the beam ends identical to the construction on the other beam end in the pair.
[0013] A clip has holes for attachment to a beam web and has spring tabs that act to ramp the end of an opposing clip over web during engagement, and then contract under pressure from the engaged connectors.
[0014] The beam itself has an end configuration essentially square but with a web cutout that eliminates interference with any stitches in the web and that also guides a clip while being engaged to form a connection. A spring pocket formed in the web of the beam, and an opening formed by the spring pocket, along with positioning bosses formed in the web, cooperate to permit a clip and beam end on one beam to engage and lock with a clip and end on an adjacent beam.
[0015] The clips themselves have elements, which cooperate with the integral beam elements, and the opposing clips, to form the connection.
[0016] The connection can be disengaged by, for instance, deforming the pockets to an open position and then separating beams sideways. The connection can be reengaged for reuse by simply restoring the pockets to their original closed position, and bringing the connectors together. When connected, the clips straddle the abutting webs with a clip on each side of the aligned webs.
[0017] In summary, the present invention combines a clip on a configured beam end, with the configured beam end itself, to form a main beam end-to-end connection with another combination of clip and configured beam end.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0018] [0018]FIG. 1 is an exploded perspective view of the clips, and the configured beam ends, that combine to form the connection of the invention.
[0019] [0019]FIG. 2 is a side elevation view of a connector clip attached to each of the aligned beam ends, just prior to being engaged in an end-to-end connection.
[0020] [0020]FIG. 3 is a side elevation of engaged clips and beam ends forming a main beam connection.
[0021] [0021]FIG. 4 is a sectional plan view of a clip attached to the end of a beam.
[0022] [0022]FIG. 5 is a sectional plan view, similar to FIG. 4, showing the clips and beam ends engaged to form the main beam connection of the invention.
[0023] [0023]FIG. 6 is a sectional plan view, similar to FIG. 5, showing the connection being disengaged to permit the main beams to be separated.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Two clips 20 and 20 ′, each identical to the other, are used to form, with grid tees 70 and 70 ′, a beam connection 96 of the invention. Clip 20 and tee 70 will be described with identification numbers. Clip 20 ′ and grid tee 70 ′ will carry the same identification numbers with a prime (′) notation.
[0025] Each clip 20 is roughly rectangular and is formed, preferably by stamping, from relatively hard steel, having spring properties. The clip can suitably have a thickness of 0.0150″, with a generally rectangular dimension of 1″ by 1¾″. Punched holes 23 and 25 are above one another and are formed in the approximate center of the clip 20 . A third hole 26 forming a triangle with the first two is formed at the rear of the clip. Arrow 27 points to the rear of the clip.
[0026] Flanges 28 and 30 are formed at the top and bottom edges of the clip 20 , to stiffen the clip. The flange 28 and 30 are angled outwardly from the clip away from the tee web 72 .
[0027] Clip 20 has, in its rearward edge 31 , a cutout 32 having an expanded section 33 and a reduced section 35 . Forward of cutout 32 in clip 20 , is cutout 36 in the form of a reversed D as seen in FIGS. 1 and 2. Forward of cutout 36 in clip 20 is an elevated contoured pan 37 .
[0028] The pan 37 has a tapered rearward section 38 , which abuts cutout 36 and a forward section 40 having a forwardly extending U-shaped portion 41 .
[0029] Spring, pierced, tabs 42 and 43 extend rearwardly of the clip and extend toward the web 72 grid tee when assembled to the tee.
[0030] Offsets 45 and 46 , at the top and bottom of the forward portion of clip 20 , extend toward the grid tee in the assembled condition.
[0031] The clips 20 and 20 ′ are intended to be secured to webs 72 and 72 ′ at the ends of a grid tee 70 and 70 ′, respectively. Grid tee 70 includes a bulb 71 , a web 72 , and a flange 73 . Stitches 75 extend along the web 72 .
[0032] The connection of the invention particularly lends itself to the grid tee disclosed in U.S. Pat. No. 6,138,416, incorporated herein by reference. The grid tee disclosed in the '416 patent permits the use of lighter gauge metal while still achieving the necessary beam strength, particularly in bending. The present invention compensates for the lighter gauge metal in the beam, at the connection, so that even with such lighter gauge metal in the beam, a strong and secure connection is obtained.
[0033] Holes 76 in the web 72 conform to the hole spacing in clip 20 , and are formed by piercing the web so that a collar 77 extends out of the web.
[0034] The web 72 has a relatively large pocket 78 formed from the web 72 . The pocket 78 is in the form of a Z in cross-section and is open in a forward direction in the web. An offset forward portion 92 of the pocket 78 serves to stiffen the pocket and to guide the forward end of a clip during engagement of the connection. The pocket 78 extends away from web 72 on the side of the web opposite to the side on which clip 20 ′ will be attached. An opening 79 is created in web 72 when pocket 78 is formed from the web 72 , as by stamping.
[0035] Web 72 at its end has a cutout 80 having forward edges 81 and 82 , and a reward tapered opening 83 .
[0036] Stitches 85 , of a type shown, for instance, in U.S. Pat. No. 5,979,055, incorporated herein by reference, extend along the web to strengthen the beam. These stitches 85 are placed in the beam during a continuous roll forming process, before the beam is cut into for instance 12 foot lengths, by for instance flying shears. Such method of making a beam by roll forming and cutting into lengths is well known.
[0037] After cutting of the beam into lengths, the ends of the beam are stamped or otherwise formed into the configuration shown in the drawings and described herein.
[0038] Portions of stitches 85 may continue to exist in the end configuration of the beams, but such portions have no effect in the connection.
[0039] Pan 37 creates a rectangular portion 86 in the plane of the web 72 that has therein a pierced V-shaped abutment 87 that extends rearwardly of clip 20 and extends toward web 72 of a grid tee 70 , to which clip 20 is attached.
[0040] The clip 20 is attached to grid tee 70 by inserting holes 23 , 25 , and 26 over collars 77 of holes 76 in grid tee web 72 at the end thereof. The collars are staked over at 91 to hold the clip 20 securely to the beam 70 . Pierced, spring tabs 42 and 43 will extend above the web at cutout 80 at 81 and 82 ,to provide a ramp effect that guides the forward end of opposing clip 21 ′ over the edges 81 and 82 , during the engagement of the connection. This avoids any interference of the opposing clip and web. Spring tabs 42 and 43 are free of contact with edges 81 and 82 , so that the tabs are free to depress when the connectors are fully engaged. Thus tabs 42 and 43 , in extended position act as ramps, and they can contract to permit engagement of the connectors.
[0041] D-cutout 36 in clip 20 will line up with opening 79 in the web 72 of grid tee 70 , with the straight edge of the D in line with the forward edge of opening 79 in the web 72 .
[0042] Rearward tapered opening 83 in clip 20 provide clearance for any stitch 85 that may extend into the area of the opening.
[0043] The clip 20 attached to configured end of beam 70 forms a connector 95 , and clip 20 ′ attached to configured end of beam 70 ′ forms a connector 95 ′.
[0044] Connector 95 is engaged with connector 95 ′ by moving the connectors together longitudinally of the aligned beams, as shown in FIGS. 2 and 3.
[0045] As seen in FIG. 2, the forward ends of clips 20 and 20 ′ attached to opposite sides of the webs 72 and 72 ′ are slid toward one another until the connectors 95 and 95 ′ are fully engaged, and locked, into a connection 96 , as seen in FIG. 3. When connection 96 is engaged, edge 88 ′ of pierced V-shaped abutment 87 ′ will extend through opening 79 and into D cutout 36 , and engage the forward edge of opening 79 and cutout 36 .
[0046] Edge 88 ′ will be secured into such engagement by pocket 78 which receives rectangular portion 86 ′ of clip 20 ′ and clamps portion 86 ′ against web 72 . The same clamping action will occur wherein pocket 78 ′ will keep edge 88 of pierced V-shaped abutment 87 against the forward edge of opening 79 ′.
[0047] In the connection 96 , the square cut ends of grid tee 70 and grid tee 70 ′ will abut, as seen particularly in FIG. 3 at 101 . The clip 20 , 20 ′ extend along each side of beam 70 , 70 ′ ends to provide a fishplate splice in the connection 96 . The clips 20 , 20 ′ act as fishplates to lap the joint of the beams 70 , 70 ′ and are secured to take sides so as to connect the beams 70 , 70 ′ end-to-end.
[0048] During the engagement of the connection, the forward end of clip 20 is guided, and also restrained vertically, as seen particularly in FIG. 3, by bosses 90 ′ in web 72 ′. Additionally, the forward end of clip 20 is restrained vertically by the engagement of offsets 45 and 46 , which extend within opening 79 ′ at the top and bottom thereof. The forward end of clip 20 is clamped against web 72 ′ so that the forward end of clip 20 is kept laterally within bosses 90 ′ and offsets 45 and 46 are kept laterally within opening 79 ′. Pocket 78 ′ has some spring effect to accomplish this clamping. The forward edge of the pocket is flared outward at 97 ′ to guide opposing clip 20 into clamping engagement.
[0049] The identical clamping action occurs between pocket 78 and clip 20 ′.
[0050] The beams that will be restrained from separating longitudinally by the engagement of edge 88 ′ with the forward edge of opening 79 and cutout 36 , in one connector, and by the engagement of edge 88 with the forward edge of opening 79 ′ and cutout 36 ′.
[0051] A further guiding action occurs during the engagement of connection 96 . V-shaped abutment 87 ′ enters rearward tapered opening 83 in cutout 80 of clip 20 , and is guided into guiding engagement with diagonal bosses 90 into pocket 78 . When edge 88 ′ of V-shaped abutment 87 ′ passes into opening 79 and D-cutout 36 , pocket 78 springs edge 88 ′ into engagement with the forward edge of D cutout 36 and forward edge of opening 79 . A similar action occurs in pocket 78 ′.
[0052] When connection 96 is in this engaged condition, offsets 45 and 46 will engage opening 79 ′ at the top and bottom thereof, and the forward portion of clip 20 will lie within bosses 90 and be restrained against vertical movement. A like engagement occurs between offsets 45 ′ and 46 ′, bosses 90 ′, and the forward end of clip 20 .
[0053] The connection can be disengaged in a manner illustrated in FIG. 6. Pockets 78 and 78 ′ are rotated in the direction shown by the arrows by inserting an edged tool, such as a screwdriver, and bending and deforming the pockets to the positions shown. Since the web metal from which the pockets are formed is a relatively soft metal, the pockets will stay in the deformed position. The connectors 95 and 95 ′ are now free to be laterally separated from one another, as shown by arrows 98 and 99 , causing the connectors 95 and 95 ′ to become disengaged.
[0054] The connectors 95 and 95 ′ can be reengaged, if desired, by reversing the disengagement steps set forth above, including bending pockets 78 and 78 ′ back to their closed position.
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An end-to-end connection for main beams in a ceiling grid for a suspended ceiling. A connector is formed at the end of a beam by combining a clip, fastened to the beam, with a configuration in the end of the beam. The connections are engaged to form a connection. The connection can be disengaged and reengaged.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application Ser. No. 60/830,269, filed Jul. 11, 2006, and titled “An improved BAM phosphor.” U.S. Provisional Application Ser. No. 60/830,269 is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention are directed to phosphor compositions that comprise a BAM phosphor BaMgAl 10 O 17 :Eu 2+ and at least one other hexaaluminate that may also be europium activated.
[0004] 2. Description of the Related Art
[0005] Owing to its high light output and excellent display of color (as represented, for example, on a CIE color diagram), the known BAM phosphor BaMgAl 10 O 17 doped with divalent europium (Eu 2+ ) has been widely used as the blue phosphor component in applications such as fluorescent lamps, light emitting diode (LED) and plasma display panels (PDP). In plasma display panel applications, BAM:Eu is conventionally adopted as the blue-emitting component under vacuum ultraviolet (VUV) excitation; however, considerable degradation in light output and color shift (toward the green) are known to be problematic. This is thought to be due to an annealing procedure during the manufacturing process, as well as to plasma radiation and/or sputtering damage that occurs during day-to-day use.
[0006] BAM has a β-alumina structure, and belongs to the family of hexaaluminates. Hexaaluminates have a column-like structure and consists of blocks of cubic closed packed (CCP) oxygen layers with cations in tetrahedral and octahedral interstices. Because the blocks are quite similar to the MgAl 2 O 4 spinel structure, hexyluminates are often referred to as “spinel blocks.” The blocks are separated by mirror planes, which contain the large cations.
[0007] The magnetoplumbite structure is similar to the β-alumina structure as both have identical spinel blocks. The difference between them lies in the mirror planes, which are loosely-packed in the magnetoplumbite case, and tightly-packed in the β-alumina structure. LaMgAl 11 O 19 is a typical magnetoplumbite. Structurally, its formula can be rewritten as [LaAlO 3 ][(Al 3 Mg)A 7 O 16 ], where [LaAlO 3 ] are the ions on the mirror plane, and the [(Al 3 Mg)Al 7 O 16 ] portion of the structure exists as the above-mentioned spinel blocks. In the formula (Al 3 Mg) are groups of ions having a 4-fold coordination, and the aluminum as part of the Al 7 oxide has a six-fold coordination. In the same manner, β-alumina BaMgAl 10 O 17 can be rewritten as [BaO][(Al 3 Mg)A 7 O 16 ], where just two ions Ba and O are presented on the mirror plane.
[0008] Diagrams of the atomic arrangements (and hence crystal structure) of three hexaaluminates are shown in FIGS. 1A-1C . FIG. 1A is β-alumina as represented by the formula NaAl 11 O 17 , which may be re-written as [NaO][Al 4 Al 7 O 16 ]; FIG. 1B is the BAM compound BaMgAl 10 O 17 , which may be written as [BaO][(Al 3 Mg)Al 7 O 16 ]; and FIG. 1C is the magnetoplumbite LaMgAl 11 O 19 , which may be written as [LaAlO 3 ][(Al 3 Mg)Al 7 O 16 ].
[0009] What is needed in the art are phosphor compositions that enhance the emission intensity and degradation resistance of the conventional BAM phosphor (BaMgAl 10 O 17 :Eu 2+ ), utilizing properties afforded by mixing the conventional BAM phosphor with other hexaaluminates.
SUMMARY OF THE INVENTION
[0010] Embodiments of the present invention are directed to a phosphor composition comprising a europium activated BAM phosphor and a hexaaluminate other than the BAM phosphor, the composition represented by the formula (x) hexaaluminate+(1−x) BaMgAl 10 O 17 :Eu 2+ , where the hexaaluminte is selected from the group consisting of a β-alumina, a β′-alumina, and a magnetoplumbite, and wherein x ranges from about 0.001 to about 0.999.
[0011] In another embodiment, the phosphor composition comprises a europium activated BAM phosphor and a hexaaluminate other than the BAM phosphor, the composition represented by the formula (x) LnMAl 11 O 19 +(1−x) BaMgAl 10 O 17 :Eu 2+ , where Ln is a trivalent lanthanide, M is a divalent cation, and x ranges from about 0.001 to about 0.5. Alternatively, the phosphor composition comprises a europium activated BAM phosphor and a hexaaluminate other than the BAM phosphor, the composition represented by the formula (x) Ln u Al v O w +(1−x) BaMgAl 10 O 17 :Eu 2+ , where Ln is a trivalent lanthanide, x ranges from about 0.001 to about 0.5, u ranges from about 0.67 to about 1, v ranges from about 11 to about 12, and w ranges from about 18 to about 19.
[0012] In another embodiment, the phosphor composition comprises a europium activated BAM phosphor and a hexaaluminate other than the BAM phosphor, the composition represented by the formula (x) M′ 1.5 Al 10.5 O 16.5 +(1−x) BaMgAl 10 O 17 :Eu 2+ . Alternatively, the phosphor composition comprises a europium activated BAM phosphor and a hexaaluminate other than the BAM phosphor, the composition represented by the formula (x) M′ 1.5 Al 10.5 O 16.5 +(1−x) BaMgAl 10 O 17 :Eu 2+ , where M′ is a monovalent cation, and x ranges from about 0.001 to about 0.5.
[0013] In another embodiment, the phosphor composition comprising a europium activated BAM phosphor and a hexaaluminate other than the BAM phosphor, the composition represented by the formula (x) M 0.75 Al 11 O 17.25 +(1−x) BaMgAl 10 O 17 :Eu 2+ , where M is a divalent cation, and x ranges from about 0.001 to about 0.5. Alternatively, the phosphor composition comprising a europium activated BAM phosphor and a hexaaluminate other than the BAM phosphor, the composition represented by the formula x (yMO.6Al 2 O 3 )+(1−x) BaMgAl 10 O 17 :Eu 2+ , where M is a divalent cation, and x ranges from about 0.001 to about 0.5, and y ranges from about 1.28 to about 1.32.
[0014] The present phosphor compositions may be synthesized by a method selected from the group consisting of liquid processing methods, co-precipitation methods, and sol-gel methods. Exemplary steps include: (a) dissolving the precursor metal salts in an aqueous based solution; (b) co-precipitating an intermediate product; (c) removing at least a portion of the water the intermediate product of step (b); (d) calcining the product of step (c); and (e) sintering the product of step (d).
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIGS. 1A-1C are diagrams showing the atomic arrangements (and hence crystal structure) of three hexaaluminates: FIG. 1A is β-alumina as represented by the formula NaAl 11 O 17 , which may be re-written as [NaO][Al 4 Al 7 O 16 ]; FIG. 1B is the BAM compound BaMgAl 10 O 17 , which may be written as [BaO][(Al 3 Mg)Al 7 O 16 ]; and FIG. 1C is the magnetoplumbite LaMgAl 11 O 19 , which may be written as [LaAlO 3 ][(Al 3 Mg)Al 7 O 16 ];
[0016] FIG. 2 is a graph of emission intensity vs. fraction of alumina (denoted by “x”), comparing heated and unheated samples;
[0017] FIG. 3 is an x-ray diffraction (XRD) pattern of the compound (Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 O 1.7 )x(Al 10.2 O 15.3 ), where x is greater than or equal to 100 percent (x≧100%); and
[0018] FIG. 4 is an x-ray diffraction (XRD) pattern of the compound (Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 O 1.7 )x(Al 10.2 O 15.3 ), where x is less than or equal to 100 percent (x≦100%).
DETAILED DESCRIPTION OF THE INVENTION
[0019] Disclosed herein are phosphor compositions comprising a BAM phosphor BaMgAl 10 O 17 activated with divalent europium (Eu 2+ ), and at least one other hexaaluminate having a similar crystal structure. The similarity among hexaaluminte structures has led the present inventors to synthesize new compositions by mixing various hexaaluminates.
Exemplary Formulations
[0020] According to embodiments of the present invention, a BAM:Eu 2+ is mixed with at least one other type of hexaaluminate, as represented by the general formula:
[0000] (x)hexaaluminate+(1−x)BaMgAl 0 O 17 :Eu 2+
[0021] where the (x) hexaaluminte includes but is not limited to a β-alumina, a β′-alumina, and a magnetoplumbite, and is not BaMgAl 10 O 17 . The phosphor composition mixture may be in the form of a solid solution of the hexaaluminate and the BAM:Eu 2+ , or it may contain distinct phases of the hexaaluminate and the BAM:Eu 2+ . The value of x in this general formula ranges from about 0.001 to about 0.999.
[0022] More specifically, and according to one embodiment of the present invention, the phosphor composition is generated by mixing the BAM phosphor with a magnetoplumbite compound, the phosphor composition represented by the formula:
[0000] (x)LnMAl 11 O 19 +(1−x)BaMgAl 10 O 17 :Eu 2+ ,
[0000] where Ln is a trivalent lanthanide, M is a divalent cation, and x ranges from about 0.001 to about 0.5. In some embodiments, M may be an alkaline earth metal from group IIA of the periodic table, the alkaline earth metal selected from the group consisting of Mg, Ca, Sr, and Ba.
[0023] According to another embodiment of the present invention, the BAM phosphor may be mixed with a lanthanide-containing hexaaluminate compounds according to the formula:
[0000] (x)Ln u Al v O w +(1−x)BaMgAl 10 O 17 :Eu 2+ ,
[0000] where Ln is a trivalent lanthanide, x ranges from about 0.001 to about 0.5, u ranges from about 0.67 to about 1, v ranges from about 11 to about 12, and w ranges from about 18 to about 19.
[0024] While not wishing to be bound by any particular theory, it may be noted that the lanthanide hexaaluminate has a magnetoplumbite framework of the type AB 12 O 19 , with vacancies in the structure. Ideally, the structure would have the formula Ln 0.67 Al 12 O 19 , in accordance with a “true” magnetoplumbite structure. However, such structures apparently do not exist as the AB 12 O 19 framework cannot accommodate a sufficient number of vacancies at the A sites. Therefore, it is believed the actual composition of a lanthanide hexaaluminate lies somewhere between the stoichiometric LnAl 11 O 18 , and the ideal stoichiometry of Ln 0.67 Al 12 O 19 . An example of such a lanthanide hexaaluminate is La 0.85 Al 11.6 O 18.7 .
[0025] In another embodiment of the present invention, the BAM phosphor may be mixed with a hexaaluminate comprising one or more β-alumina compounds such that the phosphor composition has the formula:
[0000] (x)M′Al 11 O 17 +(1−x)BaMgAl 10 O 17 :Eu 2+ ,
[0000] where M′ is a monovalent cation from group IA of the periodic table (an alkali metal), and x ranges from about 0.001 to about 0.5. The M′ cation is selected from the group consisting of Li, Na, K, Rb, and Cs.
[0026] In another embodiment of the present invention, the BAM phosphor may be mixed with a hexaaluminate comprising one or more of the so-called β′-alumina compounds such that the phosphor composition has the formula:
[0000] (x)M′ 1.5 Al 10.5 O 16.5 +(1−x)BaMgAl 10 O 17 :Eu 2+ ,
[0000] where M′ is a monovalent cation from group IA of the periodic table (an alkali metal), and x ranges from about 0.001 to about 0.5. The M′ cation is selected from the group consisting of Li, Na, K, Rb, and Cs. The assumed structure of β′-alumina has been reported before in the literature; however, whether it is a new phase other than non-stoichiometric β-alumina remains unclear.
[0027] In another embodiment of the present invention, the BAM phosphor may be mixed with one or more alkaline-earth-poor (or alkaline earth deficient, at least relative to previous embodiments) hexaaluminate compounds, such that the phosphor composition has the formula:
[0000] (x)M′ 0.75 Al 11 O 17.25 +(1−x)BaMgAl 10 O 17 :Eu 2+ ,
[0000] where M is a divalent cation, and x ranges from about 0.001 to about 0.5. The alkaline-earth-poor hexaaluminates have a β-alumina structure with about 75 percent of the group IA alkali metal ions being replaced by group IIA alkaline-earth ions and about 25 percent by oxygen ions.
[0028] In another embodiment of the present invention, the BAM phosphor may be mixed with one or more alkaline-earth-rich hexaaluminate compounds, such that the phosphor composition has the formula:
[0000] x(yMO.6Al 2 O 3 )+(1−x)BaMgAl 10 O 17 :Eu 2+ ,
[0000] where M is a divalent cation, and x ranges from about 0.001 to about 0.5, and y ranges from about 1.28 to about 1.32. These alkaline-earth-rich hexaaluminates are assumed to have a β′-alumina structure with about 75 percent of the group IA alkali metal ions being replaced by group IIA alkaline-earth ions and about 25% by oxygen ions. This embodiment provides a composition with the ideal structural formula M 1.125 Al 10.5 O 16.875 .
[0029] For certain mixtures of BAM:Eu 2+ and some other hexaaluminte, according to the embodiments outlined above, the ratio of the aluminum to the other cations may be varied to enhance luminescence output and oxidation stability. Furthermore, it is believed that by mixing BAM:Eu 2+ with other hexaaluminates according to the present embodiments, oxidative stability and light emission output are enhanced due to changes in the crystal field properties of the overall phosphor composition.
Processing Considerations
[0030] The present phosphor compositions may be synthesized by mixing the BAM phosphor BaMgAl 10 O 17 with one or more hexaaluminates other than the BAM having a similar crystal structure.
[0031] In one embodiment of the present invention, the phosphor composition may be synthesized by mixing the BAM phosphor BaMgAl 10 O 17 with the β-alumina (NaAl 11 O 17 ). The fraction of the β-alumina contained within the composition may be adjusted to vary the light emission behavior and degradation resistance of the overall composition. In this embodiment a composition is mixed having a content of about 20 percent of the β-alumina NaAl 11 O 17 and about 80 percent of the BAM. The formula of the composition may be represented by the formula:
[0000] (Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 O 17 )+x(Al 10.2 O 15.3 ),
[0000] where x ranges from about 0.7 to about 1.30.
[0032] In one example of the synthesis of the present phosphor composition, the starting materials comprised the appropriate metal nitrates in the desired mole ratios. In one embodiment, a flux may be added during processing, for example, a 5 mole percent addition of a flux such as aluminum fluoride.
[0033] Such BAM/hexaaluminate compositions have been synthesized by the present inventors using liquid mixing, co-precipitation, and/or sol-gel techniques. In accordance with these processes, metals that included sodium, barium, magnesium, aluminum, and europium, along with salts of halogens such as aluminum fluoride, were first dissolved in hot water. An aqueous solution of ammonia water was added to facilitate co-precipitation of the mixed nitrates. The solution was then heated to remove water, and the partially dried mixture was calcined at about 800° C. for about two hours. Finally, the calcined powders were sintered at about 1500° C. for about 6 hours in an atmosphere comprising nitrogen gas mixed with about 1 to 5 percent by volume hydrogen. After sintering, the powders were milled and sieved with a 25 μm sieve.
Physical Properties and Optical Performance
[0034] To perform a thermal degradation test, the powders were heated at about 510° C. for about one hour in air. The emission intensity of un-heated and heated samples were then measured using a 147 nm plasma lamp as the excitation source. Sample compositions and measurement data are shown in Table 1:
[0000]
TABLE 1
Compositions and photoemission intensities
of samples (Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 O 1.7 ) + (Al 10.2 O 15.3 )
Emission
Emission
Emission
change
Sample #
x
Compositions
(unheated)
(heated)
ratio
Control
(Ba 0.95 Eu 0.05 )MgAl 10 O 17 (BAM)
1097
1060
−4.6%
1
70%
Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 Al 7.14
952
975
+2.4%
2
80%
Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 Al 8.16
1202
1191
−0.91%
3
90%
Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 Al 9.18
1106
1102
−0.36%
4
95%
Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 Al 9.69
1133
1102
−2.7%
5
100%
Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 Al 10.2
1116
1058
−5.2%
6
105%
Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 Al 10.71
1091
1090
−0.1%
7
110%
Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 Al 11.22
1067
1069
+0.2%
8
120%
Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 Al 12.24
1059
1044
−1.4%
9
130%
Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 Al 13.26
1064
1036
−2.6%
[0035] These experiments show that of the data presented, the compositions comprising mixtures of the conventional BAM phosphor (Ba 0.95 Eu 0.05 )MgAl 10 O 17 with hexaaluminates other than that BAM in all cases demonstrate either an increase in intensity, or at least less of an intensity decrease from heating than the control.
[0036] FIG. 2 is a graph of emission intensity versus x, the fraction of alumina in the composition. In the graph, the square symbols represent unheated samples, and the circles heated samples. Data in the figure shows that the emission intensity increases dramatically as the fraction of the alumina in the composition is increased from 0.7 to 0.8, and whereas it decreases somewhat from that highest value, the emission intensity is still greater for x fractions of 0.9 to 1.3 than the emission intensity is when x is 0.7.
[0037] FIG. 3 is an x-ray diffraction (XRD) pattern of the compound (Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 O 1.7 )x(Al 10.2 O 15.3 ), where x is greater than or equal to 100 percent (x≧100%). The diffraction pattern shows a comparison of samples with increasing ratios of aluminum. The data shows that as a second phase of α-alumina became evident as the value of x was increased above 100 percent. The larger the value of x, the more prominent the diffraction peak(s) of the α-alumina became.
[0038] FIG. 4 is an x-ray diffraction (XRD) pattern of the compound (Na 0.2 Ba 0.75 Eu 0.05 Mg 0.8 O 1.7 )x(Al 10.2 O 15.3 ), where x is less than or equal to 100 percent (x≦100%). In FIG. 4 , the diffraction pattern shows a comparison of samples with smaller ratios of aluminum than found in stoichiometrical composition. It was found that a second phase, BaAlO 2 , was formed when x was decreased to about 70 percent of the stoichiometrical ratio. When x was equal to or less than about 80 percent, no second phase was formed. Furthermore, the β-alumina could not be distinguished from the BAM in the diffraction pattern. Therefore, it could not be determined in this case whether or not β-alumina existed in the form of a second phase.
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Disclosed herein are phosphor compositions comprising a BAM phosphor BaMgAl 10 O 17 :Eu 2+ and at least one other hexaaluminate that may also be europium activated. The BAM may be mixed with any number of different kinds of heaxaaluminates having a similar crystal structure. The aluminum ratio may also be adjusted to alter the defect structure or to produce a second phase. Addition of another hexaaluminate to BAM enhances emission intensity and resistance to degradation, which is beneficial to applications such as plasma display panels.
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FIELD OF THE INVENTION
[0001] This invention relates generally to the field of electric devices and more particularly, but not by way of limitation, to a current leak detector and method of calibration.
BACKGROUND
[0002] In many conventional electric circuits, electric current flows from a power source to a load and back to the power source. The intended current path is typically achieved through use of insulated conductors and electrical components. If the insulation fails or the circuit is otherwise compromised, electric current may “leak” into unintended areas of the device. Leakage current is current that escapes the intended circuit path and returns to the power supply through an unintended route.
[0003] Leakage current may travel from the circuit into a conductive housing or panel. If the housing or panel is properly grounded, the leakage current is diverted to ground. In some instances, however, the housing or panel may not be grounded or the ground may be insufficient to safely carry the leakage current. In these cases, anyone coming into contact with the housing or panel may be exposed to an electric shock.
[0004] Prior art DC current leakage detectors tend to be difficult to calibrate and lack sensitivity. The deficiencies of the prior art current leakage detectors expose operators of electrical equipment to potential harm. There is, therefore, a need for an improved current leakage detector that can either alert an operator of a current leakage event or remove the power (or both) before the operator comes into contact with the hazardous equipment.
SUMMARY OF THE INVENTION
[0005] In present embodiments, a current leakage detector is configured for detecting current leakage between a power source and a load. The current leakage detector includes a first sensing coil and a second sensing coil arranged in opposition to the first sensing coil. The current leakage detector further includes a magnetic field sensor proximate the first sensing coil and the second sensing coil and the magnetic field sensor has a response range. The current leakage detector also includes a bias circuit configured to adjust the response range of the magnetic field sensor.
[0006] In another aspect, embodiments include an electrically powered device that includes a power supply, a load and a current leakage detector for detecting current leakage between the power supply and the load. The current leakage detector includes a first sensing coil and a second sensing coil arranged in opposition to the first sensing coil. The current leakage detector further includes a magnetic field sensor proximate the first sensing coil and the second sensing coil, and the magnetic field sensor has a response range. The current leakage detector also includes a bias circuit configured to adjust the response range of the magnetic field sensor.
[0007] In yet another aspect, embodiments include a method for detecting current leakage between a power source and a load connected to the power source. The method includes the steps of providing a first sensing coil between the power source and the load and providing a second sensing coil arranged in opposition to the first sensing coil between the load and the power source. The method continues with the steps of providing a magnetic field sensor in proximity to the first and second sensing coils and providing a bias circuit. The method continues with the step of utilizing the bias circuit to place the response of the magnetic field sensor within a response range.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a depiction of a current leakage detector constructed and installed within an electric submersible pumping system.
[0009] FIG. 2 is a circuit diagram of the current leakage detector of FIG. 1 .
[0010] FIG. 3 is a process flow diagram for a method of calibrating the current leakage detector of FIG. 1
DETAILED DESCRIPTION
[0011] In accordance with an embodiment of the present invention, FIG. 1 shows a depiction of current leakage detectors 100 incorporated within a pumping system 102 . It will be appreciated that the current leakage detector 100 can be incorporated within any electric equipment and that the discussion of the incorporation of the current leakage detector 100 within the pumping system 102 is merely an application for the current leakage detector 100 .
[0012] The pumping system 102 includes a submersible pump 104 driven by an electric motor 106 . When energized, the motor 106 moves the pump 104 , which forces fluids in the wellbore 108 to the surface. The motor 106 is provided with electric power from a surface-mounted power supply 110 . The power supply 110 may include electric generators and connections to a power grid. The pumping system 102 further includes a motor drive 112 and transformer 114 that condition and control the power provided to the motor 106 . In this way, the operational characteristics of the motor 106 can be controlled and affected by the motor drive 112 , transformer 114 and power supply 110 . Although the pumping system 102 is depicted as a submersible system used to recover fluids from an underground reservoir, it will be appreciated that the pumping system 102 might also include a surface pumping system that moves fluids between surface facilities.
[0013] A first current leakage detector 100 is, in an embodiment, incorporated within the motor drive 112 (as shown in FIG. 1 ) and used to monitor current passed to the transformer 114 . A second current leak detector 100 can be placed within the transformer 114 and used to monitor current passed to the motor 106 . Each current leakage detector 100 is configured to monitor the electric current passing into and out of a load. In the exemplary embodiment depicted in FIG. 1 , the load is either the transformer 114 or the electric motor 106 . It will be appreciated that the load observed by the current leakage detector 100 could be any electric load that draws current from a power source. It will be further appreciated that additional or fewer current leakage detectors 100 may be used in embodiments.
[0014] Turning to FIG. 2 , shown therein is a circuit diagram of an embodiment of the current leakage detector 100 . In embodiments, the current leakage detector 100 includes a power source 116 , a load 118 , a coil core 120 , a first sensing coil 122 , a second sensing coil 124 , a giant magneto-restrictive (GMR) sensor 126 , a sensor amplifier 128 , a sensor analog-to-digital converter (ADC) 130 , a bias coil 132 , a bias coil driver 134 , a control unit 136 and a switch 138 . In the exemplary application of the current leakage detector 100 in FIG. 1 , the load 118 is the motor 106 and the transformer 114 . The power source 116 is used to provide power to the load 118 when the switch 138 is closed. The power source 116 is also in an embodiment configured to directly or indirectly provide power to the control unit 136 , bias coil driver 134 , sensor amplifier 128 and sensor ADC.
[0015] Current is directed to the load 118 from the power source 116 through the first sensing coil 122 . Current returns from the load 118 to the power source 116 through the second sensing coil 124 . The first and second sensing coils 122 , 124 are each wound around opposing sides of the coil core 120 . In an embodiment, the coil core 120 is formed as a unitary soft ferromagnetic core having a “block C” shape. The first and second sensing coils 122 , 124 have substantially the same number of turns and are wound in opposition on the core, but not necessarily on opposing legs of the coil core 120 so that the net magnetic coercive force produced by first and second sensing coils 122 , 124 is substantially eliminated when current passing through the first and second sensing coils 122 , 124 is the same.
[0016] If leakage current exists between the load 118 and the first and second sensing coils 122 , 124 , the current passing through the first and second sensing coils 122 , 124 will not be equal and the coercive magnetic force generated by the first and second sensing coils 122 , 124 will not be canceled. The GMR sensor 126 is magnetically coupled to the first and second sensing coils 122 , 124 and is configured to output an analog signal in response to the magnetic field generated by the presence of the coercive magnetic force generated by the current imbalance in the first and second sensing coils 122 , 124 .
[0017] The magnetic field generated by the coercive magnetic force generated by the first and second sensing coils 122 , 124 and the response signal generated by the GMR sensor 126 are both grossly nonlinear. If the coercive magnetic force generated by the first and second sensing coils 122 , 124 is small, the GMR sensor 126 may not produce a representative output signal. The signal may be disproportionately small and may be characterized by an incorrect polarity.
[0018] To improve the response of the GMR sensor 126 , the current leakage detector 100 utilizes the bias coil 132 to provide a baseline magnetic field at the GMR sensor 126 . The bias coil 132 selectively applies a bias magnetic field that moves the response provided by the GMR sensor 126 into a more predictable and useful range. From the biased baseline range, the GMR sensor 126 can more accurately and robustly signal a field imbalance between the first and second sensing coils 122 , 124 . To place the response of the GMR sensor 126 within the biased baseline range, the current leakage detector 100 includes a bias circuit 140 . The bias circuit 140 can be characterized as the collection of the GMR sensor 126 , the sensor amplifier 128 , the sensor ADC 130 , the bias coil 132 , the bias coil driver 134 , and the control unit 136 .
[0019] Generally, the control unit 136 provides a control signal to the bias coil driver 134 . The bias coil driver 134 then applies a responsive drive current to the bias coil 132 . The bias coil 132 then produces a bias magnetic field that is picked up by the GMR sensor 126 . The GMR sensor 126 produces a signal that is representative of the bias magnetic field. The signal output by the GMR sensor 126 is provided to the sensor amplifier 128 and then to the sensor ADC 130 . The digitized signal is then passed back to the control unit 136 to complete the bias circuit 140 loop.
[0020] In embodiments, the bias circuit 140 is used to calibrate the GMR sensor 126 within a selected biased baseline range using algorithms implemented by the control unit 136 . An embodiment of a method 200 of calibrating the current leakage detector 100 is depicted in FIG. 3 . The method begins at step 202 when the control unit 136 instructs the bias coil driver 134 to send a bias current (I b ) to the bias coil 132 . The magnetic field produced by the magnetic coercive force generated by the bias coil 132 is recognized by the GMR sensor 126 and registered by the control unit 136 . At step 204 , the bias current (I b ) is adjusted to the level at which the GMR sensor 126 outputs a minimum signal (V min ). The minimum voltage output by the GMR sensor 126 is recorded by the control unit 136 .
[0021] At step 206 , the control unit 136 adjusts the current supplied to the bias coil 132 to an extent that produces the maximum voltage (V max ) output by the GMR sensor 126 that can be accepted by the sensor amplifier 128 . The maximum voltage output by the GMR sensor 126 is recorded by the control unit 136 . Next, at step 208 , the control unit 136 sets an initial bias current (I b0 ) at the value that produces a voltage at the GMR sensor 126 that is approximately at the median value (V mid ) between the minimum voltage (V min ) and maximum voltage (V max ) recorded by the control unit 136 . Because of the combined nonlinearities in the response of the bias coil 132 and GMR sensor 126 , the initial bias current (I b0 ) that produces a midpoint voltage (V mid ) at the GMR sensor 126 may not represent a median value between the bias currents used to produce the minimum (V min ) and maximum (V max ) voltages at the GMR sensor 126 .
[0022] The method 200 of calibrating the current leakage detector 100 is in an embodiment carried out before the power source 116 is connected to the load 118 . Once the current leakage detector 100 is placed in operation, the GMR sensor 126 can be continuously or periodically recalibrated at step 210 to account for changes in the system. Such changes may include, for example, changes in the load 118 and temperatures changes at the first and second sensing coils. Recalibration can be carried out by adjusting the bias current (I b ) supplied to the bias coil 132 to find the median voltage (V mid ) output by the GMR sensor 126 .
[0023] In operation and after the initial bias current (I b0 ) has been determined, the switch 138 can be closed to direct current from the power source 116 to the load 118 through the first and second sensing coils 122 , 124 . The bias coil 132 applies the initial bias magnetic field to place the response of the GMR sensor 126 within the desired range so that any imbalances between the first and second sensing coils 122 , 124 is more accurately detected by the GMR sensor 126 and reported by the control unit 136 . In embodiments, the control unit 136 triggers an alarm or notification if a leakage current condition is detected. The control unit 136 can also be configured to open the switch 138 or otherwise disconnect the power source 116 in the event a leakage current condition is detected.
[0024] It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and functions of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail, especially in matters of structure and arrangement of parts within the principles of embodiments of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. It will be appreciated by those skilled in the art that the teachings of the present invention can be applied to other systems without departing from the scope and spirit of the present invention.
[0025] This written description uses examples to disclose the invention, including the preferred embodiments, 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 with insubstantial differences from the literal languages of the claims.
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A current leakage detector for detecting current leakage between a power source and a load including a first sensing coil and a second sensing coil positioned opposite the first sensing coil. The current leakage detector further includes a magnetic field sensor proximate the first sensing coil and the second sensing coil and the magnetic field sensor has a response range. The current leakage detector also includes a bias circuit configured to adjust the response range of the magnetic field sensor. A method for detecting current leakage includes providing a first sensing coil and a second sensing coil. The method continues with the steps of providing a magnetic field sensor in proximity to the first and second sensing coils and providing a bias circuit. The method continues with the step of utilizing the bias circuit to place the response of the magnetic field sensor within a preferred response range.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an information processing device, method thereof and a recording medium and relates in particular to an information processing device, method thereof and a recording medium ideal for utilization in devices connected to a digital bus such as IEEE1394 bus, etc.
2. Description of the Related Art
Along with the advances of digital technology in recent years, the use of networks to mutually connect devices by a digital bus has gradually spread. One example of a digital bus is the IEEE1394 digital serial bus. As an isochronous channel resource method for the IEEE1394 digital serial bus the applicants previously proposed, in Japanese Patent Application No. 350077/1999, a method to prevent conflicts from occurring among devices set with different channels, and transmit and receive channels set in advance for each device, when devices connected to the IEEE1394 bus are transmitting and receiving signals.
In this proposed method, the device set as the receiver is in standby awaiting input of signals from a channel set in advance, the transmitter device sends the signal on the preset channel without designating the receiver of the signal and thus allows passive transmission and reception of the signal. Channel setting of this kind is implemented by broadcast connections (hereafter, “B.C. connection”) specified in the IEEE1394 standards or the IEC-61883-1 standards, and the set channel is called the default channel.
The overall concept of the default channel is based on the precondition that when the transmit device has been changed such as by a user operation, a new device can transmit signals on the same channel. The new transmit device captures (takes over) the previously established B.C. connection and transmits signals over that captured channel so that the input signals are now switched to the receive device without the receive device performing any operation.
A point-to-point (P.P.) connection is established and overlapped onto the already established B.C. connection, when the receive device is to record the input signals onto an internal recording medium, etc. The point-to-point connection ensures that other signals will not be recorded if the transmit and receive channel the receive device uses to record signals, is captured by other devices.
In this way, a P.P. connection is therefore overlapped onto the previously established B.C. connection as described above when the receive device is recording input signals, so other transmit devices therefore cannot capture that channel. Such an arrangement is described while referring to FIG. 1 .
In the status shown in FIG. 1A, a DTV (digital television receiver) 1 , a DVTR (digital video tape recorder) 2 - 1 , and a DVTR 2 — 2 are mutually connected to an IEEE1394 bus 4 as shown in FIG. 1A, and when a DVTR 2 - 1 has started video recording, a P.P. connection is overlapped onto the B.C. connection between the DTV 1 and the DVTR 2 - 1 . When the DVTR 2 - 1 for example, has started recording, a P.P. connection is overlapped onto the B.C. connection between the DTV 1 and DVTR 2 - 1 . When the user views/hears a signal from DVTR 2 — 2 the next time, a P.P. connection is already established at DTV 1 with the DVTR 2 - 1 , so the channel cannot be captured. Consequently, the DTV 1 cannot input the signal from the DVTR 2 (DVTR 2 — 2 cannot output signals to DTV 1 ). The user cannot therefore view/hear signals from DVTR 2 — 2 .
As described above, a channel management method of this kind based on B.C. connections has the problem that the input signal cannot be switched when a P.P. connection has been established such as by starting a recording operation.
A channel management method based on P.P. connections instead of being based on B.C. connections was proposed in the related art. In this method, an isochronous signal send/receive connection was established by utilizing P.P. connections in all devices connected by an IEEE1394 bus. A method of this kind is described while referring to FIG. 2 .
When the DTV 1 and DVTR 2 - 1 must be changed from the P.P. connection shown in FIG. 2A, to the P.P. connection of DTV 1 and DVTR 2 — 2 as shown in FIG. 2C, the user first of all severs the connection between DTV 1 and DVTR 2 . That connection is severed by stopping the play operation for example by pressing the DVTR 2 - 1 stop button. The user from the DTV 1 side, then selects DVTR 2 — 2 as the connection target, and starts outputting the signal in DVTR 2 — 2 for example by pressing the play button.
In a channel management method of this kind based on P.P. connections, every time a change is made in the transmit device for transmitting signals that the user wants to view/hear, the user must use the receive device, to select the signal input destination (transmit source) constituting the transmit device, and then must arrange the processing so that the signal is output with the selected transmit device. Having to make settings on both the transmit device and the receive device in this way is exceedingly troublesome for the user.
SUMMARY OF THE INVENTION
In view of the above-mentioned problems with the related art, this invention has the object of reducing the number of user operations by allowing the elimination or restoration of P.P. connections overlapped onto B.C. connections and thus provide a device convenient for the user.
The information processing device of the present invention, along with establishing a broadcast connection, comprises: first establishing means for establishing a point-to-point connection on the broadcast connection channel, cancel means for canceling point-to-point connections established by the first establishing means, and second establishing means for establishing on the channel, the point-to-point connection canceled by the canceling means.
The device having a point-to-point connection established by the second establishing means may comprise a device having a point-to-point connection established by the first establishing means, a device outputting information input when the point-to-point connection of the second establishing means was established, and a device designated by the user.
The information processing device of the present invention further comprises memory means from among at least one of: information relating to the device with a broadcast connection and a point-to-point connection established by the first establishing means, information relating to a device exchanging data with a broadcast connection established when the point-to-point connection was canceled by the cancel means, and information relating to a device with a point-to-point connection established by the second establishing means.
The information processing device of this invention as described above, along with establishing a broadcast connection, also establishes a point-to-point connection on the broadcast connection channel, and cancels and restores the established point-to-point connection, and so is capable of easily switching the input information (device).
In the specifications of the present invention, the steps describing the program provided by the medium are of course performed in a time sequence according to the order the steps are listed. However the processing of these steps need not always be implemented in a time sequence and the steps may be implemented in serial or in parallel. Also in the specifications of the present invention, the term “system” indicates the overall device comprising a plurality of devices.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are drawings showing the connection of the related art.
FIGS. 2A and 2B are drawings showing another connection of the related art.
FIG. 3 is a drawing showing the structure of the embodiment of the information processing system of this invention.
FIG. 4 is a drawing showing the internal structure of the device shown in FIG. 3 .
FIG. 5 is a flowchart illustrating the operation of DTV 10 .
FIG. 6 is a typical display shown on DTV 10 .
FIG. 7 is another typical display shown on DTV 10 .
FIGS. 8A to 8 C are drawings for describing the connection method of the present invention.
FIG. 9 is a drawing for describing the connection method of the present invention.
FIG. 10 is a drawing for describing the connection method of the present invention.
FIG. 11 is a drawing of the medium.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiment of the present invention is hereafter described in detail while referring to the accompanying drawings. FIG. 3 is a drawing showing the structure of the embodiment of the information processing system of this invention. As shown in FIG. 3, the DTV 10 , the IRD (Integrated Receiver Decoder) 11 , the DVTR 12 - 1 and the DVTR 12 - 2 are mutually connected by way of the IEEE1394 bus 3 .
FIG. 4 is a drawing showing the internal structure of the devices connected to the IEEE1394 bus 3 , that is, the DTV 10 , the IRD 11 , the DVTR 12 - 1 and the DVTR 12 - 2 in the embodiment shown in FIG. 3. A controller 21 controls the processing of the function processor 23 based on control signals input from a remote controller (not shown in drawing) or a communication controller 22 by way of the IEEE1394 bus 3 . The function processor 23 performs the characteristic functions of the device. The function processor 23 in the case of the DTV 10 for example, outputs the image display and audio based on the input signals, and in the case of the DVTR 12 - 1 , 12 - 2 performs recording and play.
An information storage section 24 , besides storing the programs and signals (data) required for control and processing by the controller 21 and the function processor 23 , also stores information relating to the connections as described later on.
The switching of signals inputted to DTV 10 in a system comprising a device having this kind of structure is described while referring to the flowchart of FIG. 5 . In step S 1 , the user selects the transmit device (signal transmission source) from the menu displayed on the screen of the DTV 10 . The menu is displayed on the DTV 10 when the DTV 10 power is turned on or when display of the menu was commanded by a user operation such as with the accessory remote controller for the DTV 10 .
FIG. 6 shows an example of a menu as the GUI (Graphical User Interface) displayed on the DTV 10 . The user selects a desired device as the transmit device from the devices displayed on the device list display 32 by operating the cursor 31 with a remote controller, etc. Devices available as transmit devices from among the devices connected to the IEEE1394 bus 3 are displayed in a list format on the device list display 32 .
The device name where the cursor 31 is positioned is displayed with a color to allow that device name to be distinguished from the other device names. The colors of the letters are highlighted by inverting the colors of the letters on the display. Besides the device name where the cursor 31 is positioned, the device name connected to the DTV 10 at that time may also be displayed in the same way to allow recognition of the display by the user.
A connection change box 33 is provided below the list display 32 . This connection change box 33 is selected when the user desires to cancel (display state in FIG. 6) the connection or restore (described later) the connection with the device designated as the transmit device.
In step S 1 , when the user selects the desired transmit device from the display screen as shown in FIG. 6, a connection is established with the selected transmit device, in step S 2 . For example, when the IRD 11 was selected as the transmit device, in step S 2 , a B.C. connection is established between DTV 10 and IRD 11 on the same channel simultaneous with the P.P. connection.
In the processing of step S 1 when the power for DTV 10 is turned on, instead of the user selecting the desired transmit device from the menu, the connected device from the previous time before the power was turned off may instead be selected as the default transmit device. The DTV 10 may be set so that the IRD 11 is always selected as the default transmit device.
In step S 2 , when the connection is established with the device selected as the transmit device, the DTV 10 stores information on the connected equipment in the information storage section 24 . In step S 3 , information for distinguishing the various devices such as the node ID or the global unique ID is the information stored in the information storage section 24 . When this kind of information is stored in the information storage section 24 in the processing of step S 3 , signals in this case received and processed by the IRD 11 are inputted to the DTV 10 by way of the IEEE1394 bus, and the user commences viewing/hearing the desired program.
In step S 4 , the P.P. connection is temporarily canceled. In this operation, when for example, the user is viewing the desired program based on signals supplied from the IRD 11 , and wants to view a program based on signals supplied from the DVTR 12 - 1 , the user performs the specified operation to display the menu such as shown on FIG. 6 . The user then moves the cursor 31 to the connection change box 33 , and cancels the established P.P. connection in this case between the DTV 10 and the IRD 11 by making a selection.
When the connection is canceled, the menu screen shown in FIG. 6 switches to the menu screen shown in FIG. 7 . In other words, the display on the connection change box 33 switches from, “Cancel Selected Device” to “Restore Selected Device”.
In step S 4 , when the P.P. connection is canceled, the processing proceeds to step S 5 , and connection related control commences. Only the B.C. connection is still established on the DTV 10 when the P.P. connection is canceled. Therefore, the DTV 10 is in a state capable of inputting the signals transmitted on the channel utilized by the B.C. connection. The user then commands play by performing the specified operation on for example, DVTR 12 - 1 , and when the DVTR 12 - 1 in compliance with the play command, commences output of the signal on the channel utilized for the B.C. connection, that signal is inputted to the DTV 10 and video and audio are output based on that signal.
The user can in this way, view/hear programs from the desired device. Further, when the user has issued a play command to the DVTR 12 - 2 , the DVTR 12 - 2 takes over (captures) the B.C. connection channel and outputs signals on that channel so that the user can view/hear the program based on signals from the DVTR 12 - 2 .
In this way, the P.P. connection can be canceled, and the input signal (transmit device) switched to signals from the desired device just for example by issuing a play command to the desired device.
In step S 6 , when a P.P. connection restore command is output, information on the transmit equipment for which restoring of the P.P. connection was commanded, is stored in the information storage section 24 in step S 7 . The command to restore the P.P. connection involves the user deciding the desired program for viewing/hearing by switching the signals input by the DTV 10 (by switching to the program for viewing per the DTV 10 ), and for example calling up a menu screen such as shown on FIG. 7, and from that menu selecting the device to supply the desired program.
The selection of the transmit device from the menu is the same process as in step S 1 and is performed by the user moving the cursor 31 to the desired device name. Restoring the connection (in this case, the connection with IRD 11 ) to the P.P. connection before cancellation can be performed by selecting “Restore Selected Device” of connection change box 33 from the menu as shown in FIG. 7 .
Further, after the P.P. connection is canceled, a timer may be utilized so that when the signal from one device for example, was continuously input for five minutes or longer, a B.C. connection is overlapped onto the P.P. connection with that device. When utilizing a timer, the status of the transmit device having only a B.C. connection must always be known. When the restoring of a P.P. connection is commanded by means of this kind of processing, the node ID (Global Unique ID) of the transmit device only having a B.C. connection established, is stored in the information storage section 24 .
When information on the transmit device specified for restoration of the P.P. connection, is stored in step S 7 , the process proceeds to step S 8 and the P.P. connection with that transmit device is implemented.
The above-mentioned processing is further described while referring to FIG. 8 . In the processing in steps S 1 through S 3 , a B.C. connection and a P.P. connection are established on the same channel (on channel X) between the DTV 10 and the IRD 11 as shown in FIG. 8 A. Since the connections are set up so that only one signal is exchanged on one channel, in a state with the two connections of a P.P. connection and a B.C. connection established, one signal is handled by a mode for those two connections.
In the state with a P.P. connection and a B.C. connection established shown in FIG. 8A with the user inputting signals to DTV 10 , when switching of switching from IRD 11 to DVTR 12 - 1 is commanded, then as shown in FIG. 8B, the P.P. connection established between DTV 10 and IRD 11 is canceled (processing in step S 4 ). Control for connection with DVTR 12 - 1 is then performed in the processing of step S 5 so that as shown in FIG. 8C, the DTV 10 and DVTR 12 - 1 exchange data on the B.C. connection of the X channel (Xch).
In this state, when the user in step S 6 commands the restoring of the original connection (Connection change box 33 was selected on the menu shown in FIG. 7.) the status as shown in FIG. 8A is returned to, by implementing steps S 7 and S 8 .
As shown in FIG. 8C, in a connection status with signals from DVTR 12 - 1 inputted to the DTV 10 , if the connection is maintained for example, for five minutes or longer, then a P.P. connection is overlapped onto the B.C. connection as shown in FIG. 9, between the DTV 10 and the DVTR 12 - 1 .
Also, when the menu has been called up and the DVTR 12 - 2 was selected from the menu as the transmit device, then as shown in FIG. 10, a P.P. connection is established, overlapped onto the B.C. connection between the DTV 10 and the DVTR 12 - 2 .
By canceling and restoring the P.P. connection in this way, the user can input (view/hear) signals from the desired device and at the desired timing.
The above processing sequence can be implemented by hardware yet can also be implemented by software. When implementing the processing sequence with software, the software can be installed from a recording medium onto for example a computer incorporating dedicated hardware installed with the programs, or for example the software can be installed as separate programs on a general-purpose personal computer capable of implementing all functions.
The recording medium may not only be constituted as shown in FIG. 11, by a magnetic disk 61 (including floppy disks) an optical disk 62 (including CD-ROM {Compact Disk Read Only Memory}, DVD {Digital Versatile Disk}), a magneto-optical disk 63 (including MD {Mini-disk}) or a packaged medium such as a semiconductor memory 64 distributed to provide programs to the user, but may also be provided to the user incorporated into the computer or on a hard disk containing programs stored on an information storage section 24 .
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An information processing device, method thereof and a recording medium for easily switching input signals. A broadcast connection and a point-to-point connection are established between the receive device and the transmit device. When the user commands the canceling of the P.P. connection established for the receive device or the transmit device, only the broadcast connection remains established. In this state, the user receives signals on a receive device sent from the desired transmit device, and commands the restoring of the P.P. connection with the desired transmit device. The switching of input signals to the receive device is in this way performed by temporarily canceling the P.P. connection.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates generally to commercial motor vehicles and more particularly to an automated system for cycling vehicle lamps on and off to allow direct sight inspection by one person of operability of the lamp bulbs during a vehicle walkaround.
2. Description of the Problem
Federal regulations governing commercial vehicles and school busses provide for periodic inspection of various vehicle systems. Among the vehicle systems requiring inspection are exterior lamps, such as headlights, turn indicator lamps and identification lights. An inspection must determine not only if the lamp is operable, but that systems for actuating lamps for indicating turns, braking, or for flashing, are also functioning correctly. Performing such checks has generally been much easier if two people are available to make the check, one to remain in the cab of the vehicle to depress the brakes, activate turn signals and perform other similar operations while another person walks around the vehicle to view the lamps' operation. Where only one person, typically the driver, is available, such checks can be quite onerous.
Partial automation of a exterior light inspection procedure was proposed in U.S. Pat. No. 6,674,288, which is incorporated herein by reference. The Vehicle Lamp Inspection System proposed there provided for the automatic activation and deactivation of a vehicle's exterior lights in accordance with a predetermined sequence. The system was implemented over a programmable electrical system controller, programmed to implement a repeating test program in response to a user request.
SUMMARY OF THE INVENTION
According to the invention there is provided a vehicle lamp exercise feature. The lamp exercise feature provides cycling on and off of a plurality of lamps mounted to be visible on the exterior of the vehicle. The lamps are organized into functional subsets of lamps. An electrical system controller has a plurality of lamp energization output ports with an energization circuit for each functional subset of lamps, each energization circuit being connected to a different one of the lamp energization outputs. A first set of lamp activation switches for some of the functional subsets of lamps, and service brake position and parking brake position switches, are connected to the electrical system controller to provide status inputs to the electrical system controller. A gauge controller provides input points for a second set of lamp activation switches, including a lamp test switch. An ignition switch position sensing element provides a further a control input to the gauge controller. A datalink between the gauge controller and the electrical system controller allows indications of the state of status and control inputs received by the gauge controller to be communicated to the electrical system controller. The electrical system controller further includes a programmable microcomputer for switching on and off each of the plurality of energization output ports. A test program executable on the programmable microcomputer is responsive to actuation of the lamp test switch for execution. The test program includes program means for grouping selected functional subsets of lamps. The test program further provides means for sequentially activating and extinguishing the lamps of each functional subset within a group undergoing testing by selective energization of the lamp energization output ports. Further program means are responsive to detection that the park brake is set, the ignition switch position is on and all exterior lamp energization output ports are off to allow the test program to proceed upon detection of activation of the exterior lamp check switch. Still further program means provide for detecting a change in state of one of the brake position switch, the park brake position switch, or a lamp activation switch for terminating execution of the test program.
Additional effects, features and advantages will be apparent in the written description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a perspective view of a school bus equipped with lighting systems with which the present invention is advantageously employed.
FIG. 2 is a simplified front elevation of a bus instrument panel.
FIG. 3 is a high level schematic of the lighting connections for an electrical system controller.
FIG. 4 is a circuit schematic for a motor vehicle lighting system and related controls.
FIG. 5 is a flow chart of a program executed on the electrical system controller for implementing the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings and in particular referring to FIG. 1 a school bus 10 is shown. An assortment of lamps are mounted to or to be visible on the exterior of school bus 10 , including, but not limited to headlamps 12 , front turn signals 14 , front flashers 16 and side marker lights 18 .
Referring to FIG. 2 , an instrument panel 20 is positioned at a driver's station in the interior of school bus 10 . Execution of the lamp check routine of the present invention is initiated, in part, by cycling of a switch 24 mounted in a switch array 22 at the lower left portion of the panel 20 . A lamp 26 set in the switch 24 is illuminated to indicate when the program of the present invention is executing or a request for execution has been made.
FIG. 3 illustrates lighting pin connections for a programmable electrical system controller (ESC) 30 and selected input connections. ESC 30 is a high level controller for an vehicle controller area network. ESC 30 directly energizes most vehicle exterior lamps including, by group: the lowbeam headlights; the highbeam headlights; the marker lights; the left front and rear red pupil warning lights (PWL); the right front and rear red PWL; the right front amber PWL; the left front amber PWL; the left rear amber PWL; the right rear amber PWL; the left front turn signals; the right front turn signals; the right rear turn signals; the left rear turn signals; the stop lights; and, the reverse lights. ESC 30 is connected to receive directly a park brake position signal input and the PWL input from a resistor switching network. ESC 30 receives an ignition input signal from an ignition switch 331 over a controller area network bus.
FIG. 4 is a partial circuit schematic of an electrical gauge controller (EGC) 40 , ESC 30 , and some of the plurality of lamps energized under the control of the ESC. Several power switching Field Effect Transistors (FETs) used for energizing various lamps are illustrated. Fewer than the number of FETs required are illustrated because the specific circuit element is simply repeated up to the number of lamp circuits for which support is required. ESC 30 is a programmable body systems computer used to control many vehicle electrical system functions, most of which are not shown. In the past, many of these functions were controlled by switches, relays and other independently wired and powered devices. ESC 30 is based on a microprocessor 31 which executes programs and which controls switching of the plurality of power FETs 52 , 53 , 54 , 55 , 56 , 57 and 58 used to actuate vehicle exterior lights. Among those lights, and explicitly illustrated here are a park and marker light circuit 37 and an ID light circuit 38 , which are energized by Park Light FET 52 and the low and high beam headlights 61 , 48 , which are energized by FETs 53 and 54 , respectively. Yet another power FET 51 is used to energize a horn coil 36 . One FET may be used to drive the indicator light 26 in the exterior light test switch 24 . This allows indicator light 26 to flash during testing, and other certain other conditions.
Microprocessor 31 can apply activation signals to all of the lamps subject to inspection as well as to a horn coil 36 . In the case of headlights 61 , 48 this may also involve pulling high a headlight enable line by instruction to EGC 40 . Microprocessor 31 is connected to provide an activation signal to a horn power FET 51 which in turn drives a horn coil 36 . Another signal line from microprocessor 31 is connected to drive a park light FET 52 which in turn drives park/marker light bulbs 37 and license plate ID bulbs 38 . Yet another signal line from microprocessor 31 drives a low beam FET 53 , which in turn drives filaments in headlight bulbs 48 . Low beam FET 53 and park light FET 52 further require an Input on the headlight enable line to operate. Still another pin on microprocessor 31 controls a high beam FET 54 which drives high beam filaments in bulbs 61 and 48 . Remaining pins on microprocessor 31 are used to control the remaining lights of the vehicle. Four FETs 55 , 56 , 57 and 58 are illustrated as connected to receive the signals and, in turn, to power bulbs 63 , 64 , 65 , and 46 . However, those skilled in the art will realize now that any number of FETs and bulbs may be connected. Flasher operation may also be readily simulated.
Inputs to ESC 30 come from various sources. Primary among these is the electric gauge controller (EGC) 40 , which provides local control and a controller area network interface over the instruments and switches installed on instrument panel 20 . EGC 40 communicates with ESC 30 over a CAN data link (bus 60 ) which conforms to the SAE J1939 standard. CAN controllers 43 and 143 located with EGC 40 and ESC 30 , respectively, implement the network protocols and data packet decoding. EGC 40 is based on a microprocessor 41 but includes only limited and typically fixed programming. EGC 40 handles an array of microswitches 45 , and is programmed to provide manual control over headlights, park lights, marker lights, etc., as well as provide for initiation of the test cycles of the present invention, using the microswitches. Sources of direct inputs to ESC 30 , relevant to the operation of the present invention, include a park brake 140 , brake 136 , possible horn 138 and a pupil warning light resistive network 222 . The resistor network 222 is adapted from switches supplied to implement a speed control system. Naturally, other arrangements may be made for turning on the PWL.
Activation of a lamp test routine begins with cycling of one of the switches in microswitch array 45 , with is detected by EGC 40 and broadcast over bus 60 for detection by ESC 30 . Microprocessor 31 then begins sequences of actuation of the FET switches to illuminate the various lamps in accordance with predetermined routines. The test routine also requires, as a precondition, that the park brake 140 be set, all lights being checked are off, and the ignition key is in the ‘ON’ position. Cancellation of the cycle occurs upon anyone of the following: (1) tapping or depressing the brake pedal 136 ; (2) release of the park brake 140 ; (3) moving the ignition key to the start or off positions; or (4) turning on any of the lights that are in the sequence. The preconditions force the vehicle to be immobilized before the sequence can begin.
FIG. 5 is a high level flow chart which illustrates the testing cycles for the lamps. To initiate testing, as indicated at step 500 , all exterior lamps are turned off, the key is in the ignition and moved to the ON position, the park brake is set and the exterior lamp check switch 24 is pressed. This set of preconditions for execution of the test program should prevent accidental initiation of the program, for example, when the vehicle is being driven. The test routine is divided into three subroutines 510 , 520 , 540 , which are associated with different groups of lights, organized logically by function to assist the operator in his visual inspection walk around. Each subroutine may be programmed to execute repetitively for a predetermined time period, for example two minutes, with each light energization step lasting a few seconds, before the next subroutine is executed. Or, the three subroutines may be programmed to execute in parallel.
Subroutine 510 handles marker and signaling lights. At step 511 the left and right turn signals, marker lights and stop lights are energized. Next, following a one second delay (step 512 ), a subset of these lights, including the left and right turn signal lights and the stop lights are turned off (step 513 ). Following a further one second delay (step 514 ) the marker lights are turned off (step 515 ). Then, yet another one second delay is executed (step 516 ) and the subroutine returns to step 510 .
Subroutine 520 handles the pupil warning light (PWL) group. At step 521 the left red PWLS are turned on and the right red PWLS are turned off. A one second delay (step 522 ) is then executed. Next, at step 523 , the left amber PWLS are turned on and the left red PWLS are turned off. Again a one second delay is executed (step 524 ). Then, at step 525 , right amber PWLS are turned on and the left amber PWLS are turned off. Following a one second delay (step 526 ) step 527 is executed to turn on the right red PWLS and to turn off the right amber PWLS. Then a one second delay is executed at step 528 and execution is returned to step 521 .
Subroutine 540 relates to the light group associated with aiding the driver's sight, i.e. the headlights, foglights and backup lights. Step 541 provides for turning on the highbeams and turning off the lowbeams, fog lamps and back up lights. Step 542 is a three second delay, followed by step 543 where the lowbeams, fog lamps and back up lights are illuminated and the high beams are extinguished. Step 544 provides for another three second delay and execution is returned to step 541 .
Step 550 is applicable to all three subroutines and provides for disengagement of the subroutines. Upon occurrence of any of four events the routines cease execution, including, press and release of the brake pedal, release of the park brake, turning the ignition key to the off or crank positions, or manually turning on any light in the test sequences. Automatic disengagement assures that the light sequence will turn off when the driver begins driving the vehicle. In addition, the routine may be exited by turning the process off using switch 24 .
Each subroutine defines a group of lamp sets. A unique pattern of illumination and extinguishment of lamps characterizes each group, making the task of remembering which functional sets of lamps belong to each group, and better assuring that an operator does not miss one of the functional sets during walk-around of the vehicle. Patterns are marked by varying when sets are turned on and off with respect to one another from set to set and by varying the delays built into the cycling program for each group. The number of functional sets in each group is limited to four.
The invention provides for simplification of operator inspection of vehicle exterior lamps by through the automatic, sequential and repeated illumination and extinguishment of lamps. Sets of lamps are associated with one another into groups to present an easily recalled hierarchy to the user, and eliminating the need to remember overly complex patters.
While the invention is shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit and scope of the invention.
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An automated system for cycling vehicle lamps on and off allows direct inspection by one person of operability of the lamp bulbs while doing a walk around of the vehicle. The system is switch operated. Interlocks to operation are based upon the status of the vehicle's service brake, its park brake and the on/off status of the lights themselves. Lights are organized by related groups and each group given a distinctive, repeating cycle to lighten the burden of memorization on the operator.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuing application of U.S. patent application Ser. No. 10/146,966 filed May 16, 2002, the entire disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] The present embodiment relates generally to the production of pellets of alum, a smectite mineral-bearing industrial material such as bentonite (montmorillonite), attapulgite, saponite, hectorite, sepiolite and fullers earth and optionally sodium or calcium carbonate that can be delivered to concentrated or impounded phosphate located at the bottom of various bodies of water. More particularly, the pellets of alum, a smectite mineral material as described above and optionally sodium or calcium carbonate can be delivered to a wider range of locations in bodies of water including to sites known as the “sediment water interface” which is an area that can be generally defined as the top six inches of sediment combined with the deepest six inches of water. Even more particularly, the pellets of alum, a smectite mineral material as described above and optionally sodium or calcium carbonate are dropped through the body of water so that the alum is released when the pellet reaches the desired location in the water, thereby treating the phosphates more efficiently and using or consuming less alum.
[0003] Acidic metal salt and sulfate solutions, such as aluminum sulfate ((Al 2 SO 4 ) 3 .14H 2 O) solutions, commonly known and referred to as “alum,” have long been used to remove color and suspended particles, as well as organic and microbiological contaminants from water. Alum is readily available and when diluted with surface water, it can function as a coagulant, flocculent, precipitant and emulsion breaker. As a coagulant, alum removes the primary nutrient for blue-green algae in the water. This function is important because these algae remove oxygen from the water (known as biochemical oxygen demand or BOD) and thus pose a danger to fish. Alum also forms an insoluble precipitate or floccule, i.e., a floc, with the impurities in the water. The floc grows in size as it attracts suspended and colloidal particles and organic compounds present in the water. The floc settles out of the water over time and can be removed by well known techniques such as by decanting or filtration.
[0004] One of the most difficult problems in water pollution control is the growth of algae. As noted above, algal organisms exert a BOD on the water and the algal BOD can often exceed the oxygen resources of the water. Algal growths can also cause unpleasant tastes and odors in water supplies. Dissolved phosphate ions provide algae with a necessary nutrient supply. If the phosphate supply could be removed the algae would not survive or flourish in the water column and a water pollution control problem would be addressed. An additional difficulty associated with the treatment of phosphates in water is that the majority of the phosphates (50-90%) are concentrated at the sediment-water interface of an impoundment and current application techniques involving alum primarily treat the phosphates closer to the surface of the body of water. In addition, current techniques have been focused on nearly instantaneous sorption of phosphates. As a result, the body of existing products and techniques do not perform as effectively in a number of water systems, especially high energy and deep systems, and in systems that require more than just instantaneous phosphate sorption. In the former case, alum is flushed from the target waters before it can perform. In the latter case, the alum is poorly utilized in application. Also, the alum can leave an unwanted white cloud in the water for an extended period of time.
[0005] Therefore, there is a need for simple compositions, forms and methods for treating phosphate impoundments in bodies of water.
DETAILED DESCRIPTION
[0006] According to one embodiment, a phosphate impoundment is treated with a composition that includes alum and a member of the smectite family of minerals as the two major components. As used herein the term “alum” shall be used to refer to aluminum sulfate ((Al 2 SO 4 ) 3 .14H 2 O). Among the smectite bearing ores, or industrial minerals, is bentonite. Bentonite is the ore enriched in the smectite called montmorillonite. As used herein the term “smectite mineral material” shall be used to refer to bentonite, attapulgite, saponite, hectorite, sepiolite and fullers earth. This embodiment also optionally includes sodium carbonate or calcium carbonate. According to a second embodiment, the alum and smectite mineral material preferably are covered or coated by techniques well known to those skilled in the art, with one or more natural organic by-products such as corn starch, sugar-based resins, and various natural product derivatives such as chemical families of resins and starches. Suitable resins and coatings include guar gum, alginates, polyvinyl alcohol, partially hydrolyzed polyacrylamides and other similar polymers well known to those skilled in the art.
[0007] The compositions of these embodiments selectively remove phosphates from natural and man-made water systems. Phosphates are a primary nutrient for aquatic flora/fauna such as blue-green algae which produce unsightly green slimes and clouds, and undesirable odors in waters. By removing the phosphates, the algae are deprived of nourishment and therefore do not proliferate in the water column.
[0008] Each component of the compositions of the present embodiment, serves a function in the product towards the goal of optimal sorption and thus removal of phosphates. Alum is a water treatment product that is used to remove phosphates and other compounds such as dissolved organics, suspended sediment, and metals from a body of water. The primary purpose of the alum is to sorb the phosphates from the water or sediments. Alum is generally commercially available from General Chemical Corporation.
[0009] The smectite mineral material, preferably, bentonite functions to 1) optimize the timing of the dissolution of the composition in the water column, 2) buffer the pH of the water that is being treated to a neutral pH level, and 3) optimize or control the density of the composition to more precisely estimate the residence time in the water column. Bentonite is generally commercially available from Bentonite Performance Minerals.
[0010] Compositions of uncoated alum and smectite mineral material generally retain approximately 90% of their integrity or shape for up to approximately 2 minutes. Compositions of alum and smectite mineral material that have been coated with accessory additives such as water soluble resins, natural polymers and macromolecular by-products from grain and agriculture industries dissolve in water at a much slower rate than uncoated compositions. Specifically, the coated compositions generally retain approximately 90% of their integrity or shape for up to approximately 24 hours. The concentration of the accessory additives preferably is less than five percent by weight of the total composition.
[0011] According to another embodiment, the compositions preferably include a pH buffering agent selected from sodium carbonate (Na 2 CO 3 ) or calcium carbonate (Ca 2 CO 3 ). In addition to buffering the pH of the body of water, the pH buffering agent also enhances the density of the composition for use in higher energy—higher flow—water systems.
[0012] According to a preferred embodiment, the composition includes from 30-99% by weight of alum and from 1-70% of a smectite mineral material. According to another preferred embodiment, the composition further includes from 0-5% natural water soluble resins and by-products as a coating. According to still another preferred embodiment, the composition further includes from 0-30% of a pH buffering agent selected from sodium carbonate and calcium carbonate.
[0013] The compositions of the present embodiment are manufactured and produced according to techniques well known to those skilled in the art. Preferably, the compositions of the present embodiment are produced in the form of spheres to oblate spheroids, cylinders to cubes and three-dimensional rectangles ranging in size from ¼″ to 24″ in diameter. More preferably, the compositions of the present embodiment are produced in the form of tablets, pellets, extruded noodles, briquettes or ribbons by equipment well known to those skilled in the art such as extruders, tabletizers, briquetters or agglomerators. In the process of forming such tablets, extruded noodles, briquettes or ribbons, each component of the compositions are provided in powdered or granular form and the components are blended. Preferably, the raw material components are blended in the proportions noted above and are physically mixed at the desired levels in tanks or similar units of 20 to 200 ton capacity, by augers and paddles for a prescribed amount of time, preferably from 5 minutes to up to 6 hours in batch mode, or by continuous metered feed onto a common belt or in a common continuously producing extruder, pelletizer, tabletizer, or agglomerator. For instance, a typical extruder is in the form of an elongated rectangular tub with at least one and optionally two augers oriented parallel to the ground that physically mixes the materials into a uniform mixture of the composition and then passes the composition through a restricted opening to form elongated noodles or cylindrical pellets. Conventional tabletizers and pelletizers take the mixed materials from a storage tank and compress the mixture via converging die plates into forms in the order of ¼″ to 1″ diameter spheres and spheroids. Commercial agglomerators take the mixtures as a powder (having a particle size ranging from 44 μm to 100 μm) and non-compressively combines the mixture into spheroids. Preferably, the composition has a moisture content of from 1 to 15 percent by weight. Preferably, the compositions manufactured according to the above mentioned processes may be coated with accessory additives such as water soluble resins, natural polymers and macromolecular by-products from grain and agriculture industries according to techniques well known to those skilled in the art. Those skilled in the art will also recognize that other well known techniques may also be utilized to manufacture the compositions of the present embodiment.
[0014] The composition of the present embodiment has utility in the following water treatment markets: municipal water treatment polishing agent, commercial construction/engineering, agricultural feedstock (such as in piggeries, cattle, sheep and ostrich farms), aquaculture (fish farms and hatcheries, such as for shrimp, salmon and trout), natural lake and river systems and watersheds, recreational and leisure (golf course ponds, amusement parks and aquatic centers), industrial effluent management, and mining and exploration (tailings ponds and discharge systems).
[0015] The composition of the present embodiment, is a time release alum-based sorbent of phosphates in water. The vast majority of phosphate-laden water systems contain a minority of suspended or dissolved phosphates in the water column as compared to the sediment water interface. As used herein, the term “sediment water interface” shall be used to refer to an area in a body of water that is generally defined as the top six inches of sediment combined with the deepest six inches of water. In the vast majority of water systems such as lakes, rivers, ponds or trenches, the majority of the total phosphates is located at the sediment water interface. Powdered alum tends to remain in suspension removing the suspended phosphates, organic matter, and other sediment but rarely reaches the targeted problem area in need of such treatment. Preferably the density of individual tablets of the composition of the present embodiment ranges from 1.0 to 2.0 gm/cm 3 . It is also preferred that the individual pellets of the composition of the present embodiment have a diameter that ranges from ¼″ to 24″. Most preferably, the composition of the present embodiment has a density and size such that the compositions settle quickly through the water column arriving where they are needed most at the sediment water interface.
[0016] The calculation for settling in water systems is based upon the long accepted Stokes Settling Law which describes the rate of settling of a particle based upon the density of the particle and the density of the water. This law is a proven scientific principle used in a number of industries and can be used to estimate settling distances and time parameters for the composition of the present embodiment. As noted above, the uncoated composition according to the present embodiment will retain approximately 90% of its particle integrity for about 2 minutes which translates to a minimum of 50 feet of water column at the percentages of alum and smectite mineral material indicated above.
[0017] In commercial terms, the average depth of the water columns needing to be cleaned up will be about 6′, so according to Stokes Law, the uncoated product will reach the sediment water interface well in advance of the onset of significant dissolution.
Variations and Equivalents
[0018] Although only a few exemplary embodiments have been described in detail above, those skilled in the art will readily appreciate that many other modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages described herein. Accordingly, all such modifications are intended to be included within the scope of the following claims.
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Compositions including pellets of alum, a smectite mineral material and optionally sodium or calcium carbonate that can be delivered to a phosphate impoundment located at the bottom of a body of water at the bottom. The pellets of alum, smectite mineral material and optionally sodium or calcium carbonate are dropped through the body of water so that the alum is released when the pellet reaches the bottom of the impoundment thereby treating the phosphates.
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FIELD OF THE INVENTION
The present invention relates generally to semiconductor fabrication and more specifically to semiconductor transistor fabrication.
BACKGROUND OF THE INVENTION
Silicon-germanium epitaxial (Si—Ge epi) technology is becoming the mainstream in the application of heterojunction bipolar transistors. Si—Ge epi layers are used as the base material in such transistors in BiCMOS applications where bi-polar (BI) and complementary metal-oxide semiconductor (CMOS) transistors are fabricated in different areas of the same wafer. The Si—Ge epi layer could provide higher emitter injection efficiency and lower base transit time.
However, the discontinuity of the Si—Ge epi layer occurs on different intermediate layers and becomes a major issue for subsequent process steps due to poor polysilicon (poly) sheet resistance connected with the base electrode.
U.S. Pat. No. 6,388,307 B1 to Kondo et al. describes a B-doped SiGe layer in a transistor process.
U.S. Pat. No. 5,976,941 to Boles et al. describes a SiGe epi process.
U.S. Pat. No. 5,273,930 to Steele et al. describes a SiGe epi process on a silicon seed layer.
U.S. Pat. No. 5,620,907 to Jalali-Farahani et al. describes a method for a heterojunction bipolar transistor.
SUMMARY OF THE INVENTION
Accordingly, it is an object of one or more embodiments of the present invention to provide a method of fabricating semiconductor transistors utilizing Si—Ge epi layers.
Other objects will appear hereinafter.
It has now been discovered that the above and other objects of the present invention may be accomplished in the following manner. Specifically, a structure is provided and a doped Si—Ge seed layer is formed thereover. The doped Si—Ge seed layer having increased nucleation sites. A Si—Ge epitaxial layer upon the doped Si—Ge seed layer whereby the Si—Ge epitaxial layer lacks discontinuity.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more clearly understood from the following description taken in conjunction with the accompanying drawings in which like reference numerals designate similar or corresponding elements, regions and portions and in which:
FIGS. 1 to 3 schematically illustrates a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Initial Structure— FIG. 1
As shown in FIG. 1 , structure 10 has a seed layer 12 formed thereover. Structure 10 is preferably an intermediate substrate and may be a silicon substrate and is understood to possibly include a semiconductor wafer or substrate, active and passive devices formed within the wafer, conductive layers and dielectric layers (e.g., inter-poly oxide (IPO), intermetal dielectric (IMD), etc.) formed over the wafer surface. The term “semiconductor structure” is meant to include devices formed within a semiconductor wafer and the layers overlying the wafer. Structure 10 may also include silicon oxide and/or polysilicon.
Seed layer 12 is preferably a doped Si—Ge layer having a thickness of preferably from about 10 to 400 Å and more preferably from about 20 to 200 Å. Doped Si—Ge seed layer 12 is preferably doped with boron (B), C, P or As and is more preferably doped with boron (B).
When doping with boron, B 2 H 6 is introduced during the formation of Si—Ge seed layer 12 at a rate of preferably from about 0 to 100 sccm and more preferably from about 0 to 50 sccm under the following conditions:
temperature: preferably from about 500 to 750° C. and more preferably from about 600 to 700° C.; pressure: preferably from about 20 to 200 Torr and more preferably from about 50 to 150 Torr; and time: preferably from about 10 to 120 seconds and more preferably from about 10 to 60 seconds.
The dopant within doped Si—Ge seed layer 12 preferably has a concentration of from about 1E18 to 1E20 atoms/cm 2 and more preferably about 1E19 cm 2 .
The addition of a dopant to the Si—Ge forms the doped Si—Ge seed layer 12 permitting much better step coverage and eliminates discontinuity by, the inventors believe, increasing the nucleation sites.
Formation of Si—Ge Epitaxial Layer 14 — FIG. 2
As shown in FIG. 2 , a Si—Ge epitaxial (epi) layer 14 is formed upon the doped Si—Ge seed layer 12 to a thickness of preferably from about 100 to 700 Å and more preferably from about 200 to 500 Å. Si—Ge epi layer 14 is formed under the following conditions:
Si precursor: preferably SiH 4 , SiH 2 Cl 2 , SiHCl 3 or SiCl 4 and more preferably SiH 4 ; Ge precursor: preferably GeH 4 or GeCl 4 and more preferably GeH 4 ; temperature: preferably from about 500 to 750° C. and more preferably from about 600 to 700° C.; pressure: preferably from about 20 to 200 Torr and more preferably from about 50 to 150 Torr; and time: preferably from about 20 to 400 seconds and more preferably from about 100 to 300 seconds.
The epi layer 14 could have Si—Ge epi film with graded or box Ge profile. The epi film 14 might also have other doping concentrations.
Formation of Optional Cap Layer 16 — FIG. 3
As shown in FIG. 3 , a cap layer 16 may be optionally formed over the Si—Ge epitaxial layer 14 to a thickness of preferably from about 20 to 200 Å and more preferably from about 40 to 120 Å to finish the base process in a BiCMOS process flow.
Due to the doped Si—Ge seed layer, the discontinuity issue is eliminated.
Cap layer 16 is preferably comprised of silicon.
ADVANTAGES OF THE PRESENT INVENTION
The advantages of one or more embodiments of the present invention include:
1. shorten the incubation time of seed layer; 2. improve film uniformity on different substrates; and 3. improve epi quality.
While particular embodiments of the present invention have been illustrated and described, it is not intended to limit the invention, except as defined by the following claims.
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A method of forming an Si—Ge epitaxial layer comprising the following steps. A structure is provided and a doped Si—Ge seed layer is formed thereover. The doped Si—Ge seed layer having increased nucleation sites. A Si—Ge epitaxial layer upon the doped Si—Ge seed layer whereby the Si—Ge epitaxial layer lacks discontinuity.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a steam iron comprising a boiling compartment for producing a steam flow and a steam distribution circuit with a smoothing brush equipped with at least one hole for emitting steam.
[0003] 2. Brief Description of the Prior Art
[0004] French patent application FR 2 912 429 discloses a steam iron comprising a steam production device consisting of a boiling compartment with a heating body and a steam outlet through which steam can freely escape in the direction of a smoothing brush.
[0005] Such an appliance offers the advantages of being inexpensive to manufacture and capable of quickly producing a saturating flow of steam that, when combined with a fiber brushing action, allows for a quick smoothing of curtains or clothing hanging vertically on a hanger.
[0006] However, such an iron has a boiling compartment that supplies steam at atmospheric pressure, resulting in a low steam flow rate at the outlet of the smoothing brush that is detrimental to the proper penetration of steam into fabrics, particularly for thick clothing. In addition, the low speed of the steam at the outlet of the smoothing brush prevents the proper direction of the steam jet, making it impossible to precisely treat the areas of clothing that are to be smoothed, or to treat clothing arranged horizontally, since the steam naturally has a tendency to rise upwards, whereas the smoothing brush is oriented downwards.
[0007] Finally, such irons with boiling compartments operating at atmospheric pressure exhibit the disadvantage of having an irregular flow of steam at the outlet of the smoothing brush, with phases of very low steam flow following phases of high steam flow.
[0008] The present invention aims to propose an iron that remedies these disadvantages and is very easily constructed.
SUMMARY OF THE INVENTION
[0009] To this end, the object of the invention is a steam iron comprising a boiling compartment for producing a steam flow and a steam distribution circuit with a smoothing brush having a head equipped with at least one hole for emitting steam, characterized in that it comprises a steam flow acceleration device by generating a puff of air that increases the flow rate of the steam at the outlet of the smoothing brush.
[0010] According to another characteristic of the invention, the steam flow acceleration device is disposed on the smoothing brush.
[0011] According to another characteristic of the invention, the steam flow acceleration device comprises a fan.
[0012] According to another characteristic of the invention, the steam flow acceleration device comprises an air circulation conduit with an intake disposed outside of the smoothing brush and a nozzle equipped with an air outlet opening into the flow of steam.
[0013] According to another characteristic of the invention, the fan is positioned in proximity to the intake of the air circulation conduit.
[0014] According to another characteristic of the invention, the nozzle outlet opens into a steam diffusion compartment that is integrated into the head of the smoothing brush.
[0015] According to yet another characteristic of the invention, the nozzle outlet opens upstream from the steam emission hole in such a way that the steam in the diffusion compartment is propelled through the hole of the smoothing head by the flow of air emitted by the nozzle.
[0016] According to another characteristic of the invention, the passageway of the nozzle outlet is smaller than or equal to the passageway of the steam emission hole.
[0017] According to another characteristic of the invention, the nozzle outlet opens to the exterior of the head, downstream from the steam emission hole.
[0018] According to another characteristic of the invention, the distance separating the nozzle outlet from the steam emission hole is less than 1 cm.
[0019] According to another characteristic of the invention, the air circulation conduit takes the form of a hose with an intake passageway larger than the air outlet passageway.
[0020] According to yet another characteristic of the invention, the air circulation conduit comprises means for heating the air sent through the nozzle.
[0021] According to yet another characteristic of the invention, the steam flow acceleration device comprises means for diffusing an additive into the flow of steam.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The objectives, appearance and advantages of the present invention will be better understood based on the description given hereafter of a particular embodiment of the invention and variations thereof, which are presented as non-exhaustive examples, with reference to the attached drawings, wherein:
[0023] FIG. 1 is a perspective view of an iron according to a particular embodiment of the invention;
[0024] FIG. 2 is a longitudinal sectional view of the appliance presented in FIG. 1 ;
[0025] FIGS. 3 and 4 are perspective views of the smoothing brush that equips the appliance presented in FIG. 1 ;
[0026] FIG. 5 is a top view of the smoothing brush presented in FIGS. 3 and 4 ;
[0027] FIG. 6 is a transverse sectional view along the line VI-VI presented in FIG. 5 ;
[0028] FIG. 7 is a transverse sectional view along the line VII-VII presented in FIG. 6 ;
[0029] FIG. 8 is a perspective view of the component of the smoothing brush that integrates the steam flow acceleration device, shown alone;
[0030] FIG. 9 is a transverse sectional view of a variation of the embodiment of the smoothing brush of FIG. 6 ; and
[0031] FIG. 10 is a transverse sectional view of another embodiment of the smoothing brush presented in FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0032] Only the elements necessary for understanding the invention are shown. To facilitate the reading of the drawings, the same elements bear the same references from one figure to another.
[0033] FIG. 1 shows a steam iron comprising a base 1 for generating steam connected by a flexible conduit 2 to a smoothing brush 3 , said base 1 being similar to that described in greater detail in patent application FR 2 912 429.
[0034] In accordance with FIG. 2 , the base 1 comprises an top side with a filling aperture 11 opening into a water tank 10 , said tank 10 containing a boiling compartment 15 of limited volume in the shape of a bell 12 projecting into the bottom of the tank 10 and having a lower end resting against a seal 12 A extending around a heating body 13 . The heating body 13 , which is advantageously made of aluminum, encloses a 1500 watt U-shaped resistor traditionally powered by a circuit with a thermostat that is not visible in the figures and a switch 14 to interrupt the electrical supply to the resistor.
[0035] The boiling compartment 15 thus created is directly supplied with water from the tank 10 by supply channels 16 enabling the progressive transfer, through gravity, of water from the tank 10 to the boiling compartment 15 .
[0036] The top of the bell 12 comprises a steam outlet 15 A that is connected, by means of a rotary connector 17 , directly to the flexible supply conduit 2 of the smoothing brush 3 in such a way that the steam produced by the boiling compartment 15 can freely escape to the smoothing brush 3 through the flexible conduit 2 without being diffused into the tank 10 .
[0037] The flexible conduit 2 is preferably made of an EPDM (Ethylene Propylene Diene Monomer) material in order to obtain good thermal insulation, thus limiting the cooling of the steam during its passage through the flexible conduit 2 , which preferably has a length of more than 1.50 m for improved ergonomic performance.
[0038] In accordance with FIG. 3 , the smoothing brush 3 comprises a body with a cylindrical grip 30 positioned in the extension of a head 31 for diffusing the steam, said head 31 having a flat front surface 31 A equipped with a steam emission hole 32 in the shape of an oblong slit.
[0039] More particularly, according to the invention and in accordance with FIGS. 4 to 8 , the smoothing brush 3 comprises a steam flow acceleration device 4 by generating a puff of air to increase the steam flow rate at the outlet of the smoothing brush 3 .
[0040] This steam flow acceleration device 4 has a fan 40 controlled by a button 5 on the handle 30 , said fan 40 blowing through a hose 41 that passes through the body of the smoothing brush 3 and comprises an air intake 41 A positioned on the exterior of the smoothing brush 3 as well as an air ejection nozzle 43 opening into the smoothing head 3 .
[0041] As an example, the fan 40 consists of an axial fan that traditionally has a propeller powered by an electric motor integrated into the propeller boss that delivers 1 watt of power via cables (not shown on the figures), which extend along the flexible conduit 2 to the base 1 .
[0042] In accordance with FIGS. 6 and 7 , the fan 40 is preferably disposed in a housing 42 that extends outside the body of the smoothing brush 3 at the end of the hose 41 with the air intake 41 A. The hose 41 has a convergent shape from this end of the hose 41 with the air intake 41 A to a second end with the air ejection nozzle 43 , said nozzle 43 having a smaller passageway causing the flow of air entering through the intake 41 A to accelerate through the hose 41 and exit at a high rate at the outlet of the nozzle 43 .
[0043] The nozzle 43 thus forms an air ejector opening into a steam diffusion compartment 33 disposed upstream from the front surface 31 A of the smoothing head, said diffusion compartment 33 receiving steam through an aperture 33 A connected to be flexible conduit 2 by means of a coupling sleeve, and having a divergent shape from the intake 33 A to the front surface 31 A of the smoothing head.
[0044] The outlet 43 A of the nozzle 43 is preferably aligned with the steam diffusion hole 32 , said hole 32 having a passageway that is slightly greater than the passageway of the outlet 43 A of the nozzle 43 such that the jet of air emitted by the nozzle 43 easily forces the flow of steam through the steam diffusion hole 32 by means of a momentum exchange.
[0045] The resulting appliance comprises a smoothing brush 3 wherein the flow of saturating steam produced by the boiling compartment 15 can be accelerated on demand by pressing on the control button 5 , which increases the speed of the steam jet at the outlet of the smoothing brush 3 . This improves steam diffusion and regulates the flow of steam at the outlet of the appliance's smoothing brush 3 . In fact, the applicant realized that by improving steam diffusion, the use of such a steam flow acceleration device eliminated the steam hole phenomena commonly encountered with this type of appliance.
[0046] The increase in the steam flow rate at the outlet of the smoothing brush 3 also enables a more precise application of the steam jet and particularly results in a longer and more directed steam jet, even when the smoothing brush 3 is oriented downwards, thereby allowing the treatment of horizontally-arranged textiles.
[0047] Finally, this type of steam flow acceleration device 4 has the advantage of comprising a fan 40 disposed outside of the flow of steam to optimize its service life, away from excessive heat and humidity.
[0048] In a variation of the embodiment, the hose 41 of the steam flow acceleration device 4 may also comprise an electric resistor 44 , which is schematically illustrated in FIG. 6 , positioned downstream from the fan 40 .
[0049] Such a resistor 44 heats the flow of air emitted by the nozzle 43 which has the advantage of limiting any steam condensation that may appear in the smoothing brush 3 . In addition, the flow of hot air thus produced by the steam acceleration device may advantageously be used by itself, that is, without producing steam, in order to dry clothing using only the flow of hot air diffused by the nozzle 43 through the smoothing brush 3 .
[0050] In a variation of the embodiment illustrated in FIG. 9 , the smoothing brush 3 could comprise a hose 410 with an air intake 410 A and a nozzle 430 equipped with an outlet 430 A opening to the exterior of the smoothing brush 3 near the steam emission hole 32 , such that the flow of air emitted from the nozzle 430 converges with the flow of steam emitted from the steam diffusion hole 32 and accelerates the latter by means of a momentum change.
[0051] In another variation of the embodiment illustrated in FIG. 10 , the smoothing brush 3 of FIG. 6 comprises a diffuser 45 connected by a tube 46 to an additive tank (not shown in the figures) integrated into the base 1 . The additive diffuser 45 is advantageously positioned in the hose 41 of the steam flow acceleration device and allows the diffusion of an additive mist into the flow of air produced by the fan 40 . This additive mist is produced by means of an electric pump integrated into the base 1 and controlled by a button on the smoothing brush 3 , (not shown in the figures) with the pump sending the liquid additive under pressure to the diffuser 45 .
[0052] Such a device therefore has the advantage of allowing the diffusion of an additive into the flow of steam produced by the smoothing brush 3 , with the droplets emitted from the additive diffuser 45 being transported by the flow of air to the outlet 43 A of the nozzle 43 , then mixed with the flow of steam being diffused through the steam diffusion hole 32 .
[0053] The invention is in no way limited to the embodiments described and illustrated herein, which were provided solely for the purpose of example. Modifications are possible, particularly in terms of the constitution of the various elements or by substituting equivalent techniques, without in any way exceeding the scope of protection of the invention.
[0054] Thus, in a variation of embodiment not shown, the fan used could be an axial flow or radial centrifuge fan, which would have the advantage of being less cumbersome.
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A steam iron having a boiling compartment ( 15 ) for producing steam and a steam distribution circuit with a smoothing brush ( 3 ) including a head ( 31 ) equipped with at least one hole ( 32 ) for emitting a flow of steam, characterized in that it contains a steam flow acceleration device ( 4 ) that generates a puff of air to increase the steam flow rate at the outlet of the smoothing brush ( 3 ).
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This is a continuation of application Ser. No. 172,381, filed July 25, 1980 which is a continuation of Ser. No. 492,409, filed May 6, 1983 both now abandoned.
BACKGROUND OF THE INVENTION
In skylight construction for building roofs and other similar overhead structures, there have been a variety of different types of skylights and hatches developed including designs adapted to be opened and closed.
In opening the skylights there are a number of advantages that are generally sought. For example, it is desirable to have the skylight open and close freely and easily. Also, the skylight should be designed so that it can be opened to a substantial degree for those occasions when substantial or complete access through the opening in the roof structure is desired.
Naturally, it is also desirable to provide a structure that is weather proof and leak proof as well as being adapted to be inserted as a unit into a finished roof, and open upwardly. This is one of the criteria which is certainly desirable since it reduces the construction and installation cost of the unit. With the same thought in mind, it is naturally desirable to provide inexpensive component parts for the skylight assembly including parts which are inexpensive to manufacture, install and utilize. The parts should be designed so that they promote the desirable features of the skylight, for example, in connection with hinges for the movable portion of the skylight. The hinge should be designed so that it provides for free and easy opening and closing of the skylight in a quick and efficient manner.
A successful skylight design of the type under consideration is disclosed in inventor's prior U.S. Pat. No. 3,090,613 issued May 21, 1963, the contents of which are incorporated herein by reference.
SUMMARY OF THE INVENTION
With the above background in mind, it is among the primary objectives of the present invention to provide an improved skylight assembly for a roof or hatch use, particularly with significant hardware improvements. For example, an improved and simplified hinge structure is presented. The hinge is designed to be of low cost and to be easily and efficiently installed and used thereby decreasing assembly and installation cost. The hinge is designed so that it provides for freely pivotal movement of the portion of the skylight to be opened so that substantially free access can be obtained to the opening in which the skylight is mounted.
More specifically, the hinge is designed to provide for spacing of the portion of the hinge mounted on the pivotal portion of the skylight and the portion of the hinge mounted to the fixed portion of the assembly so that the skylight has freedom of movement about the pivot point and can be opened substantially greater than 90° of rotation from the closed position.
It is contemplated that the hinge of the present invention can be formed of stainless steel, be provided with a pivot pin spun on both ends, and is designed to eliminate the necessity of the use of a shim to accommodate varying thickness occurring during assembly of parts. The hinge is easily mounted by the use of as few as only two self tapping fastener elements.
It is a further objective to provide a hinge that is prebent into the desired configuration for use in the skylight assembly, includes the correct size and placement of holes for ease and efficiency of assembly, and includes only three pieces which provides for a great reduction in the number of component parts for the hinge structure thus adding to the efficiency and reducing the cost in assembly and installation. The design of a hinge of the present invention also makes it possible to easily replace hinges without requiring disassembly of major components of the skylight structure.
A still further objective of the present invention is to provide a unique actuator pole for facilitating access to the mechanism for opening and closing the skylight assembly. Since in most instances the skylight is mounted in a roof structure, access to the opening and closing mechanism of the skylight is often difficult. Accordingly, an improved structure for actuating the drive mechanism for the skylight assembly is always a desirable feature. Accordingly, a unique actuator pole is provided which is separable into two easily storable and portable halves. The two sections or halves are interconnected by a unique spline mechanism which facilitates ease of assembly and disassembly for use and storage respectively. Additionally, the pole is designed so that the one section can be easily interconnected with a handle for rotating the pole and the other section easily removably connected with a connector for coupling with the drive mechanism so that when the handle is grasped and the pole is rotated the connector attached to the drive mechanism will activate the drive mechanism and open and close the skylight according to the direction of rotation of the pole. The same type of structure employed in the spline can be employed on the handle and the connector for facilitating ease of coupling with the two sections of the pole. It is contemplated that the connector can be in the form of a loop and the means for receiving the loop on the drive mechanism of the skylight assembly can be a hook. The hook can be designed in a conventional manner to be removably mounted to the drive mechanism and replaced by a suitable handle for those uses where the drive mechanism is easily reachable and the actuator pole is not necessary.
A further improvements resides in the construction of the handle of the pole. A rotatable knob is employed to facilitate use of the handle. The knob is substantially soundless and the ability is aided by the unique design which provides for a cup-like receptacle to retain lubricant during use. The knob is coupled with the remainder of the handle in quick, efficient and inexpensive manner. No additional fasteners or other components are required. The assembly is a two piece knob and body structure.
In summary, an improved hinge is provided for a skylight and roof assembly having a skylight portion thereof pivotable between open and closed positions. The hinge includes a first leg adapted to be mounted on the movable or pivotable portion of the skylight in fixed position. A second leg of the hinge is adapted to be mounted on the fixed portion of the assembly and fixed in position thereon. A flange extends from the second leg of the hinge and mating surfaces are on the first leg and the flange adapted to receive coupling means for pivotally interengaging the first and second leg with the first leg spaced from the second leg by the flange therebetween so that the pivotable skylight portion can be pivoted between the open and closed positions along a desired arcuate path.
An actuator pole is provided for removably engaging and activating a drive mechanism for the skylight assembly to pivot the skylight portion of the assembly. The pole is formed of two separable sections, an upper section and a lower section. A spline is provided for interconnecting the two sections. A handle is removably connected to the lower section and a connector is removably connected to the upper section for removable engagement with the drive mechanism so that when the handle is shifted the connector will activate the drive mechanism and pivot the skylight.
With the above objectives among others in mind, reference is made to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In The Drawings
FIG. 1 is a plan view of a skylight assembly of the invention mounted on a roof;
FIG. 2 is a perspective view of a hinge used in the skylight assembly of the invention;
FIG. 3 is an enlarged fragmentary sectional view of the skylight assembly taken along the plane of line 3--3 of FIG. 1;
FIG. 4 is an enlarged fragmentary sectional view of the portion of the invention shown in FIG. 3 with the movable portion of the skylight assembly having been shifted to an open position;
FIG. 5 is an enlarged partially sectional plan view of a fragmentary portion of the skylight assembly showing the drive mechanism and a removable hook and a removable handle for use in operating the drive mechanism;
FIG. 5A is a fragmentary sectional view of the knob position of the removable handle of FIG. 5;
FIG. 5B is a partially sectional view of the knob of the handle of FIG. 5A prior to assembly with the body of the handle;
FIG. 6 is a partially sectional view of the actuator pole for operating the drive mechanism in assembled condition with parts broken away and removed;
FIG. 7 is a plan view of the spline for connecting the two sections of the actuator pole; and
FIG. 8 is an end view of the spline of FIG. 7.
DETAILED DESCRIPTION
In FIG. 1 a roof 20 is shown with a skylight assembly 22 incorporating the present invention mounted thereon. Roof 20 includes conventional roof sheathing 24 covered by an overlay of conventional shingles 26. Skylight 22 includes a swinging window unit 28 and box-like frame 30 as well as a flashing frame 32. The frames for skylight 22 can be formed of metal such as aluminum or from suitable lumber.
Skylight 22 includes a dome-shaped or exteriorly convex light-transparent window 34. In this connection, window 34 may be formed from a suitable resinous material commercially employed for such purposes. Window 34 preferably terminates along its periphery in a depending integral skit 36. Window 34 can be formed for example of clear acrylic plexiglas. Window 34 forms an outer dome which is spaced from an inner insulating dome 38 of similar material which is preferably clear or white translucent. The peripheral edge portion 40 of inner dome 38 is sealed as are the peripheral end portions of outer dome 34. Insulation is facilitated by the insulating space 42 between the inner and outer domes.
An extrusion 44 of conventional sealing material such as rubber is used to seal the peripheral edges of the double dome structure. Upper dome 34 rests on the upper surface 46 of extrusion 44 and is anchored to the supporting frames of the assembly in a conventional manner.
Extrusion 44 is seated on the upper surface 48 of flashing frame 32 and on the exposed upper surface 49 of hinges 50 as it extends around the periphery of the skylight assembly 22. A recess 52 in one side of extrusion 44 receives the end portion 40 of inner dome 38 in sealing interengagement. A second recess 54 below recess 52 and extrusion 44 and open outwardly and opposite to the opening to recess 52 receives an end of box frame 30 therein to provide an additional seal in the outward direction.
Hinge 50 is affixed to flashing frame 32 and to box frame 30 with the pivot point of the hinge positioned so that the interconnected box frame, extrusion and double dome portion of the skylight can pivot with respect to the flashing frame 32 thus permitting the shifting of the skylight between the open and closed positions.
In the depicted embodiment, there are two hinges 50 along one side of the rectangularly shaped skylight 22 so that the other three sides are free to permit movement of the double dome window portion away from the remainder of the skylight structure to permit access to an opening in alignment therewith in roof 20.
The details of each hinge 50 can be easily seen in FIG. 2. The hinge includes a first leg 56 which is of substantially rectangular configuration with longer upper and lower edges 58 and 60 respectively and a pair of shorter front and rear edges 62 and 64 respectively. A pair of mounting holes 66 and 68 are positioned interiorly of the edges of leg 56.
A pair of spaced hollow tubular projections 70 and 72 extend laterally from bottom edge 60.
Hinge 50 has a second U-shaped leg 74 with the closed end forming an upper base wall 76 for two spaced side walls 78 and 80 extending downwardly therefrom to provide an opening 82 therebetween. Base wall 76 and side walls 78 and 80 are also substantially rectangular in configuration generally conforming to the sides and shape of first leg 56. The U-shaped second leg 74 has a lateral flange 84 extending from the free end of side 80 adjacent to opening 82. Flange 84 terminates in three hollow tubular projections 86, 88 and 90 which are spaced along the length of flange 84 and are positioned to mate with projections 70 and 72 on first leg 56 so that the openings through all of the aligned projections are also aligned. A pin 92 is inserted through the aligned openings in the five projections to form the coupling means for coupling the two legs together and the pin 92 also forms the pivot axle about which the first leg 56 and the second leg 74 can rotate.
Side 78 has a hole 94 therethrough for extension of a conventional fastener element to mount the U-shaped legs 74 in fixed position on the skylight assembly 22.
Thus, each hinge 50 is formed of only three components, first leg 56, second leg 74, and pivot pin 92. It can be quickly and efficiently mounted to the skylight assembly 22. First leg 56 is mounted in a conventional manner to the movable portion of the skylight, for example, as shown in the depicted embodiment by the use of conventional self-tapping fasteners 96 passed through holes 66 and 68 of first leg 56 and into box-like frame 30. In turn, the U-shaped leg 74 is positioned over the upper end of flashing frame 32 so that the upper surface 48 of the flashing frame seats against the inner surface of space 76. A suitable self-tapping fastener is then passed through opening 94 in side 78 of legs 74 into flashing frame 32 to complete the mounting of the hinge to the fixed non-movable portion of the skylight assembly 22.
The assembly is then ready for use and is quickly and efficiently mounted to the roof structure to arrive at the position depicted in FIG. 1. The skylight is then operated in a conventional manner and the double window structural portion is rotated about pivot pin 92 to open the skylight to a desired degree. By positioning pivot pin 92 at the bottom end of leg 56 and side 80 and by making the leg 56 and the side 80 of sufficient length along with providing flange 84 to space the pivot pin 92 a predetermined distance from fixed U-shaped leg 74, substantially free rotation of the movable window portion of the skylight assembly is achieved. As shown in FIG. 4, the pivoting can be carried out over a considerable angular degree. In the embodiment shown, the dome can be opened more than 90°. This is a desirable feature particularly if the unit is to be used as a hatch where access to the complete opening in the roof is desired. Naturally in other environments including simply a window structure, the ability to open the dome to a greater degree is also extremely desirable.
As shown in a depicted embodiment, there are two hinges 50 employed in the assembly. Naturally the number of hinges is a matter of choice with two being an example of a convenient acceptable number.
Hinges 50 can be formed of a conventional metal material such as stainless steel. Pin 92 can be spun at both ends to avoid any problem of the pin falling out during use. The lateral width of flange 84 is a matter of choice depending upon the desired amount of freedom of movement one wishes in the chosen design criteria. The present hinges eliminate the necessity of the use of shims to accommodate for varying thicknesses and components since there is sufficient clearance for free rotation over a range of tolerances in component parts. A minimum number of fasteners are required to mount the hinges in place. There are no secondary bending operations required for the hinges which are formed in their intended use configuration during manufacture.
The holes in the hinge legs are preformed in the desired arrangement for ease of assembly and installation of the skylight assembly 22. As stated above, each hinge 50 is formed of only three pieces thus reducing cost in manufacture and assembly. Maintenance and repair is facilitated by the fact that the hinges can be easily removed and replaced without the necessity of dome disassembly and can be used to retrofit existing units.
The drive mechanism 96 is depicted in FIG. 5 and is used to open and close skylight in a conventional manner such as described in connection with U.S. Pat. No. 3,090,613. The drive mechanism is shown with a conventional handle 98 which has a recess 100 in one end and a set screw 102 for removably mounting the handle on the drive mechanism 96 in a conventional manner. For this purpose a spindle 104 is provided whereby when the handle 98 is mounted on the spindle rotation of the handle will operate the drive mechanism to open and close the skylight depending upon the direction of rotation of the handle. The surfaces surrounding recess 100 in handle 98 are provided with a plurality of ribs and the spindle 104 also has ribs on its outer surface to facilitate alignment and orientation of the handle for desired use when it is coupled with the drive mechanism.
Alternatively, in connection with the present invention a unique actuator pole 106 has been devised to facilitate operation of drive mechanism 96 when it is in a relatively inaccessible position such as on a ceiling or roof structure which is commonly the case. Actuator pole 106 is shown in detail in FIGS. 6-8 of the drawings. Where the actuator pole is to be used, handle 98 is removed from spindle 104 of drive mechanism 96 and is replaced by a hook 108. The hook has a similar recess 110 to recess 100 in the handle including appropriate ribs to facilitate alignment and orientation for use and an appropriate set screw 112 for mounting of the hook on the spindle 104. In this manner, rotation of hook 108 will rotate spindle 104 and accordingly open and close the skylight depending upon the direction of rotation.
Pole 106 is designed for ease of assembly for use and disassembly for handling, transportation and storage. It includes two tubular sections, an upper section 114 and a lower section 116. The two sections 114 and 116 are substantially the same in length and dimension and can be hollow throughout their length as shown or can be provided with recesses on either end. The open upper end 118 of upper section 114 is designed to receive one end of a connector 120. The end 122 of connector 120 which is inserted into opening 118 of section 114 includes four longitudinally extending spaced ribs 124 which are angularly spaced at approximately 90° intervals so that they are at right angles to one another. A pair of aligned openings 126 and 128 are in opposing ribs and are adapted to receive an appropriate fastener 130 which is passed through and aligned opening 132 in the side wall of the upper section 114. By means of fastener screw 130, the connector is coupled with the upper section 114 after having been inserted therein. Ribs 122 are dimensioned so that they frictionally fit with the inner surface walls of the tubular upper section and facilitate coupling of the connector to the tubular section and interconnection therebetween. Extending outwardly from portion 122, inserted in tubular upper section 114, is a closed loop 134. The hole 136 in loop 134 is dimensioned to engage with hook 108 so that when the loop 134 is rotated, the hook 108 will be rotated and accordingly spindle 104 will be rotated.
A handle 138 is designed to be interengaged with the open lower end 140 of lower section 116 in the same manner that connector 120 is coupled with upper section 114. A lower handle portion 142 extends from a coupling portion 144 which is provided with a rib arrangement 146, similar to the ribs on connector 120, for insertion into open end 140 of section 116. Opposing holes 148 and 150 in ribs 146 are positioned to be aligned with suitable openings 152 in the tubular side wall of lower section 116 for passage of a screw fastener 154 through each pair of aligned apertures to removably mount the handle 138 to lower section 116 of the pole.
The two sections 114 and 116 are coupled by means of a spline 156 which has two matching halves 158 and 160 abutting at an annular disc portion 162. Half 158 is inserted in lower end 164 of upper section 114 and the other half 160 is inserted in upper open end 166 of lower section 116. Insertion is complete when the lower edge of upper section 114 and the upper edge of lower section 116 abut against the opposing sides of annular disc 162 substantially at the center of spline 156.
The spline is designed to be coupled with the sections 114 and 116 in the same manner as connector 120 and handle 138 were connected with the sections 114 and 116. Each spline half 158 and 160 is identical as shown in detail in FIGS. 7 and 8 and includes four longitudinal ribs 163 which are angularly spaced at approximately 90° to one another. The ribs 163 are rectangular in configuration having straight edges to facilitate frictional interengagement with the tubular wall on the interior of the upper and lower sections and the coupling of the two sections together in assembling the pole 106. The spaced ribs on the spline and all of the parts inserted into the upper and lower sections of the pole accommodate dimensional variations in the tubular pole sections such as wall thickness and inner diameter thereby facilitating mass production and low manufacturing and assembly cost. The spaces between the ribs will permit deformation of the tubular sections in tight fitting condition in contrast to a tubular to tubular mating arrangement which would not permit any meaningful deformation and would require much closer tolerances. The perpendicular arrangement of ribs 163 can be seen clearly in FIG. 8. A pair of opposing holes 165 are in diametrically opposed ribs for alignment with appropriate receiving holes 167 in the upper and lower section. A suitable screw type fastener 168 can then be passed through the aligned openings to mount the spline to the upper and lower sections 114 and 116 in a quick and efficient manner to complete the assembly of the actuator pole 106.
In use, the pole can be stored in disassembled or assembled condition. If it is in disassembled condition, it can be quickly, easily and efficiently assembled. All that is required is that the two sections 114 and 116 be interconnected through the use of spline 156, as described above, and in a similar manner connector 120 is coupled with the upper end of section 114 and handle 138 is coupled with the lower end of section 116. In that assembled condition, the pole can then be coupled with hook 108 by passing the hook through hole 136 in loop 134. Thereafter, by rotating handle 138 and accompanying rotation of the coupled sections 114 and 116 and connector 120, hook 108 will be rotated. This rotates interconnected spindle 104 and causes the drive mechanism to operate the skylight to open and close it. Naturally, the direction of rotation of the pole will determine whether the skylight is being opened or closed. After use, the pole can be put aside and stored in assembled condition or can be quickly and easily disassembled for transportation and storage. Actuator pole 106 is inexpensively formed of a minimum number of components. All that is required are two tubular sections, a handle, a connector and a spline. Actually, the screw type fasteners for assembly purposes are optional since the rib type structures can all be dimensioned so that frictional interengagement between the ribs and the inner walls of the tubular sections is sufficient to maintain the pole in assembled condition during use.
Both handles 98 and 138 of the above discussed embodiments have similar gripping portions. The details of the gripping portion are depicted in detail in FIGS. 5A and 5B. Each gripping portion includes a knob 170 mounted on a body 172. The knob 170 is mounted on the end of the body and is cup-shaped in configuration with a closed end 174 and an open end 176. The open end 176 is formed as a recess to conform with the end portion 178 of the body 172. Recess 176 has a slightly larger diameter than portion 178 on the body so as to provide clearance for rotation thereabout. The closed end 174 of the knob is provided with an internal pin 180 which extends through a receiving aperture 182 in the end portion 178 of the body during assembly. The tip 184 of the pin 182 is then deformed or enlarged by a convenient means such as spinning to prevent its withdrawal back through aperture 180 due to the presence of an internal shoulder 186 on the interior of the end portion 178 of the body. The deformation of the tip 184 is done in a conventional manner and in a fashion so that clearance is provided between the pin and the body as well as between the closed end 184 of knob 170 and the body 172. Thus, knob 170 is mounted in fixed position on the body 172 and is freely rotatable with respect thereto. The clearance therebetween provides for free rotation and avoids frictional interengagement and undesirable binding and noise occurrence. Also, the clearance between the parts and the cup-shaped configuration of the knob provides a receptacle for lubricant. By lubricating the knob and body in this manner, noise and binding effects are alleviated for extended periods of time. The handle formed in this manner is inexpensive and easy to manufacture and assemble. It is formed of only two components and interconnected by a conventional effecient manner such as the spinning down of the pin to form a rivet like interconnection.
Thus the several aforenoted objects and advantages are most effectively attained. Although several somewhat preferred embodiments have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims.
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A skylight and roof assembly with at least a portion of the skylight adapted to be pivoted by a drive mechanism between open and closed positions with respect to an opening in the roof. At least one hinge is connected to the movable portion of the skylight and the fixed portion of the assembly to permit the pivotal movement. The hinge includes a first leg adapted to be mounted on the movble portion of the skylight in fixed position. The hinge includes a second leg adapted to be mounted on the non-movable portion of the skylight and roof assembly. A flange extends from the second leg and mating surfaces are on the first leg and the flange adapted to receive a coupling pin for pivotally interengaging the first and second leg with the first leg spaced from the second leg by the flange therebetween so that the movable portion of the skylight can be pivoted in a desired manner between the open and closed position. An actuator pole is provided for removably engaging and activating the drive mechanism to pivot the skylight portion. The pole is formed of two separable sections, an upper section and a lower section. A spline interconnects the two sections. A handle is removably connected to the lower section and a connector is removably connected to the upper section and is designed for removable engagement with the drive mechanism so that when the handle is shifted the connector activates the drive mechanism and pivots the skylight.
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TECHNICAL FIELD
[0001] This invention relates generally to a structural member of a work machine and, more particularly, to a particular structure of the structural member.
BACKGROUND
[0002] In work machines, such as backhoe loaders, skid steer loaders, and excavators, substantial forces are transmitted through a member that connects an implement to a frame of the work machine. The member typically includes a boom and a stick, the stick being pivotally attached with the boom. During operation of the work machine, the member experiences heavy forces as the implement penetrates the ground to dig, carries heavy loads from one location to another, or pushes or pulls material. The member, therefore, must be able to endure such heavy forces. The member, however, must also be sufficiently light to prevent the work machine from using most of its available power to manipulate the member. The member, therefore, must have a structural design that combines a heavy-duty construction along with being relatively light weight.
[0003] One known boom design is disclosed in U.S. Pat. No. 6,158,949 issued to Walth et. al. on Dec. 12, 2000. It discloses a boom design having a top boom support structure, a bottom boom support structure, a first lateral boom support structure, and a second lateral boom support structure, which cooperate with each other to define a boom void therein. This boom design requires the attachment of four supporting structures, which creates a heavier boom, increases fatigue due to the additional welding required to manufacture, and is more time consuming to manufacture. This creates a boom design that is expensive to operate due to the additional energy required to manipulate the heavy boom and is more expensive to manufacture due to the additional structures and the additional welding required.
[0004] The present invention is directed to overcoming one or more of the problems as set forth above.
SUMMARY OF THE INVENTION
[0005] In one aspect of the present invention, a structural member of a work machine has first and second-end portions, and comprises, a body having a top portion, a bottom portion, and a middle portion. The top and bottom portions have longitudinal centerlines. The middle portion is positioned between and substantially perpendicular with the top and bottom portions and positioned substantially at the longitudinal centerline of at least one of the top and bottom portions. The structural member further comprises a primary coupling formed with the body at the first-end portion of the structural member and extends from at least one of the top, bottom, and middle portions.
[0006] In another aspect of the present invention, a work machine comprises a frame, a first member, a second member, a primary coupling, and a secondary coupling. The first member has first and second end portions, a top portion having a longitudinal centerline, a bottom portion having a longitudinal centerline, and a middle portion. The middle portion is positioned between and substantially perpendicular with the top and bottom portions and positioned substantially at the longitudinal centerline of at least one of the top and bottom portions. The primary coupling is defined at the first-end portion of the first member for pivotable attachment with the frame, and the secondary coupling is defined at the second-end portion of the first member for pivotable attachment with the second member.
[0007] The present invention is a structural member of a work machine that has first and second-end portions, and comprises, a body having a top portion, a bottom portion, and a middle portion. The top and bottom portions have longitudinal centerlines. The middle portion is positioned between and substantially perpendicular with the top and bottom portions substantially at the longitudinal centerline of at least one of the top and bottom portions. The structural member further comprises a primary coupling formed with the body at the first-end portion of the structural member and extends from at least one of the top, bottom, and middle portions. The positioning of the middle portion between and substantially perpendicular with the top and bottom portions provides sufficient support for the compressive and tensional forces applied to the structural member during normal operation by distributing such forces throughout the structural member. The structural member, therefore, is able to handle heavy-duty applications with a reduced weight configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a side view of a work machine, such as a backhoe loader, incorporating a boom of the present invention;
[0009] [0009]FIG. 2 is a perspective view of the boom of FIG. 1 fabricated as a unitary casting; and
[0010] [0010]FIG. 3 is an exploded view of an alternate embodiment of the boom of FIG. 1 manufactured from various components.
DETAILED DESCRIPTION
[0011] While the invention is open to various modifications and alternative forms, a specific embodiment thereof has been shown by way of example in the drawings and will herein be described in detail. There is, however, no intent to limit the invention to the particular form disclosed.
[0012] Referring to the drawings, FIG. 1 is a work machine 1 , such as a backhoe loader, skid steer loader, or excavator, that has a frame 10 , a plurality of wheels 20 supporting the frame 10 against the ground, and an operator's compartment 30 supported on the frame 10 and positioned substantially above the wheels 20 on the rear-end portion of the work machine 1 . The work machine 1 further includes a front member 40 and a rear member 50 pivotally attached with the front and rear-end portions of the frame 10 , respectively. The front member 40 includes a multi-bar linkage 60 pivotally attached with the front-end portion of the frame 10 and a front implement 70 pivotally attached with the multi-bar linkage 60 . The front implement 70 may be a loader bucket, brush, auger, or other suitable worktool. The rear member 50 includes a boom 80 pivotally attached with the rear-end portion of the frame 10 , a stick 90 pivotally attached with the boom 80 , and a rear implement 100 pivotally attached with the stick 90 . The rear implement 100 may be a bucket, a grapple, or any other suitable worktool. The work machine 1 also includes a first hydraulic cylinder 110 that has a first-end portion attached with the boom 80 and a second-end portion attached with the stick 90 . A second hydraulic cylinder 120 has a first-end portion attached with the boom 80 and a second-end portion attached with the rear-end portion of the frame 10 . It should be understood that the work machine 1 could be of any suitable type that utilizes a boom and not just those enumerated above or the backhoe loader depicted in FIG. 1.
[0013] In FIG. 2, the boom 80 of the work machine 1 is shown in more detail. The boom 80 is made from a unitary casting and includes a body 124 that has a top portion 130 , a bottom portion 140 , and a middle portion 150 . The middle portion 150 is positioned between and substantially perpendicular with a longitudinal centerline 160 , 170 of the top and bottom portions 130 , 140 to define a substantially I-shaped beam. It should be understood that the middle portion 150 could a variety of other shapes, such as V, W, M, or any other shape so long as the middle portion 150 is located substantially along the longitudinal centerline 160 , 170 of at least one of the top and bottom portions 130 , 140 . The boom 80 also includes a primary coupling 180 at a first-end portion 190 of the boom 80 and a secondary coupling 200 at a second-end portion 210 of the boom 80 . The primary coupling 180 includes a boss 220 that is formed as an integral part of the boom 80 and is positioned between the top and bottom portions 130 , 140 , adjacent with the middle portion 150 . The boss 220 allows for the attachment of the boom 80 with the rear-end portion of the frame 10 . The secondary coupling 200 includes bifurcated legs 230 , 240 , a first boss 250 , and a second boss 260 , all of which are formed as an integral part of the boom 80 . The first boss 250 is positioned at the second-end portion 210 of the boom 80 adjacent to one of the bifurcated legs 230 of the boom 80 and the second boss 260 is positioned at the second-end portion 210 of the boom 80 adjacent to the other bifurcated leg 240 . The first and second bosses 250 , 260 allow for the attachment of the boom 80 with the stick 90 .
[0014] Further, the boom 80 includes top and bottom mounts 270 , 280 formed as an integral part of the boom 80 . The top mount 270 includes a top flange 290 positioned on the top portion 130 and a boss 300 formed on the top flange 290 . The top mount 270 is positioned between a midpoint 310 of the boom 80 and the second-end portion 210 . The bottom mount 280 includes a bottom flange 320 positioned on the bottom portion 140 and a boss 330 formed on the bottom flange 320 . The bottom mount 280 is positioned so that the boss 330 is positioned near the midpoint 310 of the boom 80 .
[0015] Finally, the body 124 of the boom 80 includes a curvilinear portion 340 positioned between the midpoint 310 of the boom 80 and the first-end portion 190 . The curvilinear portion 340 is usually positioned a predetermined distance D 1 from the first-end portion 190 and a predetermined distance D 2 from the second-end portion 210 wherein the distance D 2 is greater than D 1 . Alternatively, the curvilinear portion 340 could be positioned so that the distance D 1 is greater than the distance D 2 . The curvilinear portion 340 is formed to position the first-end portion 190 at an inclination of between 20 and 90 degrees with respect to the second-end portion 210 as shown at 350 . It should be understood that the angle of inclination 350 of the first end portion 190 with respect to the second-end portion 210 could be different depending upon the particular work machine on which the boom 80 is attached and the ranges referenced above are not meant to limit the angle of inclination of the first-end portion with respect to the second-end portion.
[0016] An alternative embodiment is depicted in FIG. 3 with reference numbers of previous Figures being used to identify similar components therein. The boom 80 is manufactured from various components through an assembly process and has a first-end portion 400 and a second-end portion 410 . The boom 80 includes top and bottom plates 420 , 430 , and a middle plate 440 welded between and substantially perpendicular with longitudinal centerlines 450 , 460 of the top and bottom plates 420 , 430 , to define a body 124 similar to that of FIG. 2. The top and bottom plates 420 , 430 each include bifurcated legs 470 , 480 , 490 , 500 positioned at the second-end portion 410 . The boom 80 also includes a primary coupling 510 defined at the first-end portion 400 and a secondary coupling 520 defined at the second-end portion 410 of the boom 80 .
[0017] The primary coupling 510 is formed by welding a boss 530 between and with the top and bottom plates 420 , 430 and with the middle plate 440 . When the middle plate 440 is welded with the top and bottom plates 420 , 430 , the top and bottom plates 420 , 430 are longer than the middle plate 440 and extend beyond the middle plate 440 at the first-end portion 400 thus creating a pocket 540 . The boss 530 fits into the pocket 540 and is welded with the top, bottom, and middle plates 420 , 430 , 440 . The primary coupling 510 pivotally attaches the boom 80 with the rear-end portion of the frame 10 .
[0018] The secondary coupling 520 is formed by positioning a curved, outwardly extending intermediate plate 550 between the bifurcated legs 470 , 480 , 490 , 500 and welding it thereto. A first boss 560 is welded between one of the bifurcated legs 470 , 490 of the top and bottom plates 420 , 430 and with the intermediate plate 550 , and a second boss 570 is welded between the other bifurcated legs 480 , 500 of the top and bottom plates 420 , 430 and with the intermediate plate 550 . The secondary coupling 520 pivotally attaches the boom 80 with the stick 90 .
[0019] The boom 80 further includes a top mount 580 and a bottom mount 600 . The top mount 580 is welded with the top plate 420 and is positioned between a midpoint 590 of the boom 80 and the second-end portion 410 . The bottom mount 600 is welded with the bottom plate 430 and is positioned substantially at the midpoint 590 of the boom 80 . The top and bottom mounts 580 , 600 include top and bottom flanges 610 , 620 that are welded with the top and bottom plates 420 , 430 , respectively. Each of the top and bottom flanges 610 , 620 include apertures (not shown) therethrough, and each such aperture has a boss 630 , 635 , 640 , 645 welded to each side thereof.
[0020] Finally, the boom 80 includes a curvilinear portion 650 that is similar to the curvilinear portion 340 in FIG. 2. The curvilinear portion 650 is formed before welding of the components by bending the top, bottom, and middle plates 420 , 430 , 440 and then welding them together. Further, although welding is mentioned as the means for attaching the various components of the boom 80 together in FIG. 3, it should be understood that any suitable means, such as bonding or the like, may be used to achieve similar results.
INDUSTRIAL APPLICABILITY
[0021] During normal operation, the implement 100 , stick 90 , and boom 80 work in unison to effectively perform work functions, such as digging a hole or moving large amounts of material. During this sort of operation, forces are transmitted through the implement 100 to the stick 90 , to the boom 80 , and ultimately to the frame 10 .
[0022] In the embodiment depicted in FIG. 2, the boom 80 is manufactured so that the top, bottom, and middle portions 130 , 140 , 150 form the body 124 as a unitary member. Additionally, the primary and secondary couplings 180 , 200 and the top and bottom mounts 270 , 280 are manufactured as part of the unitary boom 80 . The manufacturing can be accomplished by casting the boom 80 , or another suitable manufacturing process. The casting process reduces the requirement of assembling and attaching four supporting structures required for the box boom, reducing the time and cost required to manufacture the boom 80 . The reduction of the four supporting structures also reduces the overall weight of the boom 80 . Further, the reduction of welding reduces weld-induced stress and fatigue concerns. Finally, the boom 80 of FIG. 2 has a cross sectional I-shape that provides sufficient support for the compressive and tensional forces applied to the boom 80 during normal operation by distributing such forces throughout the boom 80 structure. The boom 80 , therefore, is able to handle heavy-duty applications with a reduced weight configuration.
[0023] Alternatively, as depicted in FIG. 3, the boom 80 can be manufactured from various components while having the same I-shape structure as that in FIG. 2. The middle plate 440 is welded to the top and bottom plates 420 , 430 along the longitudinal centerline of the top and bottom plates 450 , 460 . The primary coupling 510 is assembled and welded to the first-end portion 400 , and the secondary coupling 520 is assembled and welded to the second-end portion 410 . Finally, the top and bottom mounts 580 , 600 are welded to the top and bottom plates 420 , 430 , respectively. Even though there are more components than the design in FIG. 2, the manufacture of the boom 80 still reduces the time and cost because it has fewer components to assemble than other boom designs. Further, because there are fewer components to assemble and attach there is less welding required, therefore, the weld-induced stress and fatigue concerns are reduced. Again, as with the boom 80 of FIG. 2, heavy-duty applications are achieved with a reduced weight configuration.
[0024] As can be see from the descriptions above, the boom 80 can be manufactured as a unitary member or with fewer components that the box boom design requiring four supporting structures. This causes the boom 80 to be less expensive to manufacture, less expensive to operate, and reduces stress and fatigue thereof. Further, the general I-shape structure provides a stronger boom 80 with a reduced weight for increased operational advantages.
[0025] Other aspects, objects and advantages of the invention can be obtained from a study of the drawings, the disclosure and the appended claims.
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Structural members of work machines experience heavy forces and the structural member must be able to endure such heavy forces, but must also be sufficiently light to prevent the work machine from using most of its available power to manipulate the structural member. The present apparatus facilitates the heavy-duty construction along with a reduced weight by comprising top and bottom portions, a middle portion attached between and substantially perpendicular with the top and bottom portions, and a primary coupling formed at a first-end portion of the structural member and extending from at least one of the top, bottom, and middle portions to define a substantially I-shaped structural member.
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BACKGROUND OF THE INVENTION
The invention relates to heat transfer and storage apparatus. Applications include solar heating and cooling applications as thermal storage units which give improved heat transfer to or from the living space. Other applications include heat dissipation housings on machinery parts, engines, and the like.
Thermal storage units in solar heating and cooling applications are generally composed of large bodies of fluid, which are allowed to thermally stratify in a vertical direction. By natural convection currents, this places the warmer fluid near the top of the unit and the cooler fluid near the bottom.
In a vertical cross-sectional analysis of this type of system, one finds a much cooler fluid on one side of the thermal storage unit than on the other. The same is true of the warmer fluid. In a situation where the storage unit is used as an exterior wall of a living space, for example a Trombe wall, temperature transfer in either horizontal direction is not efficient. In heating modes, solar radiated heat is transferred to the top of the fluid area and, thus, to the internal surface toward the living space. In cooling modes, heat absorbed from the living space rises to the top of the fluid space and, thus, is distributed to the external surface.
SUMMARY OF THE INVENTION
The foregoing objects and other objects and advantages which shall become apparent from the detailed description of the preferred embodiment are attained in a heat transfer apparatus which includes an envelope having a vertical cross-section which has an elongated first axial side and an elongated second axial side, the first axial side is disposed at a higher elevation than the second axial side. A fluid is disposed in the envelope which substantially fills the envelope and all of the fluid is substantially in the same physical state. The apparatus also includes means for exchanging heat with the first axial side and means for exchanging heat with the second axial side.
Means may be disposed outside of the envelope which substantially limits movement of fluids which are outside of the envelope, between the first and second axial sides.
The apparatus may be mounted in a module. The module has first and second opposed faces, the first side disposed substantially on the first face and the second side disposed substantially on the second face. The apparatus may further include means for mounting the module for reversal of the first and second faces. The module may include at least some thermal insulation disposed to limit the flow of fluid which is outside of the envelope between the first and second axial faces. The means for mounting may be a pivotal mounting and may have a generally vertical axis. The module may be generally cylindrical. The module may be substantially a parallelpiped and the first and second opposed faces are major faces of the parallelpiped. The means for mounting may include means allowing movement to provide physical clearance to allow subsequent movement to reverse the first and second faces. The means for mounting may include at least one track engaging the means for mounting to allow pivotal motion of the module as well as motion along the track.
In other forms of the invention the apparatus may include an envelope having generally opposed top and bottom faces. The top and bottom faces are generally parallel and mounted to maintain the top and bottom surfaces in substantially oblique relationship to a horizontal plane. A fluid is disposed in the envelope which substantially fills the envelope and all of the fluid is substantially in the same physical state. First and second sides of the envelope are intermediate the top and bottom faces. The apparatus may also include means for exchanging heat with the first and second sides of the envelope.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The invention will be better understood by reference to the accompanying drawing in which:
FIG. 1 is a schematic elevation view of an individual sloped element, showing a convection loop of fluid while heat is being applied.
FIG. 2 is a schematic elevation view of individual sloped element, showing thermal stratification of a fluid.
FIG. 3 is a fragmentary schematic elevational cross-section view of a preferred embodiment of a compartmentalized thermal storage and transfer unit having improved thermal stratification.
FIG. 4 is a plan view of a rotatably mounted thermal storage wall using tubular fluid containers, the rotational mechanism facilitating heating and cooling modes.
FIGS. 5 and 6 are plan views of a rotatably mounted thermal storage having box type fluid containers. A mounting mechanism includes horizontal tracks perpendicular to the exterior wall to allow movement to provide clearance for rotation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is shown a schematic elevational view of an individual sloped element showing a convection loop 10, which has opposed generally parallel sides 12, 14. The side 12 is elongated and lower than the elongated side 14. A bottom 16 is generally parallel to top 18 and is disposed in oblique relationship to a horizontal. Even if there is no physical divider within this structure, such as there would be with an actual piece of pipe disposed in a loop, a convection current indicated by arrows 20, 20 will be set up.
Operation of the invention depends on the thermal stratification of a fluid 24. When a heat source 22 is applied to the side 12 of the loop 10, the fluid 24 disposed adjacent to that side 12 begins to rise. Due to the sloping nature of the top 18, which the heated fluid 24 encounters, the fluid 24 movement becomes oblique, traversing the length of the compartment or loop 10 while following the upward slope. Upon reaching the highest point in the compartment 10, the heated fluid 24 collects, thus effectively transferring heat from the lower left of the loop 10 to the upper right of the loop 10, or from one side 12 of the compartment or loop 10 to the other side 14.
FIG. 2 shows the thermal stratification principal wherein the rhombus shaped element has a triangular upper portion 30 which is generally warmer than a triangular lower portion 32.
Referring now to FIG. 3, there is shown an embodiment of the invention which includes a module 40 having a side 42, which is generally cooler than opposite side 44, which is generally warmer. The module 40 has a plurality of curvilinear dividers 46 which are substantially mutually parallel. The space in between each divider 46 in this three dimensional envelope or module 40 is filled with a fluid. The apparatus in accordance with the invention does not rely on the change of state of a substance, such as from liquid to gas, and, thus, the fluid will be all liquid or all gas at all times during the operation of the cycle of the apparatus.
The dividers 46, which may be flat or straight as in the embodiments shown in FIGS. 1 and 2, force the rising heated fluid 24 toward one side, while the cooler fluid 24 sinks to the opposite side. This results in an even distribution of heat to one vertically oriented surface 44, while the opposite vertically oriented surface 42 gets an even distribution of cooler fluid 24.
For room heating applications the compartment slope will incline towards the living space. For room cooling situations the incline will be towards the exterior of the building. If both modes are needed for seasonal changes, the heating units may be mounted to allow a 180 degree rotation on a vertical axis, as shown in the embodiments of FIGS. 4-6. A full thermal unit may consist of a multiple stacking of these compartments as shown in FIG. 3. The overall effect of this arrangement would be an increased thermal effect on the full surface area of each side.
Referring now to FIG. 4, there is shown an embodiment of the invention utilizing a plurality of generally circular modules 50, which are rotatably mounted. Each of these modules 50 has a side corresponding to the side 42 in the embodiment of FIG. 3 and side comparable to the side 44 of that same embodiment. Thus, the modules 50 may be rotated to provide heat or cooling to a room. It will be understood that the view of FIG. 5 is a plan view and that in this typical installation, glazing 52 will be disposed between the modules 50 and the outside air. The interior of a room will face the opposite side of the modules 50. Each of the modules 50 is mounted on a pivot 54 to facilitate reversal.
Referring now to FIGS. 5 and 6, there is shown another embodiment of the invention wherein a module 60 is generally rectangular. The module 60 has a warm face and a cooler face as in the embodiment of FIG. 3. These faces are the major faces of the module 60 and, as shown in FIG. 5, one such major face is disposed in facing relationship to glazing 62, which separates the module 60 from the outside air, as shown in this plan view. The module 60 is mounted on a pivot 64, which is carried on a track 66. The track 66 allows movement of the entire module 60 away from the glazing 62 so that the module 60 may be rotated to present opposite faces to the inside of a room in which the apparatus is disposed and, of course, to the outside conditions disposed, as viewed, above the glazing 62.
Many modifications and embodiments are possible within the scope and spirit of the invention.
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A fluid thermal storage and transfer unit which includes a fluid conduit which is substantially filled with a fluid which is substantially all of the same state. For example, the fluid may be all liquid. The loop of fluid conduit has first and second axial sections which are disposed at different elevations. Typically, a module incorporating the loop will have the first and second axial sections disposed on opposite sides.
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The invention relates to a method for the manufacture of woven fabric in limited lengths and a device for this method.
BACKGROUND OF THE INVENTION
The manufacture of woven fabric is today done on weaving machines, which pull their warp threads from a warp beam, that is normally prepared for warp-lengths or lot sizes of more than 1000 yards. The warp-beam is a major element for the manufacture of woven fabric. For its own manufacture there is a time consuming and costly process that is relatively independent from the warp length. Therefore only long warp lengths, as indicated before, are economically feasable in the manufacture of woven fabric. For the manufacture of standard fabric, for example for a normal white shirt fabric, it does not matter that the fabric has to be produced in so large lot sizes, because this kind of fabric is always used as a standard fabric. But for the fast moving fashion cycles which often require a huge variety of patterns, the manufacture of a normal warp beam is a handicap, because it is very difficult to forecast how much of a specific fabric will be sold later on.
Therefore it is a requirement today to find an economical process that enables the manufacture of woven fabric in relatively short lengths (small lot sizes), for example in lengths of a few hundred yards and below. A warp beam for such a short length requires so much work, that the woven fabric becomes much more expensive per yard, often so much more, that the manufacture of this fabric is economically not justifiable anymore.
SUMMARY OF THE INVENTION
The purpose of this invention is, to create a method for the manufacture of woven fabric in short lengths, for which the manufacture of a special warp beam is not economical or takes too much time.
According to one aspect of the invention there is provided a method with the following steps:
laying a layer of warp threads on a warp frame having a size which is determinative of the limited length of the fabric and holding said warp threads on said warp frame,
moving said warp frame to a weft insertion mechanism having a shed forming device,
laying weft threads into said warp threads while operating said shed forming device,
transporting said warp frame having a completed fabric thereon to a fabric removal station, removing said completed fabric from said warp frame.
For the method according to this invention no warp beam is needed. For laying of the warp threads in the warp thread station a warp frame is used, over which length the warp threads are layed and held onto the warp frame.
For the laying of the warp threads over the warp frame the known technologies for drawing-in (EPPS 460129B1, EP 0391612) and/or for weft-insertion (DEPS 3821224) can be used, i.e. in the first process-step a parallel laying of threads is done in a way like weft-threads are layed, these threads are then used as the warp threads for the subsequent manufacture of the woven fabric. Also for holding of the threads at the warp frame known technologies can be used, for example the known clamping of warp-threads in drawing-in-machines (WO 93/06282, DEAS 2625746, U.S. Pat. No. 3,523,432).
This so manufactured semi finished product in form of a layer of next to each other laying warp threads within the warp frame is then completed, by bringing in of the warp frame by means of the first transfer step into the weft thread insertion mechanism. Here, within the weft thread station the shed formation is done with a known shed forming-device (e.g. shed forming comb elements with guide bars, heddle shafts with heddles, Jaquard heddles.) If weaving heddles or Jaquard heddles are used, they are already interspersed with the warp threads in the warp thread station. The warp-frame is thereby, with the warp threads that are held by it, prepared for the shed formation and the laying of the weft threads, which are then layed in a known fashion and the beaten up to the fabric fell. Thereby, the fabric is manufactured within the warp frame up to the length and width that is determined by the warp frame. The beating up of the weft thread onto the fabric-fell can be done with a closed reed, which would also be already interspersed with the warp-threads in the warp-thread-station, as well as with an open reed (reed-comb). In this way a piece of woven fabric is manufactured without the need of a warp beam.
Woven fabric for apparel and other end uses can thus be manufactured very quickly in the required sizes and patterns, because the warp frames can be big enough to allow the manufacture of large enough pieces of fabric. The finished fabric can be taken out of the warp-frame and can directly be used for the manufacture of pieces of apparel. It is also possible to do the necessary cutting of the fabric already within the warp frame. After taking out the fabric or the remaining fabric-pieces after cutting, the warp frame is reused for laying of warp threads in the warp thread station.
The fabric in the warp-frame can also be run in its semi-finished state through further processes like they are used for the manufacture of woven fabric today, like sizing of the warp threads before the weft-insertion or finishing processes of the completed fabric.
A major advantage of the invented method is the fact, that small lot-sizes (relatively short fabric-lengths) can be manufactured economically, which is not possible by using a warp-beam. The manufacture of a warp beam consists of preparation-costs that are relatively independent of the warp-lengths, and thereby grow in importance the shorter the woven fabric is. The required long fabric lengths of today also lead to extensive ware housing which in turn lead to a very long total throughput time from the start of the process up to the end product in form of a finished piece of apparel. This total through-put time can be drastically reduced by the invented manufacturing method, because relatively short fabric lengths can be manufactured according to a certain customer demand.
The invented manufacturing-method facilitates thereby in a decisive way the economical manufacture of woven fabric and the resulting fabric-samples that have to follow the fast moving changes in fashion. This is achieved, because on the one hand as described above the relatively short fabric lengths enable a quick reaction to individual customer demands and on the other hand make a quick reordering of a fabric possible which is required, if a fabric or the resulting piece of apparel sells better than expected. This quick reaction until today was impossible in an economical way, although it is already a requirement of retailing for a long time. The invented manufacturing method will lead to an enormous increase in speed and flexibility for the entire textile chain and can lead to bringing back a lot of textile jobs into high labour cost countries.
It is possible that the wrap-frame holds the layer of threads taut or slack. Especially during the transfer steps the warp threads may be held slack, what could possibly lead to a space saving. In addition the slack holding may be helpful during sizing or the finishing-processes. Nevertheless the layer of warp threads has to be held at least partially taut where the weft threads are layed.
Especially in the warp thread-station the laying of the warp threads can be done essentially in a vertical direction, hereby gravity can be used to help guiding and straightening the warp-threads. This may also lead to a space saving compared to the horizontal positioning. But it is also possible to use the horizontal positioning for the whole method.
It is also possible to link up the warp threads of two warp frames by using a conventional knotting machine. This could help to eliminate the need to intersperse the needles and the reed in the warp thread station. The shaft of the warp frame would then be removed after knotting and before tuning through the weft thread station.
The device for the above described method consists mainly of the mentioned warp frame, that can be carried out in several different ways. At first it is necessary to provide at least two strips, shafts or rails with thread-holding-devices to face each other, that are holding the layer of warp-threads. In this case this strips, shafts or rails have to be held at the required distance from each other through special means, while the thread holding devices ensure that the threads can not slip off.
If a fixed frame should be used for carrying out this manufacturing method then the two facing strips, shafts or rails are connected by two bridges that are holding the strips, shafts or rails at a fixed distance to each other. The result is a fixed object, that is advantageous especially for short frame lengths.
It is also possible, to arrange the strips, shafts or rails in such a way, that they are moveable between the distance that is defined by the length of the held warp threads and a shorter distance. This is helpful, when for example the layer of warp threads is at first layed taut over the warp frame and after that the next transport is done, in a slack way. In the latter case the layer of warp threads would then hang below the strips, shafts or rails. Hereby it is also possible to form at least one of the strips, shafts or rails as a rotatable cylinder. This can help to save space, for example in the weft thread station. If only one cylinder is rotatable, it is possible to use a conventional practice thread carriage like it is used in warp knitting that runs across the warp frame from one side to the other, in which case through unwinding or onwinding of the previously layed warp-threads one shot after the other is layed continuously in such a way, that the fabric is formed. Hereby it is of course necessary, that one of the cylinders either the rotatable or the non rotatable moves towards the other or away from it, i.e. it has to be linked to a transfer mechanism. It is also possible, that both shafts or cylinders are rotatable, which would give the same effect regarding the space-saving, but without needing, to move one of the cylinders relative to the other. Hereby it has to be taken into account, that such an arrangement could be easier to retrofitt into existing weaving machines with their drive mechanisms for the warp beam.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail below by means of exemplary embodiments and the drawings:
They show:
FIG. 1 a mechanism in principle perspective view, that works according to the method,
FIG. 2 a plant according to FIG. 1, equipped with heddle shafts and heddles,
FIGS. 3A-3C are side views illustrating a warp thread station, a weft thread station and a take-out-station.
FIG. 4 is a perspective view of a warp thread station in a vertical position,
FIG. 5 is a perspective view of an arrangement for clamping of the warp threads,
FIG. 6 a sectional view along the line V--V from FIG. 5,
FIG. 7 is a side view of a layer of warp-threads held slack,
FIG. 8 is a side view of a layer of warp-threads held taut,
FIG. 9 is a side view of a warp frame consisting of two shafts, where one shaft is rotatable as a turnable cylinder,
FIG. 10 is a side view of a warp frame similar to FIG. 9, where both shafts are formed as rotatable cylinders,
FIG. 11 is a perspective of the addition of the process step of sizing,
FIG. 12 the process step of finishing,
FIG. 13 is a perspective view of the process step of cutting.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 a plant according to the invented method is shown, that contains the warp thread station 1, the weft thread-station 2 and the take-out-station 3. In each of these stations a warp-frame 4 is shown, that consists of the two shafts 5 and 6 and of the connecting bridges 7 and 8. Within the warp thread station 1 warp-threads 9 are layed over the warp-frame 4, by operating the insertion mechanisms 10 and 11 that work like normal weft insertion- and/or drawing-in mechanisms, which in this case lay threads, that are used as warp-threads for the final fabric later on. Hereby the warp-threads are held in the area of the shafts 5 and 6 for example by holding-devices like they are shown in FIGS. 5 and 6. Through moving of the warp-frame 4 relative to the insertion-mechanisms 10 and 11, a layer of warp-threads is layed continuously over the whole warp frame until the frame is full. Hereby it is of course necessary to move the warp frame 4 to the right, where enough room has to be provided for this movement. Finally the warp frame is moved into the position that is indicated by dotted lines.
The warp frame 15 now holding a layer of warp threads, in FIG. 1 shown in dotted lines with dotted warp threads and is then transfered by the first transfer step into the weft thread station 2. Hereby conventional weft-thread-insertion-mechanisms 12, 13 with common devices for the shed formation and the beat-up onto the fabric fell are used, which now lay the weft threads 14 across the previously layed warp-threads 9, whereby the woven fabric is created. In this station the here located warp frame 15 is moved along the weft-thread-insertion-mechanisms 12 and 13, so that finally the whole warp-frame 15 is filled up with completed fabric. The warp frame 15 is of course the same "warp-frame" like it is marked with reference 4 within the warp thread station.
After complete laying of the weft threads 14 in the weft thread station, the moving out of the warp-frame is done by means of the second transfer step into the take out station 3, where the fully produced fabric can be removed from the warp frame. The production process for the desired woven fabric is now in principle complete.
For the transport of warp frame 4 respectively the warp frame 15 conventional transport-belts used, whose detailed design does not matter within the context of this invention, i.e. conventional transport systems are employed.
FIG. 2 a plant is shown that is almost identical to the plant shown in FIG. 1, where only the heddle shafts 16, 17 and 18 that are normally used for the weft insertion are drawn in. The other shown moduls in FIG. 2 are the same as in FIG. 1 and are therefore marked with the same references. The heddle shafts 16, 17 and 18 are held by carriers, that are marked in the area of the warp thread station with the references 19 and 20. They are provided on both sides of the warp-frame. Before the start of the production process, the frame 4 is fitted with the heddle shafts 16, that are then running through all stations, and at the end of the take out station 3 are also taken out, to be refitted into another warp frame in the warp thread station. In the heddle shafts 16, 17 and 18 in the heddleshafts used wires 21 are shown. Regarding the functioning of the plant in FIG. 2 it is referred to the descriptions for FIG. 1.
In FIGS. 3A-3C the sequence of the method is shown in three diagrams A, B and C, that are drawn superimposed over each other, which show in a way the arrangement of FIGS. 1 and 2 in side elevation, whereby stations 2 and 3 are visible (station 1 is hidden by the warp-frame 4 shown in FIG. 3A, that in this figure is in a holding-position in front of station 2. Its holding-position is indicated in FIGS. 1 and 2 by the dotted lines).
FIG. 3A shows the warp-frame 4 with the heddle shafts 16 in the above mentioned holding-position, while warp frame 15 is in the area of the weft thread insertion mechanism 12, i.e. in the weft thread station 2. The frame 15 has already arrived at the end of the weft thread insertion process, by way of transport belts, which will be described further below. At first the warp frame 15 is moved into the take out station 3 and then the warp-frame 4 is moved into the station 2, which is shown in FIG. 3B. In this weft thread station 2, the warp frame marked with the reference 4 is filled with the weft threads, which are inserted across the warp threads. For this purpose the heddle shafts 16, are now connected to the weft thread insertion-mechanisms 12 and 13 (13 is not visible in FIG. 3B), so the weft threads can be woven in a conventional manner as already described above. After this the previous warp-frame 15 moves further to the right, which can be seen in FIG. 3C. In FIG. 3B the previous totally fabric filled warp frame 15 can also be seen in the take-out station 3, where the finished fabric can be removed out from the warp frame, whereupon the warp frame is transfered back to the warp thread station that is shown in FIGS. 1 and 2. This happens, while a warp frame is within the weft thread insertion mechanisms 12 and 13, as like it is shown in FIG. 3C, i.e. during the operating phase according to FIG. 3C, the warp-frame that is shown on the right side is taken away from the transport system and transferred to warp thread-station shown in FIGS. 1 and 2, if it is not planned for further processes within the warp-fame like finishing processes or cutting.
For the transport of the warp-frames 4 and 15 in the FIGS. 3A-3C controlled transport belts are planned, which move the warp-frames, where certain transport belts can be moved into and out of action by lifting them up or lowering them down. According to FIG. 3A the warp frame 4 is moved by transport belt 22 with the belt rollers 23 and 24, but the movement only starts if the previous warp frame is already moved out of the weft thread station 2. The warp frame 15 within the weft thread station 2 is moved by transport belt 25 with the belt-rollers 26 and 27, because transport belt 25 is in a higher position than transport belt 22. The warp-frame 15 is there also above the third transport belt 28 with the belt rollers 29 and 30, which takes over the warp-frame 15 after it has completely run through the weft thread, station 2, by lifting-up (see FIG. 3B) into a position so that transport belt 28 is above transport belt 25. With the transport belt 28 the warp-frame 15 is moved into the end-position, that is shown in FIG. 3B within the take-out station 3. While this is happening, a new warp frame 4 is moved into the weft thread station, as already explained. For this, the transport belt 22 was lifted up, lifting the warp frame 4 as it is shown in FIG. 3A, which is then out of reach for transport belt 25. After moving in of the warp frame 4 into the area of the weft thread insertion mechanism 12, the transport belt 22 is lowered down, so that the transport belt 25 now overlaps the warp frame 4, as it is shown in FIG. 3C.
The warp-frame that is in the weft thread station 2, is then exposed to the operation of the weft thread insertion mechanism 12, that now weaves the weft threads into the warp threads, that are held by the warp frame, until the warp-frame gets to the position that is marked with reference 15 in FIG. 3A. While the weft threads are layed within the weft thread station 2, the finished fabric is taken out of the warp frame that is in the take-out-station 3, and this frame is then transfered back to the warp-thread-station as already explained above (see FIGS. 1 and 2).
FIG. 4 shows another version of the warp thread station according to FIGS. 1 and 2, where the warp-threads 9 are layed in a vertical direction by the insertion-mechanisms 10 and 11. This can be mandated when the floorspace is limited, and in addition this may lead to an energy saving. In the fist transfer-step a transfer into the holding-position that is shown in dotted lines in FIGS. 1 and 2 is then necessary for which a conventional transfer mechanism can be used, of which the design is not relevant here.
FIG. 5 shows an example for the execution of an arrangement for clamping of the warp threads, which, as indicated above, comes into effect during the laying of the warp threads in the warp thread station 1 (see description to FIG. 1). The clamping arrangement uses the shafts 5 and 6 according to FIG. 1 in the form of the halfround shafts 31 and 32, where halfround shaft 31 is held stationary, while halfround 32 is pressed continuously further against half-round shaft 31 by the lifting-device 33, depending on the progress of laying the warp threads. The warp threads are layed by the insertion-mechanisms 10 and 11 from FIG. 1 over an additional device, in form of chain 34 with individual holders that are each equipped with a single clamp on either side, are then clamped and cut (DE-AS 26 25 746) so each holder is then holding one warp-thread, which is now moved into the area of the halfround shafts 31 and 32, where the clamps on the holders 35 are opened in a controlled movement, so the warp threads are layed next to each other with the required distance, are preclamped by the half round shafts 31 and 32 and are finally fully clamped by bringing both half round shafts completely together.
FIG. 6 shows a sectional view along the line V--V from FIG. 5. It shows the two half round shafts 31 and 32, of which halfround shaft 31 is equipped with an elastic strand 36, which presses onto an inserted thread, preclamps it at first and finally fully clamps it by bringing both half round shafts completely together.
FIG. 7 shows a warp in a slack manner, held by two shafts 5 and 6, hanging loosly between them. If the two shafts 5 and 6 are moved away from each other, the position shown in FIG. 8 results, where the warp-thread 9 is shown taut. The tautness is kept by the bridge 8. In FIGS. 9 and 10 two variants of the shafts which are belonging to the warp-frame are shown, where in FIG. 9 one shaft is formed as a rotatable cylinder and in FIG. 10 both shafts are formed as rotatable cylinders 37 and 38. With turnable cylinders like the ones shown, different distances for the two shafts of the warp frame are possible. In FIG. 11 it is shown in a schematic way, how directly after the warp thread station and before the holding-position a sizing-bath is introduced, that is used for the sizing of the warp threads which were layed into the warp frame within the warp thread station. In the holding position a dryer 40 can be seen, that is used for drying of the sized warp-threads.
FIG. 12 shows a finishing station, that can be introduced between the weft-thread-station 2 and the take-out-station 3. In this finishing station 41, the completely woven fabric is guided over several guide rollers through a set of different baths, as they are known to be necessary for finishing processes. The transport of the woven fabric 42 is done by transport belts 43 and 44, that are running on top of each other and are guiding the woven fabric through the sequence of the different baths. The transport belts 43 and 44 are made of liquid-permeable material, as for example, a kind of net or a perforated rubber belt. The woven fabric 42 is guided through the finishing station 41 in individual pieces (i.e. warp-frames), where the beginning and the end are guided by the shafts 5 and 6 from which the distance holding bridges 7 and 8 were removed, so that the woven fabric can be transported over the different guide-rollers through all baths without a problem.
At the exit of the finishing station the dryer 45 is shown, that is drying the processed woven fabric.
FIG. 13 shows in a schematic way a cutting station, that can be introduced before or within the take-out station 3. With the rotating knife 47, that is moved by the controller 46 across the woven fabric which is still held by the warp-frame 15, the desired piece of fabric can be cut out according to a pattern-chart or electronic cutting data. For this, the warp frame 15 is put onto the cutting table 49, of which the surface holds against the woven fabric 48 from one side, so the knife 47 has a good counter point while cutting from the other side.
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A method for manufacturing a woven fabric having a limited length comprising the following steps: laying a layer of warp threads on a warp frame having a size which is determinative of the limited length of the fabric and holding said warp threads, on said warp frame, moving said warp frame to a weft insertion mechanism having a shed forming device, laying weft threads into said warp threads while operating said shed forming device, transporting said warp frame having a completed fabric thereon to a fabric removal station removing said completed fabric from said warp frame.
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BACKGROUND OF THE INVENTION
This invention relates generally to repair of sewer lines, and more particularly to simple and effective apparatus and method to inexpensively repair such lines.
In the past, fracturing of clay pipe lines necessitated digging up the line along its length, removing the old pipe, installing new pipe, and filling in the dirt and repairing the overlying road surface. This was a very expensive operation, and one that hardly warranted such expense and effort where the clay pipe line was fractured in only a few places.
SUMMARY OF THE INVENTION
It is a major object of the invention to provide method and apparatus to repair such lines without digging up the line, thus saving great expense and effort.
Basically, the method employs a liner sleeve and elastomer sleeve extending about the liner sleeve, and a filler slurry, and includes the steps:
(a) installing the liner sleeve and said elastomer sleeve end wise in the sewer line to locate the two sleeves in bridging relation with the fracture, and
(b) displacing slurry into a space formed between the two sleeves to cause the elastomeric sleeve to expand and seal against the sewer line in bridging relation with the fracture.
The slurry is typically displaced radially through the liner sleeve into the space between the sleeves and via a fixture which is releasably attached to the liner sleeve to travel therewith in the sewer line, the fixture being detachable from the liner sleeve and recoverable after slurry displacement is accomplished.
Further, a drag system may be employed to drag the two sleeves endwise in the sewer line to the fracture location, and the drag system may then be released for recovery thereof. The positioning of the drag cable may be correlated to the position of a scanning camera used to preliminarily locate the fracture, whereby the position of the fracture may be accurately determined so that the elastomer sleeve may accurately bridge the fracture.
These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following description and drawings, in which:
DRAWING DESCRIPTION
FIG. 1 is a vertical elevation, in section, showing details of installation of a liner and elastomer sleeve unit;
FIG. 2 is an enlarged elevation, in section, showing details of a puller unit;
FIG. 3 is an enlarged vertical elevation showing details of a fluid connector releasably attached to a liner and sleeve unit;
FIG. 4 is a section, in elevation, on lines 4--4 of FIG. 3;
FIG. 5 is a fragmentary plan view on lines 5--5 of FIG. 3;
FIG. 6 is an enlarged vertical elevation showing sealing off of a fracture in a clay pipe line, employing the liner and sleeve unit;
FIG. 7 is an enlarged fragmentary section showing a flow smoothing ring on the liner and sleeve unit;
FIG. 8 is an enlarged fragmentary section showing end-to-end interconnection of two liner and sleeve units; and
FIG. 9 is a view like FIG. 6, showing application to a branching clay pipe line.
DETAILED DESCRIPTION
Referring first to FIG. 1, sewer line 10 has clay pipes 11 laid end-to-end, under the ground surface 12. When one or more of the pipes developes a fracture, as at 13, the problem of how to economically repair the line is presented.
In accordance with the invention, a liner and elastomer sleeve "pig" unit 14 is employed, and is introduced underground, or via first manhole 15, well 16, and the clay pipe line, to be traveled endwise therein to the location of the fracture. See FIG. 1, showing a puller cable 17. The latter is first introduced downwardly in well 16, through the pipe line 10, and run up second well 16a through manhole 15a to winch 18 on a vehicle or truck 19. As winch 18 is rotated by motor and drive 21, the cable 17 is pulled endwise, to pull unit 14 underground and along the pipe line to the location of the fracture. That location may first be determined as by a television camera 22 advanced endwise by the cable in line 10. Idler drums 23-26 and associated frames 23a-26a may first be installed in and above the wells 16 and 16a, as shown, so that the unit 14 may be pulled endwise down well 16, around drum 24, and endwise in the pipe line 10, and so that the cable will travel in the same manner, as well as up well 16a, around drum 26, and onto the winch 18. The length of the cable 17 extended when camera 22 locates the fracture may be noted and used to subsequently register the unit 14 across the fracture.
The unit 14 may be attached to the cable as by a tubular container shell 28 closely fitting endwise within the bore 29a of a liner sleeve 29 of unit 14 (see FIG. 2). The wall 28a of shell 28 is shown as of bellows shape, to expand and grip bore 29a in response to air pressurization of the shell interior 28b, air supplied via hoses 30 and 30a extending from a surface pressure source 31, and controlled by valve 32. When the valve 32 is closed, pressurization of bellows wall 28a ceases, and cable 17 and container 28 may be pulled free of the installed unit 14, as by operation of winch 18. A snap release connection of the air hose 30a to container wall 28a is shown at 33.
The unit 14 also includes an elastomer sleeve 34 attached to and extending about the liner sleeve 29, as for example as shown in FIGS. 1 and 6. Metallic bands 35 and 36 at opposite ends of the unit 14 annularly hold the ends of the elastomer sleeve tightly and sealingly against the circular surface of the lower sleeve, and in travel mode, the elastomer sleeve 34 fits closely about a cylindrical surface 29b of sleeve 29, between the bands.
FIG. 6 shows the unit having arrived at the fracture in the clay pipe sewer line. It is brought into bridging relation with the fracture, as shown. At that point, slurry 37 is displaced into a space between the sleeves and under pressure, to cause the sleeve 34 to expand outwardly and seal against the bore 11a of the sewer line pipe that is fractured, to establish an annular seal against the bore and bridging the fracture. Thereafter, the liquid contents of the line flow through the liner pipe 29, which becomes anchored to the sewer line due to the liner 34 expanding into the fraction and held there by hardening of the slurry 37 in the space 38. Typical slurries include resin which polymerizes in situ in space 38, as for example epoxy resins, and grout, and a catalyst if required.
FIGS. 3-6 show means for feeding slurry and grout components in two lines or hoses 40 and 41, and a catalyst in hose 42, extending from the surface to the unit 14. These components are fed together or blended in a mixer fitting 43 (see FIG. 5), and then fed in a bore 44 upwardly at 44a and through an attachment fitting 45 into space 38. Fitting 45 may be a grease type fitting thread connected to the wall of liner 29, as at 46. See also surface control valves 40a 41a and 42a.
Mixture fitting 43 is releasably connected to wall fitting 45, so that fitting 43 can be removed, i.e. pulled free of the unit 14, after slurry delivery to space 38. As shown, the duct 44a is within a short stroke plunger 50 urged upwardly by air pressure to grip the lower end 45a of the fitting 45, as during travel of unit 14 into FIG. 6 position, and during delivery of slurry components into space 38. Such air pressure, delivered by hose 30, is exerted upwardly against a piston 51 slidable in cylinder 52, and connected to plunger 50. At such times as disconnection and retrieval of the fitting 43 and associated apparatus is desired, the air pressure is shut off, as by closure of the valve 32, which causes the plunger 50 to release from the fitting 45. The fitting 43 may then be pulled leftwardly in FIG. 3, so that the fixture 45 lower end flange 45b slides out of a slot 54 in fixture 43, the latter then being pulled out of the sewer by operation of winch 55 reeling the hoses 30, and 40-42.
FIG. 7 shows an elastomer or rubber ring 56 attached to the forward traveling end of the unit 14, and having a flaring bore 56a, to cause sewer liquids to flow into the interior 14c of unit 14, as unit 14 travels rightwardly in FIG. 7. Note that the annular outer edge 56b of ring 56 travels closely adjacent the bore 11a of the sewer line clay pipe 11.
FIG. 8 shows the use of an elastomer annulus 59 fitting over the end of one unit 14d and over the end of a previously installed unit 14e to establish a seal therebetween. When unit 14d is pulled toward and endwise against unit 14e, the annulus 59, installed on either unit, fits over the other unit.
FIG. 9 shows a modified unit 14f, like unit 14, but having a side opening 60 to register with a branch passage 61 in a clay pipe 62.
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The repair of a sewer line having a fracture, and employing a liner sleeve and an elastomer sleeve extending about the line sleeve, and a filler slurry, includes:
(a) installing the liner sleeve and the elastomer sleeve endwise in the sewer line to locate the two sleeves in bridging relation with the fracture, and
(b) displacing slurry into a space formed between the two sleeves to cause the elastomeric sleeve to expand and seal against the sewer line in bridging relation with the fracture.
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FIELD OF THE INVENTION
The present invention relates to carbon dioxide absorbents for use in a gaseous stream, and more particularly to absorbent particles comprising calcium hydroxide and a rheology modifier for improving processing of the absorbent composition and enhancing its carbon dioxide absorption performance when formed into particles.
BACKGROUND OF THE INVENTION
A carbon dioxide absorbent is typically produced by mixing hydrated lime, Ca(OH) 2 , with water and optionally a small amount of sodium or potassium hydroxide to form a paste, which is then extruded or molded into particles, in granular or pellet form, approximately 2-3 mm in diameter and 2-5 mm in length. So-called soda lime absorbents are typically used in hospital operating rooms for inhalation anesthesiology, in recovery room re-breathing devices, and in underwater breather systems and devices. They are loaded in loose particulate form or contained within convenient disposable cartridges.
To indicate the progressive exhaustion of the absorbent, a color indicator dye which is sensitive to pH, such as diethyl violet (DEV), is added during manufacture. The dye in this case changes from a colorless state to the color purple as absorption proceeds. The state of substantial exhaustion of the carbon dioxide absorption capacity is indicated by a deep purple color. However, when the absorbent is allowed to sit idle for several hours or more after usage, the purple color can slowly fade and revert to a near colorless state. This renders it difficult for medical personnel to ascertain the absorption capacity remaining, although the purple color will eventually return when the absorbent is again exposed to carbon dioxide.
Thus, it is an objective of the present invention to prevent or minimize the reversion to colorlessness of the indicator dye.
Another objective of the present invention to prevent or minimize degradation of certain anesthetic agents. Carbon dioxide absorbents such as soda lime can cause certain anesthetic agents (e.g., sevoflurane) to degrade slightly by extracting an HF molecule to form an undesired olefin byproduct referred to as “Compound A” with the formula CF 2 ═C(CF 3 )OCH 2 F. Soda lime that contains extremely low levels of moisture can also cause other volatile anesthetic agents, such as desflurane, enflurane, and isoflurane, to degrade and form carbon monoxide.
It is also an objective of the present invention to provide a calcium hydroxide-containing absorbent that minimizes the degradation of certain volatile anesthetic agents to either Compound A (an undesired byproduct) or carbon monoxide.
U.S. Pat. No. 4,407,723 of MacGregor et al. disclosed a method for making carbon dioxide absorbents. Pure calcium hydroxide and water were mixed into a paste, extruded through a grate (e.g., meat grinder), air-dried into hardened granules, and then sized through sieves to obtain uniform size. Subsequently, an aqueous solution containing sodium hydroxide, potassium hydroxide, calcium chloride, and water was sprayed and absorbed onto the granules. Thus, the method required an extra manufacturing step, and also did not guarantee that all surfaces of the particles were sufficiently treated.
Thus, it is another objective of the present invention to provide for convenience and efficiency in the manufacturing of absorbent particles.
In U.S. Pat. No. 6,228,150, Armstrong et al. disclosed a carbon dioxide absorbent that included calcium hydroxide and a “humectant.” The humectant was considered to be either “hygroscopic” (which meant that it absorbed atmospheric water) or “deliquescent” (which meant that it absorbed atmospheric water and dissolved in the water thus absorbed). Preferred by Armstrong et al. was calcium chloride as a humectant. Armstrong et al. also wanted their calcium hydroxide-based absorbents essentially free of sodium and potassium hydroxide, purportedly to avoid carbon monoxide and Compound A arising from degradation of anesthetic agents.
Thus, it is a further objective of the present invention to avoid substantial degradation of anesthetic agents, while also providing the option of employing sodium and/or potassium hydroxide in the absorbent composition to improve carbon dioxide absorption efficiency.
Thus, a novel absorbent composition and method of manufacture are needed to avoid certain disadvantages of the prior art as mentioned above.
SUMMARY OF THE INVENTION
In surmounting the disadvantages of the prior art, the present invention provides carbon dioxide absorbent particles formed from a composition comprising calcium hydroxide, water, and a rheology modifier. The rheology modifier is a phosphonic acid or salt thereof. The absorbent particles have excellent absorption performance and can be conveniently and efficiently manufactured using conventional equipment.
Other exemplary absorbent particles of the invention further comprise sodium hydroxide and/or potassium hydroxide, calcium chloride, a pH-sensitive color indicator dye (e.g., diethyl violet), or a mixture thereof. Surprisingly, the incorporation into the particle matrix of sodium and/or potassium hydroxide, in combination with calcium chloride and color indicator dye, has numerous benefits in terms of anesthetic agent compatibility, color dye steadfastness, and extrusion efficiency.
For example, the present inventor finds that when calcium chloride is incorporated in an amount of 0.25-3.0% by total dry weight of absorbent composition, the color indicator dye (e.g., diethyl violet) does not lose color after color indication is achieved. Although the addition of calcium chloride to a wet calcium hydroxide paste can otherwise lead to agglomeration and stiffening of the paste mixture in the mixing and extrusion equipment, the use of a phosphonic acid/salt rheology modifier facilitates the mixing and extrusion processes and results in particles having strength, excellent pore structure, and crush resistance. Moreover, the particles do not create odors or demonstrate initial (dis)coloration and exhibit excellent carbon dioxide absorption performance.
An exemplary method of the invention comprises mixing the calcium hydroxide, water, and rheology modifier together, optionally with sodium and/or potassium hydroxide, calcium chloride, and color indicator dye, to form a paste; extruding or molding the paste into a plurality of particles; and allowing or causing the particles to harden.
Additional advantages and features of the present invention are described in further detail hereinafter.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
An exemplary carbon dioxide absorbent of the present invention comprises calcium hydroxide in an amount of 83% to 99%, and a rheology modifier in an amount of 0.05% to 5.0%, all percentages herein being based on total dry weight of the absorbent composition. The phrase “total dry weight” as used herein shall refer to the composition, after the components are mixed together with water to form a paste, formed into a plurality of particles while in paste form, and oven dried so that water content is less than 0.1% by weight.
Therefore, unless indicated otherwise, all percentages set forth herein are based on the total dry weight of components (excluding water moisture) in the hardened or solidified absorbent and expressed as “% dry wt”. The percentage of water shall be expressed in terms of percentage total weight (“% total wt).
In further exemplary absorbent compositions, sodium hydroxide, potassium hydroxide, or a mixture thereof, in the amount of 0.01% to 6.0% dry wt, more preferably 0.1% to 2.0% dry wt, and most preferably 0.1 to 1.0% dry wt can be incorporated into the absorbent composition.
Still other exemplary absorbents of the invention comprise calcium chloride and a pH-sensitive color indicator dye. For example, calcium chloride can be incorporated in the amount of 0.1% to 6.0% dry wt, more preferably 0.25% to 3.0% dry wt, and most preferably 0.5 to 2% dry wt; and a pH-sensitive color indicator dye can be incorporated in the amount of 0.01% to 0.5% dry wt, more preferably 0.02% to 0.2% dry wt, and most preferably 0.02 to 0.1% dry wt can also be incorporated into the absorbent composition. When calcium chloride is intimately incorporated into the absorbent composition matrix in an amount of at least 0.5% dry wt, the present inventor finds that pH-sensitive color indicator dyes, such as diethyl violet (“DEV”) and thiazol yellow G, will not revert to a colorless state when sufficient amounts of carbon dioxide have been absorbed in the composition and the pH-sensitive color dye has changed (in the case of DEV to a dark purple). Other acceptable dyes include ethyl violet, basic violet, Clayton yellow, direct yellow 9 and Titan yellow.
The absorbent particles of the invention are preferably processed by mixing the raw materials together to form a paste, then extruding the paste through a die into granular particles having an average length of 1-10 mm and an average width of 0.5-5.0 mm. Alternatively, the particles may be molded or pelletized using trays or molds. The particles are allowed to dry (in ambient air) or caused to dry or harden (by heating in an oven) so that they can be packed into bags, containers or cartridges. After being allowed or caused to harden, the particles are then sieved to obtain the desired particle sizes and then rehydrated by spraying water onto their outer surfaces to ensure that they have sufficient water content (5-25% by total weight of absorbent, more preferably 12-19%) to facilitate absorption of carbon dioxide. Typically, absorbent particles are used in a 4-8 mesh granular size (e.g., 2.36-4.75 mm mesh size openings), although 6-12 mesh granular sizes (1.70-3.35 mm mesh size openings) may also be used. It is contemplated that absorbent compositions of the invention are ideally suited for making particles having similar average size when conventional mixing and extrusion or molding methods are employed for forming the absorbent into particles for use in inhalation anesthesiology devices and other rebreathing devices.
A preferred rheology modifier suitable for plasticizing exemplary absorbent compositions of the present invention is phosphonic acid or a salt thereof. Exemplary phosphonic acids or salts include the following:
amino tri (methylene-phosphonic acid) (which is synonymous with phosphonic acid, nitrilotis (methylene) tri) amino tri (methylene-phosphonic acid), pentasodium salt (which is synonymous with phosphonic acid, nitrilotris (methylene) tri-penta sodium salt) 1-hydroxyethylene-1,1,-diphosphonic acid (which is synonymous with (hydroxyethylidene) diphosphonic acid)) 1-hydroxyethylene-1,1,-diphosphonic acid tetra sodium salt (which is synonymous with hydroxyethylidene diphosphonic acid tetra sodium salt) diethylenetriamine penta(methylene phosphonic acid) (which is synonymous with phosphonic acid), [(phosphonomethyl)imino]bis[2,1-ethanediylnitrilobis(methylene)]] tetrakis [(phosphonomethyl)imino]bis[2,1-ethanediylnitrilobis(methylene)]] tetrakis, pentasodium salt 2-phosphonobutane-1,2,4-tricarboxylic acid.
These phosphonic acids, or the salts thereof (e.g., alkali or alkaline earth metals), can be incorporated into the absorbent composition in the amount of 0.05 to 5% dry wt, more preferably 0.1 to 1.5% dry wt, and most preferably 0.1 to 0.6% dry wt.
It is contemplated that other phosphonic acids and phosphonates would be suitable for the uses of the present invention, in addition to those which have been identified above for illustrative purposes, as known to those of skilled in the art with the benefit of the present invention disclosure. Phosphonic acids and/or salts thereof which are believed suitable for use in the present invention are available from one or more of the following manufacturers: Bayer Corporation of Pittsburg, Pa.; Digital Specialty Chemicals, Inc. of Dublin, N.H.; Solutia, Inc. of St. Louis, Mo.; and Wujin Fine Chemical Factory of Jiangsu, China.
Preferred absorbent particles of the invention have a porosity of 20-60%, more preferably 25-50%, and most preferably 30-45%, all porosity percentages provided herein referring to pore volume in the absorbent composition matrix after mixing, extrusion, and oven drying of the particles. Porosity provides a measure of the amount of surface area of the particles that is available for reaction with carbon dioxide. The pore volume is expressed in terms of cubic centimeters per 100 grams of dry weight of the carbon dioxide absorbent composition particles (cc/100 gms dry wt) with all moisture removed (i.e., less than 0.1% moisture content). Porosity is determined by saturating a known weight of the dried absorbent composition with iso-octane, draining off all excess iso-octane solvent, and determining the weight and volume of iso-octane absorbed by the absorbent particles. The iso-octane is not physically absorbed by the particles and only occupies the pore space contained in the particles.
Preferred absorbent particles of the invention should have a hardness of 75% to 99%, and more preferably 80-95%, the hardness percentages being calculated as follows. The measurement of “hardness” is an indirect measure of the strength and friability of the absorbent particles after the absorbent composition is mixed, extruded, and allowed to harden into solid particles. Unlike the porosity test, however, the dried solid particles should be hardness-tested with 12-19% water content. Particles are screened through a stack of sieves consisting of progressively smaller and smaller opening sizes: 4-mesh, 6-mesh, and 8-mesh (which corresponds to US ASTM E11 sieves with opening of 4.75 mm, 3.35 mm, 2.36 mm, respectively) to remove particles having coarseness greater than 4-mesh and fineness less than 8-mesh. Fifty grams of the sample particles retained on the 6-mesh screen are placed into a steel cylindrical cup, having a slightly concave bottom, into which a close-fitting cylindrical piston is placed. The piston is connected to a hydraulic air piston, and pressure is exerted through the piston and imparted into the particles in the cup for 10 seconds, such that the resultant pressure is 90 pounds per square inch at the plunger contact against the particles. The contents of the pressurized particles are then placed onto a 12-mesh sieve (1.70 mm openings), and shaken using a sieve shaker (e.g., RO-TAP) for 30 seconds, and the weight of the particles that have fallen through the 12-mesh sieve is measured. Hence, hardness is calculated by determining the percentage of material that remains coarser than the 12-mesh sieve (1.70 mm) after subjecting the absorbent particles to the aforementioned controlled crushing action.
The following examples are provided for illustrative purposes only, and are not intended to limit the scope of the invention.
EXAMPLE 1
Carbon dioxide absorbent in particle form can be made as follows. The following components can be added into a paddle or bladed mixer, such as a sigma blade mixer, in accordance with the percentages provided above, in any order. The inventor prefers the following order for adding the ingredients: calcium hydroxide, water, diethyl violet color indicator dye, calcium chloride, and (optionally) sodium hydroxide. The components are mixed together at low speed for about one to five minutes until a paste is obtained having the general consistency of a cookie dough batter. The paste is discharged into an extruder having 1-3 mm hole openings, and the paste is extruded into spaghetti-shaped noodles which are dried in an oven until hard. The extrudate is then to be crushed gently to break the absorbent into separate particles that can be sieved to achieve the desired size particles and sprayed with water to ensure that water content is 12-19% based on total weight of the particles. However, one of the problems of the particular composition is that during mixing and extrusion, the composition begins to stiffen noticeably after a few minutes, and the rate of stiffening corresponds with the increase in concentration of calcium chloride in the mix.
EXAMPLE 2
Test A (Control)
Into the hopper of an in-line continuous paddle mixer, an absorbent composition comprising calcium hydroxide, sodium hydroxide (optional), and diethyl violet were combined with water (30% by wt) to form a paste that was extruded through a die. The paste was observed to be somewhat harsh and slightly difficult to extrude, because there was a strain placed on the equipment. Additional water had to be added to facilitate mixing and extrusion; however, this added water increased the porosity and reduced the hardness and strength of the resultant particles.
Test B
When calcium chloride was incorporated into the absorbent composition described above in Test A, the resultant paste could not be extruded through the in-line paddle mixer after 10-20 minutes, even when additional water was added to the paste mixture. Furthermore, the extruder became plugged so that the equipment needed to be shut down and cleaned out. Thus, the addition of calcium chloride was observed to produce a harsher mix due to agglomeration of the calcium hydroxide particles and stiffening of the paste mixture.
Test C
When a phosphonic acid or salt was incorporated into the absorbent composition described in Test B, the paddle mixer and extruder did not plug up and the paste mixture demonstrated a highly workable consistency. Moreover, the particles were extruded with ease and demonstrated a smoother surface than was seen on the particles produced in Tests A and B. A summary of the effect of various test compositions on processing and extrusion is provided below in Table 1.
TABLE 1
Test
Processing and Extrusion
A
slightly difficult to extrude
B
Very poor, not able to be extruded
C
Good workability and extrusion
EXAMPLE 3
The carbon dioxide absorption performance of an absorbent is best determined by evaluating its performance under conditions similar to actual use. For use in medical applications and anesthesia machines, a simulated medical test for carbon dioxide absorbency performance was accomplished as follows.
Composition #1
A control carbon dioxide absorbent composition was formulated as follows: calcium hydroxide (98-99% dry wt); sodium hydroxide (0.1-1% dry wt); diethyl violet (0.02-0.1% dry wt); and water (28-33% total weight).
Composition #2
A carbon dioxide absorbent composition of the present invention was formulated as follows: calcium hydroxide (96-99% dry wt); sodium hydroxide (0.1-1.0% dry wt); diethyl violet (0.02-0.1% dry wt); calcium chloride (0.5-2.0% dry wt); water (28-33% by total weight); and a phosphonic acid/salt (0.1-0.6% dry wt).
The compositions were mixed into a paste using a continuous in-line paddle mixer and extruded through a die to form particles, which were oven dried and then sized to produce 4-8 mesh particles. Water was then sprayed onto the particle surfaces to ensure a moisture content of 12-19% by total weight.
Composition #1 had a porosity of 36.2 cc/100 gm and a hardness of 92.8% and Composition #2 had a porosity of 43.5 cc/100 gm and a hardness of 85.9%.
Each composition was then tested in a simulated medical test using an Ohmeda anesthesia machine (Datex-Ohmeda, Inc.) at an oxygen fresh gas flow of 1 liter/minute, ventilator settings of 1 liter tidal volume and 10 breaths per minute, 160 cc/minute carbon dioxide gas flow into a test lung to simulate a 72.6 kg human patient under anesthesia, and using 1,050 gm of absorbent in particle form. Carbon dioxide gas is fed continuously into the test lung, exits into the expiratory side of the breathing circuit and then through the absorbent until the absorbent does not fully absorb all the carbon dioxide. Hence, the “CO 2 breakthrough” point was determined when 0.5% of the effluent coming through the particles on the inspiratory side of the breathing circuit (to the patient) was carbon dioxide that was not being absorbed. Each composition was tested four times until 0.5% CO 2 breakthrough and the results averaged
Composition #1 was found to have a CO 2 breakthrough after 20.9 hours, while Composition #2 was found to have CO 2 breakthrough after 24.2 hours. Thus, the exemplary composition (#2) of the present invention was shown to have a significant improvement in terms of carbon dioxide absorption performance. A summary of the effect of the composition with and without CaCl 2 and phosphonate plasticizer on CO 2 absorption performance is provided below in Table 2. A commercial product, Amsorb™, (Armstrong Medical Ltd, Coleraine, N. Ireland) which is a mixture of Ca(OH) 2 , approximately 1% CaCl 2 , and approximately 1% CaSO 4 hemihydrate, is included for comparison and was found to have significantly lower performance.
TABLE 2
Hours to 0.5%
Porosity,
Hardness
CO 2 breakthrough
cc/100 gm
%
Composition #1
20.9 +/− 1.2
36.2
92.8
Composition #2
24.2 +/− 0.3
43.5
85.9
Amsorb ™
14.6 +/− 0.8
38.7
88.4
EXAMPLE 4
Compositions #1 and #2, described above in Example 3, were each tested for performance in terms of diethyl violet color indicator dye steadfastness. The color behavior of the compositions were observed at the end of the simulated medical test described in Example 3. After the Ohmeda anesthesia machine was turned off, the purple colors of the absorbent particles were observed over time. It was observed that Composition #1 faded to colorless after 4-8 hours, while the Composition #2 remained purple even after 4-8 weeks.
EXAMPLE 5
Composition #1 and #2, described above in Example 3, were tested with respect to degradation effects on a volatile anesthetic agent. Each composition was placed into an Ohmeda anesthesia machine under the following conditions and tested using a 1.5% concentration of sevoflurane (in the breathing circuit): 0.5 liter/min oxygen fresh gas flow; 500 cc tidal volume; 16 breaths per minute, 450 cc/min carbon dioxide gas flow, and using 1,050 gms of absorbent in particle form. The concentration of Compound A increases with temperature, so a high flow rate of carbon dioxide gas was used in order to increase the temperature of the absorbent to 57-60° C. due to the exothermic reaction between CO 2 and Ca(OH) 2 . The samples were tested over a period of 60 to 120 minutes, and samples were taken every 20 minutes and analyzed by gas chromatography for the decomposition product, Compound A. The concentration of Compound A would peak at 40 minutes, then decrease slightly between 40 to 120 minutes. Each composition was tested three times and the results averaged. Composition #1 was found to have a peak value of 24.3 ppm of Compound A. Composition #2 was found to have a peak value of 1.8 ppm of Compound A.
A summary of the effect of Composition #1 and #2 on the degradation of sevoflurane to Compound A and of desflurane to carbon monoxide (discussed below in Example 6) are provided below in Table 3. Composition #2, which contains the phosphonate rheology modifier, has minimized or reduced the degradation of the anesthetic agents. The results for Amsorb™ are included for comparison and are similar to those for Composition #2.
TABLE 3
Compound A
Carbon Monoxide
Peak value, ppm
peak value, ppm
Composition #1
24.3 +/− 2.1
1,530 +/− 339
Composition #2
1.8 +/− 0.1
0.0
Amsorb ™
1.3 +/− 0.2
0.0
EXAMPLE 6
If Ca(OH) 2 -based soda lime CO 2 absorbents are allowed to dry out, the volatile anesthetic agent, desflurane, will react with the dry absorbent and decompose to form carbon monoxide. Composition #1 and #2, described above in Example 3, were dried in an oven at 110° C. to remove all moisture, and then tested to determine the decomposition of desflurane into carbon monoxide. Each composition was placed into a Dräger anesthesia machine (Dräger Medical Inc.-USA) under the following conditions and tested using a 6% concentration of desflurane (in the breathing circuit): 0.5 liter/min oxygen fresh gas flow; 500 cc tidal volume; 16 breaths per minute, and using 1,050 gms of absorbent in particle form. No carbon dioxide was used in this test because the reaction between the absorbent and CO 2 would produce water, which would increase the moisture content of the absorbent and interfere with the test. The samples were tested over a period of 60 minutes, and samples were taken every 20 minutes and analyzed by gas chromatography for carbon monoxide. The concentration of carbon monoxide would peak at 20 minutes, then decrease between 20 and 60 minutes. Each composition was tested two times and the results averaged. Composition #1 was found to have a peak value of 1,530 ppm of carbon monoxide. Composition #2 was found to have a peak value of 0 ppm of carbon monoxide. Amsorb™ was found to have a peak value of 0 ppm of carbon monoxide.
EXAMPLE 7
Various plasticizers were tested but were found to be unsuccessful for achieving the objectives of the present invention.
A carbon dioxide absorbent composition (Composition #3, control) was formulated using calcium hydroxide (96-99% dry wt), sodium hydroxide (0.10-1.0% dry wt), calcium chloride (0.5-2.0% dry wt), diethyl violet dye (0.02-0.1% dry wt), and water (28-33% based on total weight). When this Composition #3 was placed into a continuous in-line paddle mixer or a sigma blade batch mixer, the paste was difficult to mix and extrude.
A plasticizer, calcium lignosulfonate, in the amount of 0.2-0.9% dry wt was incorporated into the absorbent. Processing was improved but a slight odor and tan color were imparted to the absorbent particles, and carbon dioxide absorption efficiency was reduced. Therefore, this plasticizer did not fulfill the purposes of the present invention.
Another plasticizer, naphthalene sulfonate condensate (DARACEM® 19, W. R. Grace & Co.-Conn.) in the amount of 0.4-1.0% dry wt, was also tested with the absorbent composition. Processing was improved and carbon dioxide absorption efficiency was good. However, the plasticizer imparted a moderate odor and a purple color to the unreacted particles, so that the plasticizer was deemed by the inventor to be unacceptable for medical purposes.
Another plasticizer, sodium gluconate, in the amount of 0.05-0.2% dry wt, was also tested with the absorbent composition. Processing and hardness were improved, and no color or odor was produced; but carbon dioxide absorption performance was reduced significantly. Hence, this plasticizer did not fulfill the objectives of the present invention.
Another plasticizer, a sodium polyacrylate, in the amount of 0.4-0.6% dry wt, was also tested with the absorbent composition. Processing was not significantly improved, if at all; and an odor was imparted to the absorbent. Hence, this plasticizer did not fulfill the objectives of the present invention.
Another plasticizer, a modified polyacrylic acid (ADVA® FLOW™, W. R. Grace & Co.-Conn.), in the amount of 0.2-0.6% dry wt, was also tested with the absorbent composition. Processing was extremely poor, and the paste mixture could not be mixed or extruded. Hence, this plasticizer could not fulfill the objectives of the present invention.
Another plasticizer, a modified polycarboxylate salt containing a defoamer (ADVA® 100™, W. R. Grace & Co.-Conn.), in the amount of 0.06-0.49% dry wt, was also tested with the absorbent composition. Processing was improved slightly, and carbon dioxide absorption efficiency was improved; but a slight odor was imparted to the absorbent. Hence, this plasticizer did not fulfill the objectives of the present invention.
Another plasticizer, citric acid, in the amount of 0.02-0.8% dry wt, was also tested with the absorbent composition. Processing was improved, but the particles had low hardness and carbon dioxide absorption performance was reduced significantly. Hence, this plasticizer did not fulfill the objectives of the present invention.
A fumed silica (e.g., CAB-O-SIL™ from Cabot Corporation) in the amount of 1-2% dry wt, was also tested with the absorbent composition. While processing was noticeably improved, the particles showed decreased carbon dioxide absorbency, and hence objectives of the present invention were not achieved.
In contrast, when numerous phosphonic acids or salts (as identified in the foregoing specification) were incorporated as a rheology modifier into the absorbent composition, the composition became easier to mix and extrude. The resultant particles had no odor or discoloration, and had strength and excellent carbon dioxide absorption performance.
A summary of the effect of various plasticizing agents on processing, odor, color and simulated medical test CO 2 absorption performance is provided in Table 4.
TABLE 4
Concen-
tration
Pro-
Medical
Plasticizer
(% w/w)
cessing
Odor
Color
Test
Composition
0
Poor
None
None
Control
#3, no
plasticizer
Calcium lignin
0.2-0.9
Improved
Slight
Tan
Reduce
sulfonate
Napthalene
0.4-1.0
Improved
Moderate
Purple
Good
sulfonate
condensate
Sodium gluconate
0.05-0.2
Improved
None
None
Poor
Sodium
0.4-0.6
No change
Slight
None
Good
polyacrylate
Modified
0.2-0.6
Poor
Slight
None
Not
polyacrylic acid
deter-
mined
Sodium
0.06-0.49
Slightly
Slight
None
Very
polycarboxylate
better
good
Citric acid
0.02-0.8
Good
None
None
Poor
Fumed silica
1-2
Very good
None
None
Poor
Phosphonic
0.1-0.5
Very good
None
None
Very
acid/Phosphonate
good
The foregoing examples and exemplary embodiments are provided above for illustrative purposes only and are not intended to limit the scope of the present invention.
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Exemplary carbon dioxide absorbent compositions of the invention incorporate calcium hydroxide, water, and a phosphonic acid or salt thereof. The composition is made into a paste and formed into particles that are conveniently and efficiently processable. When hardened, the particles have excellent carbon dioxide absorbent performance, crush resistance, and pore structure.
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[0001] This nonprovisional application is a continuation of International Application No. PCT/EP2016/054562, which was filed on Mar. 3, 2016, and which claims priority to German Patent Application No. 10 2015 103 649.5, which was filed in Germany on Mar. 12, 2015, and which are both herein incorporated by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention relates to a light module for a lighting device of a vehicle, in particular for a headlamp, having a light source and an optical element which is accommodated on a support body, and wherein an adjuster for adjusting the optical element to the light source is provided in order to adjust a radiation position of the light source relative to the optical element.
Description of the Background Art
[0003] WO 2014/008523 A1, which corresponds to U.S. Pat. No. 9,458,976, describes light modules for a lighting device of a vehicle which have a light source and an optical element in the form of a reflector, and the optical element is accommodated on a support body, and wherein a device for adjusting the optical element relative to the light source is provided in order to adjust a radiation position of the light source relative to the optical element. In this case, an adjustment is possible mainly in a longitudinal direction which forms the direction in which light that can be generated with the light module is emitted. A longitudinal direction simultaneously also forms the direction of travel of the vehicle, so that the optical element can be moved back and forth accordingly. Likewise, the optical element can be pivoted about a vertical direction, for example, to adjust a left or right position. The adjuster comprises mounting brackets which are arranged between a support body for receiving the light source and the light source itself. The tilting and pivoting thereby occurs by rotating about an axis in a transverse direction and by rotating about an axis in the vertical direction, wherein a height adjustment of the optical element relative to the light source is not possible.
SUMMARY OF THE INVENTION
[0004] It is therefore an object of the invention to refine a light module with an adjuster that enables a broadened adjustment of the optical element relative to the light source.
[0005] In an exemplary embodiment, the adjuster comprises a wedge element which is arranged movably between the support body and the optical element so that, when the wedge element is shifted, an adjustment of the optical element relative to the light source can be made at least in a vertical direction.
[0006] In an exemplary embodiment, the wedge element can be arranged between the support body and the optical element, which can be shifted such that the vertical position of the optical element above the support body is changed. By means of a wedge angle of the wedge element, for example, of 5 degrees, a shift with a large displacement path, for example, in the longitudinal direction, produces only a small change in position of the optical element above the support body in the vertical direction. A fine adjustment of the vertical position of the optical element above the support body is thereby possible by pushing the wedge element further between the support body and the optical element or withdrawing it therefrom.
[0007] According to an embodiment of the light module, the wedge element has an obliquely formed wedge surface, and the support body has a likewise obliquely formed bearing surface corresponding to the wedge surface. The wedge surface thereby bears against the bearing surface and slides on it when the wedge element is shifted.
[0008] The optical element can also have a bearing surface, which is formed obliquely and corresponds to the wedge surface of the wedge. However, an adjustment of the optical element above the wedge element in a longitudinal direction would not be possible without adjusting the vertical direction.
[0009] If the wedge surface and the bearing surface are formed between the wedge element and the support body and the contact surface of the wedge element has no bevel in the direction of the optical element, the optical element on the wedge element can also be adjusted in a longitudinal direction or even in a transverse direction without changing the vertical position of the optical element above the support body.
[0010] According to an embodiment of the light module, the adjuster for adjustment also comprises a first eccentric element with an eccentric, which is provided for shifting the wedge element in relation to the support body, the first eccentric element being arranged in an operative connection with the support body and with the wedge element. The eccentric element is preferably rotatably accommodated in the support body about an axis in the vertical direction, and the eccentric of the eccentric element is seated in an eccentric seat of the wedge element, so that a shifting of the wedge element above the support body is produced when the eccentric element rotates. The eccentric element advantageously has a tool seat, for example, for a screwdriver, so that the eccentric element can be rotated in a simple manner about the axis in the vertical direction. For this purpose, the optical element has a passage through which the tool can be guided in order to rotate the first eccentric element disposed between the support body and the wedge element.
[0011] According to an embodiment of the light module, at least one guide element is formed between the support body and the wedge element, wherein at least the wedge element is guided in a longitudinal direction above the support body by means of the guide element. For example, the guide element can be designed as a cylindrical pin, and two cylindrical pins can be provided for guiding the wedge element above the support body, which pins can be shifted in longitudinal holes introduced in the wedge element. Conversely, there is also the possibility of placing the cylindrical pins on the wedge element, which pins can be shifted in longitudinal holes introduced in the support body. In this case, the cylindrical pins can be made so long that they continue to pass through the elongated holes which are introduced in a base section of the optical element, so that it is possible to guide the optical element in the longitudinal direction above the support body independently of the position of the wedge element. The optical element thereby sits with the base section on the top side of the wedge element, and if the base section is guided via the guide elements in a longitudinal direction of the light module, the optical element can also be adjusted in the longitudinal direction.
[0012] If the optical element can be shifted relative to the support body, for example, in the longitudinal direction, the adjuster for adjustment can also comprise a second eccentric element with an eccentric, which is provided for shifting the optical element in relation to the support body. The second eccentric element can be arranged in an operative connection with the support body and with the optical element. In this case, the second eccentric element passes through the wedge element without forming an interaction with the wedge element. If the second eccentric element is rotated, for example, by using a suitable tool, the eccentric of the second eccentric element can be rotated in an eccentric seat in the optical element, as a result of which the optical element is shifted above the support body. The eccentric element can be rotated with a cylindrical section in a seat in the support body about a fixed axis in the vertical direction.
[0013] The eccentric seats form oval, elliptical, or ovoid contours, and the eccentric of the eccentric element preferably forms a cam shape, so that the wedge element or the optical element is shifted above the support body in that the cam cap of the eccentric is rotated within the contour of the eccentric seat and thereby slides in it.
[0014] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes, combinations, and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:
[0016] FIG. 1 shows a flying view of a light module with an optical element above a light source, a support body, and an adjuster for adjustment;
[0017] FIG. 2 shows a perspective view of a support body and a wedge element;
[0018] FIG. 3 shows the arrangement of the support body and the wedge element according to FIG. 2 , wherein an optical element is additionally shown;
[0019] FIG. 4 a shows a side view of the light module with a wedge element in a first position; and
[0020] FIG. 4 b shows a view of the light module with a wedge element which has been pushed further into the region between the optical element and the support body, as compared with the position in FIG. 4 a.
DETAILED DESCRIPTION
[0021] FIG. 1 shows, in a flying view, a light module 1 with a light source 10 , with an optical element 11 , with a support body 12 , and with an adjuster 13 for adjusting optical element 11 above support body 12 . A first eccentric element 15 with an eccentric 16 and a second eccentric element 18 with an eccentric 19 are also shown.
[0022] Optical element 11 has a reflector 20 and a base section 21 , wherein optical element 11 can also have, for example, a lens or a lens system, a light-conducting body, or the like. The adjuster 13 described below for the adjustment of optical element 11 above support body 12 enable an adjustment in the illustrated vertical direction Z and, independently of this, an adjustment in the illustrated longitudinal direction X, wherein there remain further possibilities for an adjustment, for example, in a transverse direction Y, by the adjuster 13 for adjustment.
[0023] The adjuster 13 for adjustment comprise a wedge element 14 having a wedge surface 14 a , which is brought into contact with a bearing surface 12 a on support body 12 . With respect to a horizontally extending longitudinal direction X, bearing surface 12 a has an inclination corresponding to an inclination of wedge surface 14 a . If wedge element 14 is placed on support body 12 and shifted in the longitudinal direction X, thus the height of a mounting surface 14 b on wedge element 14 changes but without tilting, wherein mounting surface 14 b is formed opposite to bearing surface 14 a and points in the vertical direction Z. If optical element 11 has a base surface 11 a of base section 21 on mounting surface 14 b and wedge element 14 is shifted in the longitudinal direction X, the height position of optical element 11 above support body 12 changes without tilting. Light source 10 can be accommodated on support body 12 , and support body 12 can form a heat sink. As a result of the shifting of optical element 11 in the vertical direction Z, reflector 20 also shifts above light source 10 so that the shifting of reflector 20 above light source 10 can be adjusted by this shifting.
[0024] Guide elements 17 are disposed on support body 12 in the form of cylindrical pins which point with their cylinder axis in the vertical direction Z. Wedge element 14 has elongated holes 22 , and guide elements 17 pass through elongated holes 22 when wedge element 14 is placed on support body 12 . Due to the formation of elongated holes 22 with a longitudinal extension in the longitudinal direction X, a guidance is achieved when wedge element 14 is shifted so that wedge element 14 is moved guided on support body 12 .
[0025] First eccentric element 15 , which is accommodated with a cylindrical section 23 in a bore 24 in support body 12 , is used to shift wedge element 14 on support body 12 . Eccentric 16 , however, is accommodated in an eccentric seat 25 , which is introduced in wedge element 14 . If first eccentric element 15 is rotated, cylindrical section 23 can rotate in bore 24 about a spatially fixed axis in the vertical direction Z, and eccentric 16 rotates in eccentric seat 25 , with wedge element 14 being shifted in the longitudinal direction X. Thus, first eccentric element 15 forms an operative connection between support body 12 and wedge element 14 , eccentric 16 being accommodated in eccentric seat 25 in such a way that eccentric 16 does not protrude above mounting surface 14 b of wedge element 14 .
[0026] Second eccentric element 18 with eccentric 19 also has a cylindrical section 26 with which second eccentric element 18 is inserted in a bore 27 in support body 12 . Thus, second eccentric element 18 as well can be rotated in an axis in the vertical direction Z. Eccentric 19 is accommodated in an eccentric seat 28 , which is introduced into base section 21 of optical element 11 . If second eccentric element 18 is rotated, the cam contour of eccentric 19 travels along the inner contour of eccentric seat 28 and shifts optical element 11 in the longitudinal direction X, regardless of the position of wedge element 14 . In order to avoid an interaction between second eccentric element 18 and wedge element 14 , wedge element 14 has a through-opening 29 through which cylindrical section 26 of second eccentric element 18 extends without creating an interaction with wedge element 14 .
[0027] FIG. 2 shows a perspective view of support body 12 on which wedge element 14 is placed. The view shows the passing of guide elements 17 through elongated holes 22 , wherein by way of example only guide elements 17 are located on support body 12 , and elongated holes 22 are introduced in wedge element 14 . Alternatively, guide elements 17 can be mounted on wedge element 14 , whereas elongated holes 22 are formed on support body 12 . First eccentric element 15 is shown disposed between support body 12 and wedge element 14 , and it can be seen that eccentric 16 sits in eccentric seat 25 .
[0028] If first eccentric element 15 is rotated, eccentric 16 moves in eccentric seat 25 so that a shifting of wedge element 14 on support body 12 is produced in the longitudinal direction X.
[0029] FIG. 3 shows the further arrangement of optical element 11 on wedge element 14 and second eccentric element 18 is inserted in eccentric seat 28 in optical element 11 . If second eccentric element 18 is rotated, for example, with a tool which is inserted in the indicated cross slot on the top side in second eccentric element 18 , eccentric 19 travels in eccentric seat 28 and optical element 11 can be shifted in the longitudinal direction X in relation to support body 12 , without wedge element 14 being shifted.
[0030] A shifting of optical element 11 in the vertical direction Z relative to light source 10 can be produced as a result with the first eccentric element (concealed), whereas second eccentric element 18 produces a shift of optical element 11 in the longitudinal direction X in relation to light source 10 . Light source 10 can be accommodated on support body 12 and support body 12 can form a heat sink, for example.
[0031] FIGS. 4 a and 4 b show a side view of support body 12 , wedge element 14 , and optical element 11 , wedge element 14 being located between support body 12 and optical element 11 . In this case, wedge surface 14 a of wedge element 14 bears against bearing surface 12 a of support body 12 , and mounting surface 14 b of wedge element 14 bears against base surface 11 a of optical element 11 . Shown furthermore are guide elements 17 for guiding wedge element 14 and optical element 11 in the longitudinal direction X shown.
[0032] If wedge element 14 is shifted in the longitudinal direction X, wedge element 14 can be brought from the position shown in FIG. 4 a to the position shown in FIG. 4 b . A shifting of optical element 11 in the vertical direction Z is produced by the inclination of bearing surface 12 a and wedge surface 14 a , wherein the shifting of wedge element 14 is produced by means of first eccentric element 15 , as described in connection with the preceding figures.
[0033] If a shifting in the longitudinal direction X is to be produced in addition to and independently of the shifting of optical element 11 in the vertical direction Z, second eccentric element 18 can be rotated about the vertical direction Z so that optical element 11 is shifted independently of the position of wedge element 14 in longitudinal direction X. In this case, base surface 11 a slides on mounting surface 14 b of wedge element 14 .
[0034] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.
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A light module for a lighting device of a vehicle, in particular for a headlamp, having a light source and an optical element which is accommodated on a support body, and wherein an adjuster is provided for adjusting the optical element to the light source in order to adjust a radiation position of the light source relative to the optical element. The adjuster has a wedge element, which is arranged movably between the support body and the optical element so that when the wedge element is shifted an adjustment of the optical element to the light source can be produced at least in a vertical direction.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/650,882, filed Feb. 7, 2005, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The present invention relates to systems, apparatus, and methods for providing a disinfectant solution to the grey water of an aerobic septic system.
BACKGROUND
In aerobic septic systems, following digestion of the waste, a grey water reservoir is used to store the grey water. State and federal regulations typically require that a minimum level of disinfectant, for instance chlorine, be present in the grey water contained in the grey water reservoir prior to discharge. For example, in Texas, a level of 1 ppm chlorine is to be maintained. Typically, solid chlorine pellets that dissolve to release chlorine are used to disinfect grey water. The incoming grey water is passed over a chlorine pellet to sufficiently chlorinate the incoming water. However, these chlorine pellets can be expensive. Such pellets can cost up to three times as much as an equivalent amount of chlorine that is commercially available in the form of household chlorine bleach.
Previous devices for adding household chlorine bleach to a grey water reservoir either added the chlorine all at once prior to dispersal or in a drip-wise fashion. Those systems that add the chlorine all at once allow the grey water to remain untreated for a long period. This can be problematic if the grey water reservoir is ever pierced, allowing the untreated grey water to seep into the ground. Furthermore, an extended period without treatment may allow the grey water to ferment, causing noxious odors.
One previously known system for use with a standard residential septic system consisted of a cap, with a pre-cut hole, screwed to the top of a commercially available household bleach bottle. The bleach bottle was then inverted over a gray water reservoir tank, inside the pumping access hatch, to let the bleach drip out over time. Such devices have numerous limitations including limited capacity, limited options for placement, difficulty in accessing the grey water reservoir to suspend the device, difficulty in refilling the device, and the lack of an ability to reversibly adjust the drip rate. However, some septic tank systems make disinfectant available to grey water by flowing grey water through a pipe in which is maintained a chlorine tablet by a chlorine tablet feeding mechanism, which pipe then drains into the grey water reservoir tank. Some such systems may not be suitable for disinfection using the prior art device, or it may be cumbersome to do so.
Thus, systems and methods that provide alternate, easier to use, and less expensive ways of adding disinfectant to the grey water of an aerobic septic system would be an improvement in the art.
SUMMARY
The present invention provides systems and methods for the slow, uniform addition of a disinfectant solution comprising an active ingredient, such as chlorine, by means of a drip device to achieve a substantially constant level of active disinfectant ingredient flow into grey water of an aerobic septic system prior to dispersal. This may be accomplished through the use of an appropriately configured container space for containing a volume of a disinfectant solution and a valve for regulating the drip-wise flow of the disinfectant solution out of the container space and into the grey water.
Thus, apparatus for disinfecting the grey water of an aerobic septic system are disclosed. These apparatus include a container space for holding a volume of disinfectant solution that is configured for insertion into a chlorine tablet dispensing system and a valve, which may be an adjustable valve, for regulating the drip-wise addition of disinfectant solution to the grey water of an aerobic septic system.
The present invention also includes methods for disinfecting the grey water of an aerobic septic system. Using the teachings of the present invention, the grey water of an aerobic septic system may be disinfected by the addition of a disinfectant solution through a valve in a drip-wise manner to the grey water in a tank of a conventional septic system.
DESCRIPTION OF THE DRAWINGS
It will be appreciated by those of ordinary skill in the art that the elements depicted in the various drawings are for exemplary purposes only. The nature of the present invention, including the best mode, as well as other embodiments of the present invention, may be more clearly understood by reference to the following detailed description of the invention, to the appended claims, and to the several drawings.
FIG. 1 is an exterior perspective view showing a portion of one illustrative embodiment of an assembled apparatus for grey water reservoir chlorination.
FIG. 2 is an interior perspective view of the embodiment of FIG. 1 .
FIG. 3 is a cross-sectional view of a portion the embodiment of FIGS. 1 and 2 .
FIG. 4 is a sectional view of one embodiment of an aerobic septic system including an assembled apparatus for grey water reservoir chlorination as it may be used in adding a disinfectant solution to a grey water reservoir.
FIG. 5 is a sectional view of one embodiment of a standard septic system tablet chlorinator that is adapted for use with the apparatus of FIGS. 1 to 3 .
DETAILED DESCRIPTION
The present invention relates to systems and methods related to drip system for supplying disinfectant solution to the grey water in an aerobic septic system. It will be appreciated by those skilled in the art that the embodiments herein described, while illustrating certain embodiments, are not intended to so limit the invention or the scope of the appended claims. Those skilled in the art will also understand that various combinations or modifications of the embodiments presented herein can be made without departing from the scope of the invention. All such alternate embodiments are within the scope of the present invention. Similarly, while the drawings depict illustrative embodiments of devices and components in accordance with the present invention and illustrate the principles upon which the depicted device or component is based, they are only illustrative and any modification of the invented features presented herein are to be considered within the scope of this invention.
In one illustrative embodiment, suitable disinfectant solutions for grey water contained in a storage reservoir or “grey water tank” of an aerobic septic system are oxidizing solutions. One such suitable oxidizing solution may be a solution of from about 5% to about 6% sodium hypochlorite solution, such as that commonly available as household chlorine bleach (suitable household chlorine bleaches include those sold under the trademark CLOROX™ and competing brands). It will be appreciated that other concentrations of sodium hypochlorite solutions may be used, where desirable. Further, other oxidizing agents including, but not limited to, calcium hypochlorite, potassium hypochlorite, bromine, hydrogen peroxide, and others, may be used in aqueous solution of suitable strength. It will be of course appreciated by one of skill in the art any disinfectant suitable for use in a disinfectant solution to be added to a grey water tank may be used within the scope of the present invention.
Depicted in FIGS. 1 , 2 and 3 is one illustrative embodiment of an apparatus in accordance with the present invention. As depicted, an apparatus for grey water reservoir chlorination generally indicated at 100 , includes a reservoir R for holding disinfectant solution which is configured by size and shape to fit inside the chlorine tablet dispenser of a standard septic tank system. Most chlorine tablet dispensers consist of an elongated tube extending from a hatch located at or above the ground surface to either a grey water reservoir or to a tube through which grey water flows into a holding tank. A chlorine tablet feeding mechanism is located inside the elongated tube. Accordingly, the reservoir R may be a tube 106 , which is depicted as a tube having a round cross-section. It will be appreciated that a tube having any cross-sectional shape may be used, as is desirable for the installation required. For example, tube 106 may have a square, rectangular, triangular, elliptical or other cross section, provided the tube 106 can fit within the chlorine tablet dispenser tube.
Tube 106 has a distal end wall, which may be an end cap, as indicated generally at 102 . In the distal end wall is disposed a drip valve generally indicated at 104 . Drip valve 104 is configured so as to have an end for liquid exit 108 and an end for liquid entry 116 ( FIG. 2 ). Distal end wall or end cap 102 includes an exterior face 110 and an interior face 118 ( FIG. 2 ). End cap 102 may further include a fastening structure, such as annular edge 112 and annular lip 114 , for operatively fastening cap 102 to tube 106 . It will be appreciated that any suitable system known to those of ordinary skill in the art for attaching a cap to a container in a watertight manner may be used. Such systems include, but are not limited to, interlocking threads, friction fittings, rubber or synthetic O-rings, and various sealants such as, but not limited to, glues or epoxies. It will be further appreciated by one of skill in the art that although the illustrative embodiment depicts an injection molded plastic “male” cap, the present invention may be adapted to use a “female” cap or any other device or means for closing one end of a tube and can be made of any suitable material, including, buy not limited to, rubber, plastic, metal, or wood.
FIG. 1 further shows drip valve 104 operatively disposed through the body of the distal end wall, represented as end cap 102 . As illustrated, drip valve 104 is disposed through the end cap 102 such that the end for liquid exit 108 is on the same side of cap 102 as exterior face 110 the and the end for liquid entry 116 ( FIG. 2 ) is on the same side of cap 102 as interior face 118 ( FIG. 2 ). Drip valve 104 may be configured in a single fixed configuration, such that the drip-rate of disinfectant solution passing through drip valve 104 is fixed by the fixed size of the opening(s) therein. Alternatively, the drip-rate may be selectively adjustable. In such embodiments, the drip valve 104 may have different drip settings that can be selected for different flow-rates. For example, the rotation of the outer cap 105 of drip valve 104 may adjust the volume of the passages therethrough or of the liquid exit opening 109 . The drip-rate may thus be controlled by selecting a drip setting through rotating the end for liquid exit 108 . Different settings may thus control the drip rate by altering the passage size through which the disinfectant solution passes. Suitable valves may include drip line sprinkler heads designed for a drip irrigation system, which are adapted for use. One such suitable valve is the SHRUBBLER™, available from ANTELCO PTY LTD CORPORATION, which may be adapted for use by being glued in an opening made in the end cap 102 .
Typically, the drip setting is selected to allow for a desired drip rate, such that a suitable amount of active ingredient in a disinfectant solution may be delivered at a desired rate. A preferable drip rate for an active ingredient is such that the level of coliform bacteria is maintained below the levels required by law or such that the amount of active ingredient in the grey water reservoir is maintained above the levels required to sufficiently disinfect the grey water reservoir or required by statute, for example Title 30 Texas Administrative Code § 317 or other pertinent state or local requirements. In addition, the rate of addition for an active ingredient is preferably kept below the maximum concentration of disinfectant allowed by statute or below a concentration that may damage the septic tank system or the drain field site (often under a residential lawn). For example, a desired (or required minimum) level of chlorine in the grey water tank may be 0.5 mg/L. In use, the valve 104 may be adjusted as necessary to ensure appropriate flow of a chlorine solution into the septic system to maintain the grey water tank above this level.
It will be appreciated by one of skill in the art that the drip rate may be controlled by valves 104 other than a drip valve. Suitable valves may include, but are not limited to, ball valves, butterfly valves, globe valves, rotary valves, stopcocks or any other device for limiting the flow of liquid which allows controlled variation in the size of the opening through which the liquid may flow. Alternatively, the drip-rate may be regulated by using a mechanical pump, such as a variable drip pump, peristaltic pump or diastaltic pump, which may be used to pump disinfectant solution in a drop-wise manner from the reservoir 102 into the grey water reservoir at a rate similar to that determined by the other methods.
FIG. 2 depicts an interior view of the apparatus 100 of FIG. 1 . Visible in this view are the end for liquid entry 116 of drip valve 104 and the interior face 118 of cap generally 102 .
As best seen in FIG. 3 , an end cap 102 may be attached to tube 106 to form the distal end wall of a container space 120 . When end cap 102 is joined to a tube 106 , cap 102 is typically disposed such that interior face 118 and end for liquid entry 116 are disposed toward the container space 120 and exterior face 110 and end for liquid exit 108 are disposed toward the exterior environment. Container space 120 has a closed distal end generally 122 and a proximal end generally 124 . As will be appreciated by one of skill in the art, proximal end 124 may include a removable cap, if desired or needed by the user. Such a removable cap may or may not be airtight. It will be appreciated that the fastening of cap 102 to tube 106 represents but one method of constructing a container space 120 . Any other structure or container that can be joined with a cap such as cap 102 to form a container may be used.
As represented in FIG. 3 , tube 106 in some embodiments may be exemplified by a length of commercially available pipe. Such pipe may be formed from PVC, ABS or other suitable plastic, suitable metal, or any other suitable material. The pipe must be of sufficiently narrow diameter to fit within the chlorine tablet feeder tube of a septic tank system. For example, a 2½ inch of 3 inch PVC pipe may be used. The pipe may be of any suitable length, although it is currently preferred to be of sufficient length to extend to the top of the feeder tube. For some emplacements, an extended pipe may be inserted into the feeder tube and the appropriate length marked, following which the pipe is trimmed to proper length.
It will be further appreciated that, although container space 120 of the depicted embodiment is constructed from cap 102 and tube 106 , the methods and systems of the present invention may be practiced using any container space which is capable of holding a disinfectant solution and has a boundary walls through which a drip valve 104 may be operatively disposed.
As shown in FIG. 4 , the assembled apparatus 100 may be suspended in communication with the grey water reservoir 402 of an aerobic septic system generally 400 , such that disinfectant solution may be provided in a drip-wise manner thereto. For example, apparatus 100 may be inserted into the 4″ diameter feed tube 406 designed to provide chlorine pellets (such as in U.S. Pat. No. 6,294,086 B1) such that the end for liquid exit 108 of drip valve 104 faces the grey water 404 . It will be appreciated that any other holder for apparatus 100 , such as a specially constructed holster or a rope may be used.
It will be appreciated that drip valve 104 disposed through the body of any boundary wall of container space 120 may be any number of drip valves such that a desired drip-rate may be maintained. Multiple drip valves will allow for a single container space 120 to serve a larger reservoir 402 where the increased drip rate is beyond the ability of a single drip valve to supply. Of course, multiple systems 100 may be used to treat a larger reservoir 402 as well.
In one illustrative method according to the invention, a drip chlorinator apparatus 100 is inverted over the grey water 404 in the grey water reservoir 402 such that the proximal end 124 of the apparatus 100 remains above the distal end 122 . Commercially available household chlorine bleach may then be added to the proximal end 124 of the apparatus 100 . The drip valve 104 may be then adjusted to control the drip rate of the household chlorine bleach, through the adjustable drip valve 104 , and into the grey water 404 in the grey water reservoir 402 of an aerobic septic system 400 . The disinfecting solution drip-rate may then be regulated to effectuate a controlled rate of addition for the active ingredient into the grey water reservoir 402 .
As depicted in FIG. 5 , an apparatus 100 in accordance with the present invention may be used in a chlorine tablet feeder C of an aerobic septic tank system. One such standard chlorine tablet feeder is that described in U.S. Pat. No. 6,281,802, the disclosure of which is incorporated by reference herein in its entirety.
For such use, the tablet feeding mechanism or low tablet alarm system is removed from the chlorinator feed tube 506 and the apparatus 100 inserted therein. This insertion may include marking and cutting the pipe to a suitable length to form container space 120 . The distal end 122 resides at the lower end of the chlorinator feed tube, near fitting F. A suitable holster, sling or stop may be placed in the chlorine tablet feeder C to maintain the apparatus 100 in proper position. Disinfectant solution is then added to the apparatus 100 reservoir R through proximal end 124 and flows in a drip-wise fashion through drip valve 104 . The disinfectant solution thus mixes with grey water flowing through pipe P as indicated by arrows G. The apparatus may be refilled with disinfectant solution as needed, and may be withdrawn should adjustment of the drip-valve 104 be desired.
In another illustrative method according to the invention, the chlorine tablet feeder is removed from the septic system and a drip chlorinator apparatus 100 is placed into the feeder C such that the proximal end 124 of the apparatus 100 remains above the distal end 122 . Commercially available household chlorine bleach may then be added to the proximal end 124 of the apparatus 100 . The drip valve 104 may be then adjusted to control the drip rate of the household chlorine bleach, through the adjustable drip valve 104 and into the grey water 404 in the grey water reservoir 402 of an aerobic septic system 400 . The level of chlorine in the grey water may be determined by any standard chlorine level analysis. The disinfecting solution drip-rate may then be regulated to effectuate a controlled rate of addition for the active ingredient into the grey water reservoir 402
A preferred drip rate of disinfectant solution for any solution container or any size reservoir 402 can easily be determined by comparing the drip-rate of an experimental drip setting with the drip-rate of approximately 1.08 drops/minute required by an embodiment using 5-6% sodium hypochlorite solution to treat a 200-300 gallon reservoir 402 . For example, a test drip setting may be selected and allowed to operate for 24 hours. The disinfectant concentration in the grey water reservoir can then be measured and compared to a desired concentration. The drip valve 104 may then be adjusted to increase the drip rate of the disinfectant solution if the disinfectant concentration in the grey water reservoir is below the desired level or may be adjusted to decrease the drip rate of the disinfectant solution if the disinfectant concentration in the grey water reservoir is higher than the desired level. It will be appreciated by one of skill in the art that, instead of adjusting drip valve 104 , the concentration of the disinfectant in the disinfectant solution may be adjusted as required. This process can be repeated as often as necessary so as to select a drip rate which provides a desired concentration of disinfectant in the grey water reservoir. It will be appreciated by one of skill in the art that the drip rate may change as the head pressure provided by the remaining disinfectant in the container space is diminished. To overcome the decrease in head pressure, one may refill the container space as needed to maintain a suitable drip rate or a drip rate may be selected for the average head pressure and so maintain an average suitable drip rate over time.
While this invention has been described in certain illustrative embodiments, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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Methods and apparatus for the slow, generally uniform addition of a disinfectant solution comprising an active ingredient, such as chlorine, to achieve a substantially constant level of active ingredient in the liquid of a grey water reservoir of a residential septic tank system prior to dispersal. A container configured to reside in a standard chlorine tablet dispenser is filled with a disinfectant solution, which contains a disinfecting substance as an active ingredient. A drip-valve is used to regulate the drip flow of the disinfecting solution out of the container and into the grey water reservoir.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to devices for lifting a filled upright water bottle, rotating the lifted water bottle to an inverted position, and placing the inverted water bottle into the receiving well of a water cooler. More specifically, the present invention relates to an improved mechanism and method for grasping the water bottle and additionally an improved mechanism and method for lifting and inverting the lifted water bottle.
[0002] Many offices and establishments offer bottled water to their employees and patrons. Water bottles are normally associated with a water cooler for dispensing and are initially sealed with a cap which is removed in order that the bottle may be lifted and inverted to be placed neck down into the receiving well of the cooler. These plastic or glass bottles, when full of water, are cumbersome and heavy so that some persons simply cannot perform the task of lifting and inverting the water bottle and then lowering it into the well of the cooler.
[0003] An apparatus for lifting, rotating, and mounting a water bottle into a water cooler, is disclosed in U.S. Pat. No. 5,379,814 [Posly], the disclosure of which is hereby incorporated by reference. The apparatus disclosed contemplates a mechanism for gripping the water bottle comprising a plate supporting a pair of flexible fastening straps including conventional fasteners such as Velcro, for releasably embracing and supporting the bottle. The apparatus disclosed further contemplates a mechanism for rotating the water bottle, as it is being lifted, comprising a pair of 90° rotating cams attached via a support shaft to the rear of the plate. The cams are adapted to cam or bear against two rotatable bearings, mounted in series to the vertical frame of the apparatus, which serve as cam followers in causing the cams, support shaft, and plate to rotate in two 90° increments so that a water bottle mounted to the plate will turn from an upright position to an inverted position as the bottle is lifted.
[0004] In use, the prior art apparatus starts with the lifting mechanism at its lowered position. A full water bottle resting upright on the ground is secured to the lifting mechanism by the fastening straps. Next, the bottle is elevated by the lifting mechanism, being rotated during the lift by 90° when the first cam encounters the first roller bearing and by another 90° when the second cam encounters the second roller bearing. Next, the bottle is lowered by the lifting mechanism so that the bottle comes to rest on a water cooler with the bottle neck positioned inside the well of the cooler. Finally, the fastening straps are removed to release the bottle and the apparatus is moved away. To reset the apparatus so that it is ready to use on another water bottle, the lifting mechanism is returned to its lowered position. During the process of securing, elevating, and rotating the bottle, a bottle closure device is disposed on the mouth of the bottle so that no water spills from the inverted bottle, the bottle closure device adapted to interact with the well of a water cooler to open under the weight of the water bottle once the bottle is placed into the well.
[0005] It is a principal object of the present invention to provide an apparatus for lifting, rotating, and mounting a water bottle that includes an improved mechanism and method for gripping a water bottle. It is a further object of the present invention to provide an apparatus for lifting, rotating, and mounting a water bottle which includes an improved mechanism and method for rotating a lifted water bottle from an upright position to an inverted position, independently from the lifting mechanism, so that the bottle may be inverted either during the lift or afterward.
[0006] Other objects will appear hereinafter.
SUMMARY OF THE INVENTION
[0007] The present invention provides an apparatus for lifting, rotating, and mounting a water bottle into a water cooler which includes both a bottle gripping mechanism and a bottle rotating mechanism that are significantly different from that disclosed in the prior art, in combination with the bottle lifting mechanism previously disclosed in U.S. Pat. No. 5,379,814 [Posly].
[0008] The bottle gripping mechanism of the present invention includes a pair of pivotably mounted gripper arms actuated by a motor driven cam. The gripper arms secure the water bottle to the lifting mechanism surely, and can be varied in construction to accommodate water bottles of different geometries, as required. The bottle rotating mechanism of the present invention includes a rotatably mounted horizontal support shaft suspending the bottle gripping mechanism from the bottle lifting mechanism, the rotatably mounted support shaft being actuated by a motor.
[0009] In performing their respective functions as part of the apparatus of the present invention, the three mechanisms interact as follows. The gripping mechanism grips a water bottle. The rotating mechanism rotates the gripping mechanism along with the bottle. The lifting mechanism raises and lowers the rotating mechanism and the gripping mechanism along with the bottle. During at least the steps of rotating the bottle to an inverted position and then lowering it into the well of a water cooler, a bottle closure device (similar or equivalent to that disclosed in U.S. Pat. No. 5,379,814 [Posly], as previously described) is disposed on the mouth of the bottle so that no water spills from the inverted bottle before it comes to rest in the well of the water cooler.
[0010] In use, the apparatus starts with the lifting mechanism at its lowered position, with the gripping mechanism released from its gripping state. A full water bottle resting upright on the ground is first grabbed by the gripping mechanism. Next, the bottle, along with the gripping and rotating mechanisms, is elevated by the lifting mechanism. During or after the lift, the bottle, along with the gripping mechanism, is inverted by the rotating mechanism. Next, the bottle, along with the gripping and rotating mechanisms, is lowered by the lifting mechanism so that the bottle comes to rest on a water cooler with the bottle neck positioned inside the well of the cooler. Finally, the bottle is released by unclamping the gripping mechanism and the apparatus is moved away. To reset the apparatus so that it is ready to use on another water bottle, the empty gripping mechanism and the rotating mechanism are then lowered by the lifting mechanism, restoring the lifting mechanism to its lowered position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For the purpose of illustrating the invention, there is shown in the drawings forms which are presently preferred; it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
[0012] FIG. 1 is an isometric view of the water bottle lifting, rotating, and mounting apparatus of the present invention.
[0013] FIG. 2 is a sectional view taken along Line 2 - 2 of FIG. 1 looking down showing the gripper mechanism, the rotator mechanism, and the elevator assembly of the present invention.
[0014] FIG. 2A is the same view as FIG. 2 showing the gripper arms disengaged.
[0015] FIG. 3 is an enlarged view of the cam and the connecting arms to the gripper arms in the disengaged position.
[0016] FIG. 3A is an enlarged view of the cam and the connecting arms to the gripper arms in the engaged position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The following detailed description is of the best presently contemplated mode of carrying out the invention. The description is not intended in a limiting sense, and is made solely for the purpose of illustrating the general principles of the invention. The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings.
[0018] Referring now to the drawings in detail, where like numerals refer to like parts or elements, there is shown in FIG. 1 an isometric view of the water bottle lifting, rotating, and mounting apparatus 10 of the present invention. The apparatus 10 includes a base 12 which may be of welded tubular steel frame construction or of aluminum or suitable plastic construction or a combination of each. Swivel castors or wheels 14 may be at each of the corners of the base 12 to advantageously render the apparatus 10 readily movable or portable in any direction from one location to another.
[0019] The base 12 is formed with an opening 16 so that legs 18 and 20 can straddle an upright water bottle 22 resting on the floor. The base 12 has mounted thereon a bracket 24 supporting an elevator motor 26 with attached reduction gearbox 28 and journaling the lower end of a vertical threaded rod or screw 30 . The base 12 also supports a vertical elevator frame 32 that includes at least one vertical rail 34 and a vertical elevator rail 36 . The elevator frame 32 includes a top plate 38 to which the top of each rail 34 and the top of the elevator rail 36 are connected and the threaded rod 30 is suitably journaled. A pair of handles 40 optionally extends from the elevator frame 32 for facilitating movement of the apparatus 10 on the wheels 14 .
[0020] The bottle elevator assembly 42 , as illustrated in finer detail in FIGS. 2 and 2 A, comprises an elevator bracket 46 and an elevator nut 56 , and is integrally connected to a rotator mechanism 68 comprising a support sleeve 58 and a rotator motor 62 . The bottle elevator assembly 42 cooperates with the threaded rod 30 and the elevator rail 36 in elevating the bottle 22 .
[0021] The elevator bracket 46 embraces the vertical elevator rail 36 . Nylon roller bushings 48 are rotatably mounted on clevis pins 50 and engage with the rail 36 in facilitating the vertical raising and lowering of the bottle 22 . The clevis pins 50 also serve to couple the angle iron tensioners 52 to the bracket 46 . Tensioning bolts 54 extend through and bear against the pair of angle iron tensioners 52 on opposed sides of the rail 36 and serve to pull the associated pair of tensioners 52 together and consequently pull the roller bushings 48 tightly against the rail 36 .
[0022] Connected to the bracket 46 is the elevator nut 56 that meshes with the threads of the vertical threaded rod 30 in raising and lowering the elevator assembly 42 . The elevator bracket 46 is also rigidly affixed to a horizontally oriented support sleeve 58 that is adapted for receiving the rotatable support shaft 60 . Further affixed to the support sleeve 58 by the motor mounting bracket 66 is the rotator motor 62 .
[0023] The horizontal support shaft 60 is supported rotatably inside the support sleeve 58 . The rotator motor 62 drives a first end of the support shaft 60 via the rotator drive coupling 64 . Mounted at the opposite end of the support shaft 60 is the bottle gripping mechanism 70 . In the preferred embodiment, the rotator drive coupling 64 comprises a belt 92 tensioned about a sheave 94 disposed on the output shaft of the rotator motor 62 and another sheave 96 disposed on the one end of the support shaft 60 .
[0024] The bottle gripping mechanism 70 comprises an alignment plate 78 , a gripper motor 72 , and a pair of gripper arms 82 . The alignment plate 78 is rigidly affixed to the end of the support shaft 60 and provides mounting support for the other components of the gripping mechanism 70 . The upper and lower portions of the plate 78 are shaped to accommodate a water bottle 22 . Mounted to the rear side of the plate 78 , below the support shaft 60 , is the gripper gearbox 74 that, in turn, supports a gripper motor 72 . The gripper motor 72 drives the gripper gearbox 74 , and the output of the gripper gearbox 74 drives the gripper cam 76 , which is rotatably mounted through the support shaft 60 .
[0025] Further, affixed to the rear side of the plate 78 are two symmetrically positioned gripper hinge pins 84 about which the pair of gripper arms 82 are pivotably mounted. A corresponding pair of connecting arms 80 pivotably couples the gripper cam 76 to each of the gripper arms 82 , so that rotation of the cam 76 causes the gripper arms 82 to pivot about the hinge pins 84 inwardly and outwardly with respect to the water bottle 22 . Operation of the gripper cam 76 is shown in detail in FIGS. 3 and 3 A.
[0026] In the illustrated embodiment of FIG. 1 , each gripper arm 82 comprises an upper arm 86 and a lower arm 88 , interconnected at one end by the hinge pin 84 and at the other end by a cross brace 90 , the arms 86 and 88 being curved or shaped to accommodate a water bottle 22 . It is recognized that many other specific constructions of gripper arms 82 may be equally effective in carrying out the desired function of the gripping mechanism 70 . Additionally, the gripper arms 82 may be configured to accommodate water bottles 22 of any shape.
[0027] The operation of the water bottle lifting, rotating, and mounting apparatus 10 may be described as follows. Initially, the apparatus 10 is moved to a location at which it may be associated with a full water bottle 22 that is to be mounted on a water cooler (not illustrated). For convenience of operation, it is also assumed that the valve closure device disclosed in U.S. Pat. No. 5,379,814 [Posly], or a similarly functioning device, is on the neck of the bottle 22 . The legs 18 and 20 straddle the bottle 22 that is disposed in the opening 16 . The elevator assembly 42 is in its lowered position so that the alignment plate 78 may be centered on the bottle 22 with the upper and lower curved portions of the plate 78 positioned generally around the upper and lower portions of the bottle 22 and the curved gripper arms 82 positioned around the sides of the bottle 22 .
[0028] Next, the gripper motor 72 is activated by a switch or other activating device, causing the gripper cam 76 to rotate via the gripper gearbox 74 and thus forcing the gripper connecting arms 80 outward. The connecting arms 80 , in turn cause the gripper arms 82 to pivot about the hinge pins 84 inwardly towards the water bottle 22 until the gripper arms 82 are firmly and securely clamped about and against the sides of the bottle 22 . The gripper motor 72 is stopped and locked to retain the gripper arms 82 in this position.
[0029] Next, the elevator motor 26 is activated by a switch or other activating device, causing the threaded rod 30 to rotate via the gearbox 28 , raising the elevator nut 56 up, thus lifting the elevator assembly 42 and the water bottle 22 , guided by the elevator rail 36 . When the bottle 22 has reached sufficient height to be capable of being mounted in a water cooler, the elevator motor 36 is deactivated. During or following the lifting action, the rotator motor 62 is activated by a switch or other activating device, causing the support shaft 60 to rotate within the support sleeve 58 via the rotator drive coupling 64 , and thus rotating the bottle 22 . When the bottle has rotated 180° from an upright position to an inverted position, the rotator motor 62 is deactivated and the water bottle 22 remains suspended vertically with its neck pointing downward.
[0030] The apparatus 10 may now be laterally moved and positioned to align the neck of the bottle 22 with respect to the well of the water cooler. The elevator motor 26 is then activated in the reverse direction, causing the elevator assembly 42 and the inverted water bottle 22 to be lowered. When the neck of the bottle 22 is in the water cooler to a sufficient extent, the elevator motor 26 is deactivated and the elevator assembly 42 stops. The gripper motor 72 is then unlocked and activated in the reverse direction, causing the gripper arms 82 to pivot outwardly from the water bottle 22 , releasing the bottle 22 to rest in the well of the cooler. The apparatus 10 may now be moved away from the water cooler, as the bottle mounting operation is complete.
[0031] To return the apparatus 10 to its original starting position, the elevator motor 26 is activated in the reverse direction until the elevator assembly 42 is at its lowered position. For ease of storage, the gripper motor 72 may also be activated in its forward direction to rotate the gripper arms 82 inwardly. Note that the rotator motor 62 need not be activated since the gripping mechanism 70 is symmetrical about the horizontal axis and thus can function in exactly the same fashion when starting in either the “upright” or “inverted” position.
[0032] Note that each motor may be controlled manually via switches or automatically by using a combination of sensors or limit switches or other control instrumentation. For purposes of the apparatus of the present invention, the method disclosed herein for lifting, rotating, and mounting a water bottle into a water cooler is the same regardless of the means used to activate and deactivate the elevator motor 26 , the gripper motor 72 , and the rotator motor 62 .
[0033] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, the described embodiments are to be considered in all respects as being illustrative and not restrictive, with the scope of the invention being indicated by the appended claims, rather than the foregoing detailed description, as indicating the scope of the invention as well as all modifications which may fall within a range of equivalency which are also intended to be embraced therein.
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An apparatus for lifting, rotating, and mounting a water bottle into a water cooler, the apparatus having a motorized mechanism for securely gripping the bottle, a motorized mechanism for raising and lowering the bottle, and a motorized mechanism for rotationally inverting the bottle, the apparatus enabling a person with limited physical strength to lift and move a full upright water bottle from the floor, invert the bottle, and place it neck down into the well of a water cooler.
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This application is a continuation of patent application Ser. No. 10/002,190 filed on Nov. 28, 2001, now U.S. Pat. No. 6,802,162.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a construction block having good insulation and fault-tolerant properties.
2. Background of the Prior Art
Construction blocks are typically but not necessarily rectangular members having a pair of faces joined by four sides. These blocks, which are use to build partition structures, are usually transparent or translucent and may have a texture pattern on the faces. The outer surface of the blocks may be smooth or may have an appropriate mechanism for joining the block to other blocks. U.S. Pat. No. 5,595,033 to Frey, 5,588,271 to Pitchford and my U.S. Pat. No. 5,778,620 are examples of such mechanisms. The blocks, which are made from glass, plastic or a similar material, are typically formed as two generally identical halves welded or adhered together forming a seam.
These construction blocks, which enjoy wide popularity in the construction industry, have several areas that can benefit from improvement. Although, modern construction blocks have a relatively high level of thermal insulation and sound insulation capability, these levels can always withstand being raised. Another problem with present construction blocks is found in seam failure. A small hole along the seam not only reduces the insulation properties of that block but also serves as in introduction point for moisture to enter the interior chamber of the block. The moisture within the block condenses and becomes unsightly. The moisture introduction is exacerbated by the bellowing effect created by the block due to the difference in temperature between the block face on the interior of the building and the temperature of the block face on the exterior of the building which is exacerbated by the cycling of the construction block due to the heating of the block due to the relative heat of the day and the cooling of the block due to the relative coolness of the night.
Therefore, there is a need in the art for a construction block that addresses the aforementioned shortcomings of the present day blocks. Such a construction block must have improved thermal and sound insulation properties and must limit the adverse effects of a failed seam.
SUMMARY OF THE INVENTION
The construction block and method of the present invention addresses the aforementioned needs in the art. The construction block increases the thermal efficiency and sound insulation of the block. The construction block also attacks the moisture problem experienced from a failed seam by outright eliminating the condensation within the interior chamber of the block or by isolating the condensation from the sight of a user. The bellowing effect—which tends to pull air from the exterior of the block into the interior chamber of the block through the pinhole in the welded block seam is reduced. A method of increasing the thermal efficiency or eliminating the condensation is also disclosed.
The construction block of the present invention is comprised of a pair of body members each having a face joined by a plurality of side edges with inwardly directed side portions, edge portions of the side portions in abutting relationship with the edge portions of the other body member and joined by a welded or adhesive seam defining an interior chamber. A baffle having an outer periphery is located within the interior space and disposed generally parallel with the pair of faces and along the seam, to form two separate areas within the interior chamber whereby a bellow effect of the faces is reduced. The baffle has an upwardly turned up edge and the one or both of the body members has a recessed section for receiving the turned up edge
Means for joining the construction block with other construction blocks, may but need not be provided.
An appropriate desiccant, an insulation gas, or both are disposed within the interior chamber of the construction block. The desiccant lies at the bottom of the construction block out of sight of a user. At least one opening can be provided on the block for introduction of the desiccant or insulation gas, the opening being airtight sealed after introduction. Alternately, at least one weakened area, which may or not be perforated, may be provided on the construction block. The weakened area can be punched by a screwdriver or similar instrument for creating the opening. A locator mark can be provided on the block in the area defined by the weakened area for easy and consistent location of the weakened area. Alternately, the locator mark can be provided on the block (without the block having a weakened area) so that a person can drill an opening at the locator mark. The opening, weakened area, or locator mark can be located on at least one of the faces, on at least one of the sides or both. By providing these members on the side of the block, the sealed opening will not be visible to a user.
The baffle or a face of the block may have an appropriate coating, such as an optical or heat reflective coating, thereon.
The baffle serves several important roles. The baffle adds additional thermal insulation capacity and sound insulation capacity to the construction block. The baffle reduces the bellow effects created by the inner positioned face and the outer positioned face. The baffle separates the interior chamber into two or more sub-chambers. For example, by placing two baffles into the interior chamber, one baffle on one side of the seam and the other baffle on the other side of the seam, the interior chamber is separated into three sub-chambers. Therefore, any moisture and the resulting condensation that is introduced into the construction block through a failure in the seam is isolated within the middle sub-chamber out of sight of a user. Lastly, the baffles may be used to add to the overall aesthetic qualities of the block by coming indifferent colors, patterns including light diffusing patterns, smoked appearance, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one of the construction block of the present invention.
FIG. 2 is a perspective view of the two body member used to form the construction block, with the body members separated from one another and one of the body members partially sectioned.
FIG. 3 is a sectioned view of the construction block taken along line 3 - 3 in FIG. 1 .
Similar reference numerals refer to similar parts throughout the several views of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, it is seen that the construction block and method of the present invention, generally denoted by reference numeral 10 , is comprised of a generally rectangular body that is formed from two similar body members 12 each having a face portion 14 with inwardly directed side portions 16 , edge portions 18 of the side portions 16 in abutting relationship with each other and joined by a welded or adhesive seam 20 to define an interior chamber. The joiner of the two body members 12 can be accomplished in appropriate fashion such as by heat welding the two halves along the seam 20 , using an appropriate adhesive, etc. It is expressly understood that the construction block 10 can be constructed in a shape other than rectangular, and having other than four sides, in keeping within the scope and spirit of the present invention. The outer surface of the construction block 10 can be generally smooth, as illustrated, or can have any appropriate structure for joining the construction block 10 to other construction blocks 10 , as is well known in the art. The faces 14 of the construction block 10 can be transparent, translucent, or opaque. The face portion 14 may also have an appropriate textured surface, such as a wave pattern, column pattern, etc., if desired. The body members 12 are formed from an appropriate resin material, such as acrylic, polycarbonate, copolymers, etc.
A baffle 22 having an outer periphery 24 is located within the interior chamber of the joined body members 12 and is disposed generally parallel with the pair of faces 14 and along the seam 20 , to form two separate areas within the interior chamber whereby a bellow effect of the faces 14 is reduced by limiting the amount of air that passes between the two separate areas created by the baffle 22 within the interior chamber. The outer periphery 24 of the baffle 22 is joined to one or more of the of the side faces 16 of either or both of the body members 12 that make up the construction block 10 . The baffle 22 may have an upwardly turned up edge 26 and one or both of the body members 12 has a recessed section 28 for receiving the turned up edge 26 of the baffle 22 . The baffle 22 may have an opening 30 located thereon in order to allow any insulation gas that is introduced into one of the separate areas to pass into the other areas within the interior chamber.
In order to create the construction block 10 of the present invention, the baffle 22 is positioned within the interior chamber of the two body members 12 . If one or both of the body members 12 has a recessed section 28 , the baffle 22 is seated therein. The two body members 12 are brought together such that the respective edge portions 18 abut one another along a seam 20 . The two body members 12 are either joined to one another, either by heat welding or by adhesion or other appropriate joinder technique.
Each baffle 22 , or a face of the block, preferably an interior face, can be provided with an appropriate coating 34 such as an optical or a heat reflective coating on one or both surfaces. This coating 34 can be used to control the effects of the sun, such as an ultraviolet light barrier coating or can be a visual coating, such as a tint, a color, or a reflective surface in order to change the overall appearance and/or thermal efficiency created by the construction block 10 . By placing the coating 34 on the baffle 22 or an interior face of the block 10 , the coating is safely sealed within interior of the construction block 10 so that it cannot be scratched or otherwise tampered with.
Disposed within the interior chamber of the construction block 10 can be an appropriate desiccant 36 for absorbing any moisture within the interior chamber. As the desiccant 36 will fall to the bottom of the interior chamber, it will not be readily visible even in a construction block 10 having transparent faces 14 . Alternately, or in addition to the desiccant 36 , an insulation gas may be disposed within the interior chamber. The insulation gas is chosen from the group consisting of argon, krypton, xenon, or combinations thereof or any other insulating gas or combination thereof.
In order to introduce the desiccant 36 or insulation gas into the interior chamber, the construction block 10 may be formed with at least one opening 32 located thereon. The opening 32 can be located on at least one of the faces 14 , on at least one of the sides 16 , or both. After the desiccant 36 or insulation gas is introduced into the interior chamber, each opening 32 may be sealed in any appropriate fashion.
Alternately, at least one weakened portion can be provided on at least one of the faces 14 , on at least one of the side edges 16 , or both. The weakened portion may be punched out with a screwdriver, drill or other similar tool and the desiccant or insulation gas introduced through the opening thus created.
Again, after the desiccant 36 or insulation gas is introduced into the interior chamber, each opening may be sealed in any appropriate fashion. A locator mark (not illustrated) can be provided on the area encompassed by the weakened portion for easy location of the weakened area. Alternately, the locator mark may be provided on any appropriate portion of the construction block 10 so that the area identified by the locator mark may be drilled to provide a consistent location for the opening for introduction of the desiccant 36 or insulation gas. Again, after the desiccant 36 or insulation gas is introduced into the interior chamber, each opening may be sealed in any appropriate fashion.
While the invention has been particularly shown and described with reference to an embodiment thereof, it will be appreciated by those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the invention.
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A construction block which has improved thermal insulation qualities, has improved sound transmission migration reduction properties, and which reduces or outright eliminates the effects of a seam failure. The construction block is comprised of a pair of generally parallel faces joined by a plurality of sides. At least one baffle is disposed within the interior chamber and is located along the weld seam that joins the two body member halves of the construction block. A desiccant or insulation gas, or both can be disposed within the interior chamber of the block.
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RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 14/679,510 filed on Apr. 6, 2015, which claims priority to U.S. Provisional Patent Application No. 61/977,296, filed on Apr. 9, 2014, the entire disclosure of each of these applications being incorporated herein by this reference.
FIELD OF THE INVENTION
The present invention relates to carbamoyl hydrazine derivatives, processes for preparing them, pharmaceutical compositions containing them, and their use as pharmaceuticals as modulators of the N-formyl peptide receptor (FPR), including the N-formyl peptide receptor 2 (FPR2). The invention relates specifically to the use of these compounds and their pharmaceutical compositions to treat disorders associated with FPR modulation, such as FPR2 modulation.
BACKGROUND OF THE INVENTION
The FPR2 receptor is a G protein-coupled receptor that is expressed on inflammatory cells such as monocytes and neutrophils, as well as T cells, and has been shown to play a critical role in leukocyte trafficking during inflammation and human pathology. FPR2 is an exceptionally promiscuous receptor that responds to a large array of exogenous and endogenous ligands, including serum amyloid A (SAA), chemokine variant sCKPβ8-1, the neuroprotective peptide human, anti-inflammatory eicosanoid lipoxin A4 (LXA4) and glucocorticoid-modulated protein annexin A1. FPR2 transduces anti-inflammatory effects of LXA4 in many systems, but it also can mediate the pro-inflammatory signaling cascade of peptides such as SAA. The ability of the receptor to mediate two opposite effects is proposed to be a result of different receptor domains used by different agonists (Parmentier, Marc et al., Cytokine & Growth Factor Reviews 17 (2006) 501-519).
Activation of FPR2 by LXA4 or its analogs and by Annexin I protein has been shown to result in anti-inflammatory activity by promoting active resolution of inflammation which involves inhibition of polymorphonuclear neutrophil (PMN) and eosinophil migration and also stimulating monocyte migration, enabling clearance of apoptotic cells from the site of inflammation in a nonphlogistic manner. In addition, FPR2 has been shown to inhibit natural killer (NK) cell cytotoxicity and promote activation of T cells, which further contributes to down-regulation of tissue damaging inflammatory signals. FPR2/LXA4 interaction has been shown to be beneficial in experimental models of ischemia reperfusion, angiogenesis, dermal inflammation, chemotherapy-induced alopecia, ocular inflammation such as endotoxin-induced uveitis, corneal wound healing, re-epithelialization etc. FPR2 thus represents an important novel pro-resolutionary molecular target for the development of new therapeutic agents in diseases with excessive inflammatory responses.
SUMMARY OF THE INVENTION
We have now discovered a group of novel compounds which are potent and selective FPR2 modulators. As such, the compounds described herein are useful in treating a wide variety of disorders associated with modulation of the FPR receptor, such as FPR2. 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 FPR2 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 FPR modulation, such as FPR2 modulation.
In one aspect, the invention provides a compound having Formula I or the individual enantiomers, diastereoisomers, zwitterions, tautomers or a pharmaceutically acceptable salt thereof:
wherein:
R 1 is H, optionally substituted C 1-6 alkyl, C 1-6 haloalkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted heterocycle, halogen, —OR 10 , —C 2-6 alkenyl, —C 2-6 alkynyl, —CN, —C(O)R 11 , amine, amide, urea, sulfonamide, sulfone, sulfoxide, sulfide, sulfonic acid, nitro, phosphate or phosphonic acid;
R 2 is H, optionally substituted C 1-6 alkyl, C 1-6 haloalkyl, optionally substituted C 3-8 -cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted heterocycle, halogen, —OR 10 , —C 2-6 alkenyl, —C 2-6 alkynyl, —CN, —C(O)R 11 , amine, amide, urea, sulfonamide, sulfone, sulfoxide, sulfide, sulfonic acid, nitro, phosphate or phosphonic acid;
R 3 is H, optionally substituted C 1-6 alkyl, C 1-6 haloalkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted heterocycle, halogen, —OR 10 , —C 2-6 alkenyl, —C 2-6 alkynyl, —CN, —C(O)R 11 , amine, amide, urea, sulfonamide, sulfone, sulfoxide, sulfide, sulfonic acid, nitro, phosphate or phosphonic acid;
R 4 is H, optionally substituted C 1-6 alkyl, C 1-6 haloalkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted heterocycle, halogen, —OR 10 , —C 2-6 alkenyl, —C 2-6 alkynyl, —CN, —C(O)R 11 , amine, amide, urea, sulfonamide, sulfone, sulfoxide, sulfide, sulfonic acid, nitro, phosphate or phosphonic acid;
R 5 is H, optionally substituted C 1-6 alkyl, C 1-6 haloalkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted heterocycle, halogen, —OR 10 , —C 2-6 alkenyl, —C 2-6 alkynyl, —CN, —C(O)R 11 , amine, amide, urea, sulfonamide, sulfone, sulfoxide, sulfide, sulfonic acid, nitro, phosphate or phosphonic acid;
R 6 is H or optionally substituted C 1-6 alkyl;
R 7 is H or optionally substituted C 1-6 alkyl;
R 8 is H or optionally substituted C 1-6 alkyl;
R 9 is H or optionally substituted C 1-6 alkyl;
a is 0, 1, 2 or 3;
R 10 is —OH or optionally substituted C 1-6 alkyl; and
R 11 is —OH, —OC 1-6 alkyl or optionally substituted C 1-6 alkyl;
with the proviso that the compound of Formula I is not of structure:
In another aspect, the invention provides a compound represented by Formula I, wherein:
R 1 is H or halogen;
R 2 is H or halogen;
R 3 is C 1-6 haloalkyl or halogen;
R 4 is H or halogen;
R 5 is H or halogen;
R 6 is H or optionally substituted C 1-6 alkyl;
R 7 is H or optionally substituted C 1-6 alkyl;
R 8 is H or optionally substituted C 1-6 alkyl;
R 9 is H or optionally substituted C 1-6 alkyl;
a is 0, 1, 2 or 3;
with the proviso that the compound of Formula I is not of structure:
In another aspect, the invention provides a compound represented by Formula I, wherein:
R 1 is H or halogen;
R 2 is H or halogen;
R 3 is C 1-6 haloalkyl;
R 4 is H or halogen;
R 5 is H or halogen;
R 6 is H or optionally substituted C 1-6 alkyl;
R 7 is H or optionally substituted C 1-6 alkyl;
R 8 is H or optionally substituted C 1-6 alkyl;
R 9 is H or optionally substituted C 1-6 alkyl; and
a is 0, 1, 2 or 3.
In another aspect, the invention provides a compound represented by Formula I, wherein:
R 1 is H or halogen;
R 2 is H or halogen;
R 3 is halogen;
R 4 is H or halogen;
R 5 is H or halogen;
R 6 is H or optionally substituted C 1-6 alkyl;
R 7 is H or optionally substituted C 1-6 alkyl;
R 8 is H or optionally substituted C 1-6 alkyl;
R 9 is H or optionally substituted C 1-6 alkyl;
a is 0, 1, 2 or 3;
with the proviso that the compound of Formula I is not of structure:
In another aspect, the invention provides a compound represented by Formula I, wherein:
R 1 is H or halogen;
R 2 is H or halogen;
R 3 is C 1-6 haloalkyl or halogen;
R 4 is H or halogen;
R 5 is H or halogen;
R 6 is H or optionally substituted C 1-6 alkyl;
R 7 is H or optionally substituted C 1-6 alkyl;
R 8 is H or optionally substituted C 1-6 alkyl;
R 9 is H; and
a is 0, 1, 2 or 3.
In another aspect, the invention provides a compound represented by Formula I, wherein:
R 1 is H or halogen;
R 2 is H or halogen;
R 3 is C 1-6 haloalkyl or halogen;
R 4 is H or halogen;
R 5 is H or halogen;
R 6 is H or optionally substituted C 1-6 alkyl;
R 7 is H or optionally substituted C 1-6 alkyl;
R 8 is H or optionally substituted C 1-6 alkyl;
R 9 is optionally substituted C 1-6 alkyl;
a is 0, 1, 2 or 3;
with the proviso that the compound of Formula I is not of structure:
In another aspect, the invention provides a compound represented by Formula I, wherein:
R 1 is H or halogen;
R 2 is H or halogen;
R 3 is C 1-6 haloalkyl;
R 4 is H or halogen;
R 5 is H or halogen;
R 6 is H or optionally substituted C 1-6 alkyl;
R 7 is H or optionally substituted C 1-6 alkyl;
R 8 is H or optionally substituted C 1-6 alkyl;
R 9 is optionally substituted C 1-6 alkyl; and
a is 0, 1, 2 or 3.
In another aspect, the invention provides a compound represented by Formula I, wherein:
R 1 is H or halogen;
R 2 is H or halogen;
R 3 is C 1-6 haloalkyl;
R 4 is H or halogen;
R 5 is H or halogen;
R 6 is H or optionally substituted C 1-6 alkyl;
R 7 is H or optionally substituted C 1-6 alkyl;
R 8 is H or optionally substituted C 1-6 alkyl;
R 9 is optionally substituted C 1-6 alkyl; and
a is 0, 1, 2 or 3.
In another aspect, the invention provides a compound represented by Formula I, wherein:
R 1 is H or halogen;
R 2 is H;
R 3 is halogen or C 1-6 haloalkyl;
R 4 is H;
R 5 is H or halogen;
R 6 is H or optionally substituted C 1-6 alkyl;
R 7 is H;
R 8 is H;
R 9 is H or optionally substituted C 1-6 alkyl; and
a is 0 or 1.
In another aspect, the invention provides a compound represented by Formula I, wherein:
R 1 is H or halogen;
R 2 is H or halogen;
R 3 is halogen;
R 4 is H or halogen;
R 5 is H or halogen;
R 6 is H or optionally substituted C 1-6 alkyl;
R 7 is H or optionally substituted C 1-6 alkyl;
R 8 is H or optionally substituted C 1-6 alkyl;
R 9 is H; and
a is 0, 1, 2 or 3.
In another aspect, the invention provides a compound represented by Formula I, wherein:
R 1 is H or halogen;
R 2 is H or halogen;
R 3 is halogen;
R 4 is H or halogen;
R 5 is H or halogen;
R 6 is H or optionally substituted C 1-6 alkyl;
R 7 is H or optionally substituted C 1-6 alkyl;
R 8 is H or optionally substituted C 1-6 alkyl;
R 9 is optionally substituted C 1-6 alkyl;
a is 0, 1, 2 or 3;
with the proviso that the compound of Formula I is not of structure:
In another aspect, the invention provides a compound represented by Formula I, wherein:
R 1 is H or halogen;
R 2 is H;
R 3 is halogen or C 1-6 haloalkyl;
R 4 is H;
R 5 is H or halogen;
R 6 is H or optionally substituted C 1-6 alkyl;
R 7 is H or optionally substituted C 1-6 alkyl;
R 8 is H or optionally substituted C 1-6 alkyl;
R 9 is H or optionally substituted C 1-6 alkyl; and
a is 0 or 1.
In another aspect, the invention provides a compound represented by Formula I, wherein:
R 1 is H or halogen;
R 2 is H;
R 3 is halogen or C 1-6 haloalkyl;
R 4 is H;
R 5 is H or halogen;
R 6 is H or C 1-6 alkyl;
R 7 is H or C 1-6 alkyl;
R 8 is H or C 1-6 alkyl;
R 9 is H or C 1-6 alkyl; and
a is 0 or 1.
In another aspect, the invention provides a compound having Formula I, or the individual enantiomers, diastereoisomers, zwitterions, tautomers or a pharmaceutically acceptable salt thereof:
wherein:
R 1 is H, optionally substituted C 1-6 alkyl, C 1-6 haloalkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted heterocycle, halogen, —OR 10 , —C 2-6 alkenyl, —C 2-6 alkynyl, —CN, —C(O)R 11 , amine, amide, urea, sulfonamide, sulfone, sulfoxide, sulfide, sulfonic acid, nitro, phosphate or phosphonic acid;
R 2 is H, optionally substituted C 1-6 alkyl, C 1-6 haloalkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted heterocycle, halogen, —OR 10 , —C 2-6 alkenyl, —C 2-6 alkynyl, —CN, —C(O)R 11 , amine, amide, urea, sulfonamide, sulfone, sulfoxide, sulfide, sulfonic acid, nitro, phosphate or phosphonic acid;
R 3 is H, optionally substituted C 1-6 alkyl, C 1-6 haloalkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted heterocycle, halogen, —OR 10 , —C 2-6 alkenyl, —C 2-6 alkynyl, —CN, —C(O)R 11 , amine, amide, urea, sulfonamide, sulfone, sulfoxide, sulfide, sulfonic acid, nitro, phosphate or phosphonic acid;
R 4 is H, optionally substituted C 1-6 alkyl, C 1-6 haloalkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted heterocycle, halogen, —OR 10 , —C 2-6 alkenyl, —C 2-6 alkynyl, —CN, —C(O)R 11 , amine, amide, urea, sulfonamide, sulfone, sulfoxide, sulfide, sulfonic acid, nitro, phosphate or phosphonic acid;
R 5 is H, optionally substituted C 1-6 alkyl, C 1-6 haloalkyl, optionally substituted C 3-8 cycloalkyl, optionally substituted C 6-10 aryl, optionally substituted heterocycle, halogen, —OR 10 , —C 2-6 alkenyl, —C 2-6 alkynyl, —CN, —C(O)R 11 , amine, amide, urea, sulfonamide, sulfone, sulfoxide, sulfide, sulfonic acid, nitro, phosphate or phosphonic acid;
R 6 is H or optionally substituted C 1-6 alkyl;
R 7 is H or optionally substituted C 1-6 alkyl;
R 8 is H or optionally substituted C 1-6 alkyl;
R 9 is H or optionally substituted C 1-6 alkyl;
a is 0, 1, 2 or 3;
R 10 is —OH or optionally substituted C 1-6 alkyl; and
R 11 is —OH, —OC 1-6 alkyl or optionally substituted C 1-6 alkyl;
provided that when a is 1, at least one of R 6 , R 7 and R 9 is not H.
In another aspect, the invention provides a compound represented by Formula I, wherein:
R 1 is H or halogen;
R 2 is H;
R 3 is halogen or C 1-6 haloalkyl;
R 4 is H;
R 5 is H or halogen;
R 6 is H or optionally substituted C 1-6 alkyl;
R 7 is H or optionally substituted C 1-6 alkyl;
R 8 is H or optionally substituted C 1-6 alkyl;
R 9 is H or optionally substituted C 1-6 alkyl; and
a is 0 or 1;
provided that when a is 1, at least one of R 6 , R 7 and R 9 is not H.
In another aspect, the invention provides a compound represented by Formula I, wherein:
R 1 is H or halogen;
R 2 is H;
R 3 is halogen or C 1-6 haloalkyl;
R 4 is H;
R 5 is H or halogen;
R 6 is H or C 1-6 alkyl;
R 7 is H or C 1-6 alkyl;
R 8 is H or C 1-6 alkyl;
R 9 is H or C 1-6 alkyl; and
a is 0 or 1;
provided that when a is 1, at least one of R 6 , R 7 and R 9 is not H.
The term “alkyl”, as used herein, refers to saturated, monovalent or divalent hydrocarbon moieties having linear or branched moieties or combinations thereof and containing 1 to 6 carbon atoms (i.e., C 1-6 alkyl). One or more methylene (CH 2 ) groups of the alkyl can be replaced by oxygen, sulfur, carbonyl, sulfoxide, sulfonyl, or by a divalent C 3-6 cycloalkyl. One or more methine (CH) groups of the alkyl can be replaced by nitrogen. Alkyl groups are optionally substituted with one or more groups including, but not limited to: halogen, hydroxyl, cycloalkyl, heterocycle, aryl, ether, amine, nitro, nitrile, amide, sulfonamide, ester, aldehyde, carboxylic acid, ketone, sulfonic acid, phosphonic acid, and/or phosphoric acid.
The term “cycloalkyl”, as used herein, refers to a monovalent or divalent group of 3 to 8 carbon atoms (i.e., C 3-8 cycloalkyl) derived from a saturated cyclic hydrocarbon. Cycloalkyl groups can be monocyclic or polycyclic. Cycloalkyl groups are optionally substituted with one or more groups including, but not limited to: halogens, hydroxyls, cycloalkyls, heterocycles, aryls, ethers, amines, nitros, nitriles, amides, sulfonamides, esters, aldehydes, carboxylic acids, ketones, sulfonic acids, phosphonic acids, phosphoric acids.
The term “cycloalkenyl”, as used herein, refers to a monovalent or divalent group of 3 to 8 carbon atoms (i.e., C 3-8 cycloalkenyl) derived from a saturated cycloalkyl having one or more double bonds. Cycloalkenyl groups can be monocyclic or polycyclic. Cycloalkenyl groups are optionally substituted by one or more groups including, but not limited to halogens, hydroxyls, cycloalkyls, heterocycles, aryls, ethers, amines, nitros, nitriles, amides, sulfonamides, esters, aldehydes, carboxylic acids, ketones, sulfonic acids, phosphonic acids, phosphoric acids.
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 (i.e., C 2-6 alkenyl), 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 are optionally substituted with C 1-3 alkyl.
The term “alkynyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms (i.e., C 2-6 alkynyl) 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 can be aromatic or non-aromatic, saturated or non-saturated, containing at least one heteroatom selected from O, N and S, or combinations of at least two thereof, interrupting the carbocyclic ring structure. The heterocyclic ring can be interrupted by one or more C═O; the S heteroatom can be oxidized. Heterocycles can be monocyclic or polycyclic. Heterocyclic ring moieties are optionally substituted with one or more groups including, but not limited to: halogens, hydroxyls, cycloalkyls, heterocycles, aminos, nitros, nitriles, amides, ethers, esters, ketones, carboxylic acids, aldehydes, sulfonamides, sulfonic acids, phosphonic acids, phosphoric acids.
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 (i.e., C 6-10 aryl). Aryl groups are optionally substituted by one or more groups including, but not limited to: halogens, hydroxyls, cycloalkyls, heterocycles, aminos, nitros, nitriles, amides, ethers, esters, carboxylic acids, aldehydes, ketones, sulfonamides sulfonic acids, phosphonic acids, phosphoric acids. Aryl can be monocyclic or polycyclic.
The term “amine” as used herein, represents a group of formula “—NR x R y ”, wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl or heterocyclyl, as defined above.
The term “amide” as used herein, represents a group of formula “—C(O)N(R x )(R y )” or “—NR x C(O)R y ” wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl or heterocyclyl, as defined above.
The term “sulfonamide” as used herein, represents a group of formula “—S(O) 2 N(R x )(R y )” or “—NR x S(O) 2 R y ” wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl or heterocyclyl, as defined above.
The term “ester” as used herein, represents a group of formula “—C(O)O(R x )”, wherein R x is alkyl, aryl, cycloalkyl, cycloalkenyl or heterocyclyl, as defined above.
The term “aldehyde” as used herein, represents a group of formula “—C(O)H”.
The term “ketone” as used herein, represents a group of formula “—C(O)R x ” wherein R x is alkyl, aryl, cycloalkyl, cycloalkenyl or heterocyclyl, as defined above.
The term “hydroxyl” as used herein, represents a group of formula “—OH”.
The term “amino” as used herein, represents a group of formula “—NH 2 ”.
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 “—OS(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 “sulphonic acid” as used herein, represents a group of formula “—S(O) 2 OH”.
The term “nitro” as used herein, represents a group of formula “—NO 2 ”.
The term “nitrile” as used herein, represents a group of formula “—CN”.
The term “ether” as used herein, represents a group of formula “—OR x , wherein R x is alkyl, aryl, cycloalkyl, cycloalkenyl or heterocyclyl, as defined above.
Some compounds of the invention are:
4-{2-[(4-Bromo-2-fluorophenyl)carbamoyl]-1-propylhydrazinyl}-4-oxobutanoic acid; Ethyl 4-{2-[(4-bromo-2-fluorophenyl)carbamoyl]-1-propylhydrazinyl}-4-oxobutanoate; Ethyl 4-{2-[(4-bromophenyl)carbamoyl]-1-butylhydrazinyl}-4-oxobutanoate; 4-[1-(2-Methylpropyl)-2-{[4-(trifluoromethyl)phenyl]carbamoyl}hydrazinyl]-4-oxobutanoic acid; 4-oxo-4-(1-Propyl-2-{[4-(trifluoromethyl)phenyl]carbamoyl}hydrazinyl)butanoic acid; Ethyl 4-[1-(2-methylpropyl)-2-{[4-(trifluoromethyl)phenyl]carbamoyl}hydrazinyl]-4-oxobutanoate; Ethyl 4-oxo-4-(1-propyl-2-{[4-(trifluoromethyl)phenyl]carbamoyl}hydrazinyl) butanoate; 4-{2-[(4-Bromo-2-fluorophenyl)carbamoyl]-1-(2-methylpropyl)hydrazinyl}-4-oxobutanoic acid; Ethyl 4-{2-[(4-bromo-2-fluorophenyl)carbamoyl]-1-(2-methylpropyl)hydrazinyl}-4-oxobutanoate; 4-{2-[(4-Bromophenyl)carbamoyl]-1-(2-methylpropyl)hydrazinyl}-4-oxobutanoic acid; Ethyl 4-{2-[(4-bromophenyl)carbamoyl]-1-(2-methylpropyl)hydrazinyl}-4-oxobutanoate; 4-{2-[(4-Bromophenyl)carbamoyl]hydrazinyl}-2,2-diethyl-4-oxobutanoic acid; 2-(2-{2-[(4-Bromophenyl)carbamoyl]hydrazinyl}-2-oxoethyl)-2-propylpentanoic acid; Methyl 2-(2-{2-[(4-Bromophenyl)carbamoyl]hydrazinyl}-2-oxoethyl)-2-propylpentanoate; 4-{2-[(4-Bromophenyl)carbamoyl]hydrazinyl}-2,2-dimethyl-4-oxobutanoic acid; 3-{2-[(4-Bromophenyl)carbamoyl]hydrazinyl}-2,2-dimethyl-3-oxopropanoic acid; and Ethyl 3-{2-[(4-Bromophenyl)carbamoyl]hydrazinyl}-3-oxopropanoate.
Some compounds of Formula I and some of their intermediates have at least one asymmetric center in their structure. This asymmetric center may be present in an R or S configuration, said R and S notation corresponding to 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, hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid and the like; or an organic acid such as for example, acetic acid, hydroxyacetic acid, propanoic acid, lactic acid, pyruvic acid, malonic acid, fumaric acid, maleic acid, oxalic acid, tartaric acid, succinic acid, malic acid, ascorbic acid, benzoic acid, tannic acid, pamoic acid, citric acid, methylsulfonic acid, ethanesulfonic acid, benzenesulfonic acid, formic and the like (Handbook of Pharmaceutical Salts, P. Heinrich Stahl & Camille G. Wermuth (Eds), Verlag Helvetica Chimica Acta—Zürich, 2002, 329-345).
The base addition salt form of a compound of Formula I that occurs in its acid form can be obtained by treating the acid with an appropriate base such as an inorganic base, for example, sodium hydroxide, magnesium hydroxide, potassium hydroxide, calcium hydroxide, ammonia and the like; or an organic base such as for example, L-Arginine, ethanolamine, betaine, benzathine, morpholine and the like. (Handbook of Pharmaceutical Salts, P. Heinrich Stahl & Camille G. Wermuth (Eds), Verlag Helvetica Chimica Acta—Zürich, 2002, 329-345).
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 FPR, including FPR2.
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 the FPR, including FPR2. 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.
Therapeutic utilities of the FPR modulators, including those which modulate FPR2, are ocular inflammatory diseases including, but not limited to, wet and dry age-related macular degeneration (ARMD), uveitis, dry eye, keratitis, allergic eye disease and conditions affecting the posterior part of the eye, such as maculopathies and retinal degeneration including non-exudative age related macular degeneration, exudative age related macular degeneration, choroidal neovascularization, diabetic retinopathy (proliferative), retinopathy of prematurity (ROP), acute macular neuroretinopathy, central serous chorioretinopathy, cystoid macular edema, and diabetic macular edema; infectious keratitis, herpetic keratitis, corneal angiogenesis, lymphangiogenesis, retinitis, and choroiditis such as acute multifocal placoid pigment epitheliopathy, Behcet's disease, birdshot retinochoroidopathy, infectious (syphilis, lyme, tuberculosis, toxoplasmosis), intermediate uveitis (pars planitis), multifocal choroiditis, multiple evanescent white dot syndrome (mewds), ocular sarcoidosis, posterior scleritis, serpiginous choroiditis, subretinal fibrosis and uveitis syndrome, Vogt-Koyanagi-and Harada syndrome; vascular diseases/exudative diseases such as retinal arterial occlusive disease, central retinal vein occlusion, cystoids macular edema, disseminated intravascular coagulopathy, branch retinal vein occlusion, hypertensive fundus changes, ocular ischemic syndrome, retinal arterial microaneurysms, Coat's disease, parafoveal telangiectasias, hemi-retinal vein occlusion, papillophlebitis, central retinal artery occlusion, branch retinal artery occlusion, carotid artery disease (CAD), frosted branch angiitis, sickle cell retinopathy and other hemoglobinopathies, angioid streaks, familial exudative vitreoretinopathy, and Eales disease; traumatic/surgical conditions such as sympathetic ophthalmia, uveitic retinal disease, retinal detachment, trauma, conditions caused by laser, conditions caused by photodynamic therapy, photocoagulation, hypoperfusion during surgery, radiation retinopathy, and bone marrow transplant retinopathy; proliferative disorders such as proliferative vitreal retinopathy and epiretinal membranes, and proliferative diabetic retinopathy; infectious disorders such as ocular histoplasmosis, ocular toxocariasis, presumed ocular histoplasmosis syndrome (POHS), endophthalmitis, toxoplasmosis, retinal diseases associated with HIV infection, choroidal disease associate with HIV infection, uveitic disease associate with HIV infection, viral retinitis, acute retinal necrosis, progressive outer retinal necrosis, fungal retinal diseases, ocular syphilis, ocular tuberculosis, diffuse unilateral subacute neuroretinitis, and myiasis; genetic disorders such as retinitis pigmentosa, systemic disorders with associated retinal dystrophies, congenital stationary night blindness, cone dystrophies, Stargardt's disease and fundus flavimaculatus, Best's disease, pattern dystrophy of the retinal pigmented epithelium, X-linked retinoschisis, Sorsby's fundus dystrophy, benign concentric maculopathy, Bietti's crystalline dystrophy, and pseudoxanthoma elasticum; retinal tears/holes such as retinal detachment, macular hole, and giant retinal tear; tumors such as retinal disease associated with tumors, congenital hypertrophy of the retinal pigmented epithelium, posterior uveal melanoma, choroidal hemangioma, choroidal osteoma, choroidal metastasis, combined hamartoma of the retina and retinal pigmented epithelium, retinoblastoma, vasoproliferative tumors of the ocular fundus, retinal astrocytoma, and intraocular lymphoid tumors; and miscellaneous other diseases affecting the posterior part of the eye such as punctate inner choroidopathy, acute posterior multifocal placoid pigment epitheliopathy, myopic retinal degeneration, and acute retinal pigment epitheliitis, systemic inflammatory diseases such as stroke, coronary artery disease, obstructive airway diseases, HIV-mediated retroviral infections, cardiovascular disorders including coronary artery disease, neuroinflammation, neurological disorders, pain and immunological disorders, asthma, allergic disorders, inflammation, systemic lupus erythematosus, psoriasis, CNS disorders such as Alzheimer's disease, arthritis, sepsis, inflammatory bowel disease, cachexia, angina pectoris, post-surgical corneal inflammation, blepharitis, MGD, dermal wound healing, corneal wound healing burns, rosacea, atopic dermatitis, acne, psoriasis, seborrheic dermatitis, actinic keratoses, viral warts, photoaging rheumatoid arthritis and related inflammatory disorders, alopecia, glaucoma, branch vein occlusion, Best's vitelliform macular degeneration, retinitis pigmentosa, proliferative vitreoretinopathy (PVR), and any other degenerative disease of either the photoreceptors or the RPE (Perretti, Mauro et al. Pharmacology & Therapeutics 127 (2010) 175-188.)
These compounds are useful for the treatment of mammals, including humans, with a range of conditions and diseases that are alleviated by FPR modulation (such as FPR2 modulation): including, but not limited to the treatment of ocular inflammatory diseases: wet and dry age-related macular degeneration (ARMD), dry eye, keratitis, allergic eye disease and conditions affecting the posterior part of the eye, such as maculopathies and retinal degeneration including non-exudative age related macular degeneration, exudative age related macular degeneration, choroidal neovascularization, diabetic retinopathy (proliferative), retinopathy of prematurity (ROP), acute macular neuroretinopathy, central serous chorioretinopathy, cystoid macular edema, and diabetic macular edema; infectious keratitis, herpetic keratitis, corneal angiogenesis, lymphangiogenesis, uveitis, retinitis, and choroiditis such as acute multifocal placoid pigment epitheliopathy, Behcet's disease, birdshot retinochoroidopathy, infectious (syphilis, lyme, tuberculosis, toxoplasmosis), intermediate uveitis (pars planitis), multifocal choroiditis, multiple evanescent white dot syndrome (mewds), ocular sarcoidosis, posterior scleritis, serpiginous choroiditis, subretinal fibrosis and uveitis syndrome, Vogt-Koyanagi-and Harada syndrome; vascular diseases/exudative diseases such as retinal arterial occlusive disease, central retinal vein occlusion, cystoids macular edema, disseminated intravascular coagulopathy, branch retinal vein occlusion, hypertensive fundus changes, ocular ischemic syndrome, retinal arterial microaneurysms, Coat's disease, parafoveal telangiectasis, telangiectasias, hemi-retinal vein occlusion, papillophlebitis, central retinal artery occlusion, branch retinal artery occlusion, carotid artery disease (CAD), frosted branch angiitis, sickle cell retinopathy and other hemoglobinopathies, angioid streaks, familial exudative vitreoretinopathy, and Eales disease; traumatic/surgical conditions such as sympathetic ophthalmia, uveitic retinal disease, retinal detachment, trauma, conditions caused by laser, conditions caused by photodynamic therapy, photocoagulation, hypoperfusion during surgery, radiation retinopathy, and bone marrow transplant retinopathy; proliferative disorders such as proliferative vitreal retinopathy and epiretinal membranes, and proliferative diabetic retinopathy; infectious disorders such as ocular histoplasmosis, ocular toxocariasis, presumed ocular histoplasmosis syndrome (POHS), endophthalmitis, toxoplasmosis, retinal diseases associated with HIV infection, choroidal disease associate with HIV infection, uveitic disease associate with HIV infection, viral retinitis, acute retinal necrosis, progressive outer retinal necrosis, fungal retinal diseases, ocular syphilis, ocular tuberculosis, diffuse unilateral subacute neuroretinitis, and myiasis; genetic disorders such as retinitis pigmentosa, systemic disorders with associated retinal dystrophies, congenital stationary night blindness, cone dystrophies, Stargardt's disease and fundus flavimaculatus, Best's disease, pattern dystrophy of the retinal pigmented epithelium, X-linked retinoschisis, Sorsby's fundus dystrophy, benign concentric maculopathy, Bietti's crystalline dystrophy, and pseudoxanthoma elasticum; retinal tears/holes such as retinal detachment, macular hole, and giant retinal tear; tumors such as retinal disease associated with tumors, congenital hypertrophy of the retinal pigmented epithelium, posterior uveal melanoma, choroidal hemangioma, choroidal osteoma, choroidal metastasis, combined hamartoma of the retina and retinal pigmented epithelium, retinoblastoma, vasoproliferative tumors of the ocular fundus, retinal astrocytoma, and intraocular lymphoid tumors; and miscellaneous other diseases affecting the posterior part of the eye such as punctate inner choroidopathy, acute posterior multifocal placoid pigment epitheliopathy, myopic retinal degeneration, and acute retinal pigment epitheliitis, systemic inflammatory diseases such as stroke, coronary artery disease, obstructive airway diseases, HIV-mediated retroviral infections, cardiovascular disorders including coronary artery disease, neuroinflammation, neurological disorders, pain and immunological disorders, asthma, allergic disorders, inflammation, systemic lupus erythematosus, psoriasis, CNS disorders such as Alzheimer's disease, arthritis, sepsis, inflammatory bowel disease, cachexia, angina pectoris, post-surgical corneal inflammation, blepharitis, MGD, dermal wound healing, burns, corneal wound healing, rosacea, atopic dermatitis, acne, psoriasis, seborrheic dermatitis, actinic keratoses, viral warts, photoaging rheumatoid arthritis and related inflammatory disorders, alopecia, glaucoma, branch vein occlusion, Best's vitelliform macular degeneration, retinitis pigmentosa, proliferative vitreoretinopathy (PVR), and any other degenerative disease of either the photoreceptors or the RPE.
In still another embodiment of the invention, there are provided methods for treating disorders associated with modulation of the FPR receptor, such as modulation of the FPR2 receptor. 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, individual enantiomers, and individual 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 inflammatory diseases including, but not limited to, uveitis, dry eye, keratitis, allergic eye disease and conditions affecting the posterior part of the eye, such as maculopathies and retinal degeneration including non-exudative age related macular degeneration, exudative age related macular degeneration, choroidal neovascularization, diabetic retinopathy, acute macular neuroretinopathy, central serous chorioretinopathy, cystoid macular edema, and diabetic macular edema; infectious keratitis, herpetic keratitis, corneal angiogenesis, lymphangiogenesis, retinitis, and choroiditis such as acute multifocal placoid pigment epitheliopathy, Behcet's disease, birdshot retinochoroidopathy, infectious (syphilis, lyme, tuberculosis, toxoplasmosis), intermediate uveitis (pars planitis), multifocal choroiditis, multiple evanescent white dot syndrome (mewds), ocular sarcoidosis, posterior scleritis, serpiginous choroiditis, subretinal fibrosis and uveitis syndrome, Vogt-Koyanagi-and Harada syndrome; vascular diseases/exudative diseases such as retinal arterial occlusive disease, central retinal vein occlusion, disseminated intravascular coagulopathy, branch retinal vein occlusion, hypertensive fundus changes, ocular ischemic syndrome, retinal arterial microaneurysms, Coat's disease, parafoveal telangiectasis, hemi-retinal vein occlusion, papillophlebitis, central retinal artery occlusion, branch retinal artery occlusion, carotid artery disease (CAD), frosted branch angiitis, sickle cell retinopathy and other hemoglobinopathies, angioid streaks, familial exudative vitreoretinopathy, and Eales disease; traumatic/surgical conditions such as sympathetic ophthalmia, uveitic retinal disease, retinal detachment, trauma, conditions caused by laser, conditions caused by photodynamic therapy, photocoagulation, hypoperfusion during surgery, radiation retinopathy, and bone marrow transplant retinopathy; proliferative disorders such as proliferative vitreal retinopathy and epiretinal membranes, and proliferative diabetic retinopathy; infectious disorders such as ocular histoplasmosis, ocular toxocariasis, presumed ocular histoplasmosis syndrome (POHS), endophthalmitis, toxoplasmosis, retinal diseases associated with HIV infection, choroidal disease associate with HIV infection, uveitic disease associate with HIV infection, viral retinitis, acute retinal necrosis, progressive outer retinal necrosis, fungal retinal diseases, ocular syphilis, ocular tuberculosis, diffuse unilateral subacute neuroretinitis, and myiasis; genetic disorders such as retinitis pigmentosa, systemic disorders with associated retinal dystrophies, congenital stationary night blindness, cone dystrophies, Stargardt's disease and fundus flavimaculatus, Best's disease, pattern dystrophy of the retinal pigmented epithelium, X-linked retinoschisis, Sorsby's fundus dystrophy, benign concentric maculopathy, Bietti's crystalline dystrophy, and pseudoxanthoma elasticum; retinal tears/holes such as retinal detachment, macular hole, and giant retinal tear; tumors such as retinal disease associated with tumors, congenital hypertrophy of the retinal pigmented epithelium, posterior uveal melanoma, choroidal hemangioma, choroidal osteoma, choroidal metastasis, combined hamartoma of the retina and retinal pigmented epithelium, retinoblastoma, vasoproliferative tumors of the ocular fundus, retinal astrocytoma, and intraocular lymphoid tumors; and miscellaneous other diseases affecting the posterior part of the eye such as punctate inner choroidopathy, acute posterior multifocal placoid pigment epitheliopathy, myopic retinal degeneration, and acute retinal pigment epitheliitis, systemic inflammatory diseases such as stroke, coronary artery disease, obstructive airway diseases, HIV-mediated retroviral infections, cardiovascular disorders including coronary artery disease, neuroinflammation, neurological disorders, pain and immunological disorders, asthma, allergic disorders, inflammation, systemic lupus erythematosus, psoriasis, CNS disorders such as Alzheimer's disease, arthritis, sepsis, inflammatory bowel disease, cachexia, angina pectoris, post-surgical corneal inflammation, blepharitis, MGD, dermal wound healing, burns, corneal wound healing, rosacea, atopic dermatitis, acne, psoriasis, seborrheic dermatitis, actinic keratoses, viral warts, photoaging rheumatoid arthritis and related inflammatory disorders, alopecia, glaucoma, branch vein occlusion, Best's vitelliform macular degeneration, retinitis pigmentosa, proliferative vitreoretinopathy (PVR), and any other degenerative disease of either the photoreceptors or the RPE.
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 of 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.
Pharmaceutical compositions containing invention compounds may be in a form suitable for topical use, for example, as oily suspensions, as solutions or suspensions in aqueous liquids or nonaqueous liquids, or as oil-in-water or water-in-oil liquid emulsions. Pharmaceutical compositions may be prepared by combining a therapeutically effective amount of at least one compound according to the present invention, or a pharmaceutically acceptable salt thereof, as an active ingredient with conventional ophthalmically acceptable pharmaceutical excipients and by preparation of unit dosage suitable for topical ocular use. The therapeutically efficient amount typically is between about 0.001 and about 5% (w/v), preferably about 0.001 to about 2.0% (w/v) in liquid formulations.
For ophthalmic application, preferably solutions are prepared using a physiological saline solution as a major vehicle. The pH of such ophthalmic solutions should preferably be maintained between 4.5 and 8.0 with an appropriate buffer system, a neutral pH being preferred but not essential. The formulations may also contain conventional pharmaceutically acceptable preservatives, stabilizers and surfactants. Preferred preservatives that may be used in the pharmaceutical compositions of the present invention include, but are not limited to, benzalkonium chloride, chlorobutanol, thimerosal, phenylmercuric acetate and phenylmercuric nitrate. A preferred surfactant is, for example, Tween 80. Likewise, various preferred vehicles may be used in the ophthalmic preparations of the present invention. These vehicles include, but are not limited to, polyvinyl alcohol, povidone, hydroxypropyl methyl cellulose, poloxamers, carboxymethyl cellulose, hydroxyethyl cellulose cyclodextrin and purified water.
Tonicity adjustors may be added as needed or convenient. They include, but are not limited to, salts, particularly sodium chloride, potassium chloride, mannitol and glycerin, or any other suitable ophthalmically acceptable tonicity adjustor.
Various buffers and means for adjusting pH may be used so long as the resulting preparation is ophthalmically acceptable. Accordingly, buffers include acetate buffers, citrate buffers, phosphate buffers and borate buffers. Acids or bases may be used to adjust the pH of these formulations as needed.
In a similar manner an ophthalmically acceptable antioxidant for use in the present invention includes, but is not limited to, sodium metabisulfite, sodium thiosulfate, acetylcysteine, butylated hydroxyanisole and butylated hydroxytoluene. Other excipient components which may be included in the ophthalmic preparations are chelating agents. The preferred chelating agent is edentate disodium, although other chelating agents may also be used in place of or in conjunction with it.
The ingredients are usually used in the following amounts:
Ingredient
Amount (% w/v)
active ingredient
about 0.001-5
preservative
0-0.10
vehicle
0-40
tonicity adjustor
0-10
buffer
0.01-10
pH adjustor
q.s. pH 4.5-7.8
antioxidant
as needed
surfactant
as needed
purified water
to make 100%
The actual dose of the active compounds of the present invention depends on the specific compound, and on the condition to be treated; the selection of the appropriate dose is well within the knowledge of the skilled artisan.
The ophthalmic formulations of the present invention are conveniently packaged in forms suitable for metered application, such as in containers equipped with a dropper, to facilitate application to the eye. Containers suitable for drop wise application are usually made of suitable inert, non-toxic plastic material, and generally contain between about 0.5 and about 15 ml solution. One package may contain one or more unit doses. Especially preservative-free solutions are often formulated in non-resealable containers containing up to about ten, preferably up to about five units doses, where a typical unit dose is from one to about 8 drops, preferably one to about 3 drops. The volume of one drop usually is about 20-35 μl.
The compounds of the invention 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 the FPR receptor, such as FPR2. Thus, in further embodiments of the invention, there are provided methods for treating a disorder associated with modulation of the FPR receptor, such as modulation of the FPR2 receptor. 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. Synthetic Scheme 1, set forth below, illustrates how the compounds according to the invention can be made.
Compounds within the scope of the invention may be prepared as depicted in Scheme 1. In general, a N-arylhydrazinecarboxamide can be alkylated with an aldehyde under reductive amination conditions (e.g., NaCNBH 3 ) to produce a N′-substituted N-arylhydrazinecarboxamide. This compound (or an unsubstituted N-arylhydrazinecarboxamide) can be treated with an appropriately substituted acid chloride in the presence of a base or a substituted carboxylic acid in the presence of a coupling agent like EDC to provide compounds of Formula I.
At this stage, those skilled in the art will appreciate that many additional compounds that fall under the scope of the invention covered by Formula I may be prepared by performing various common chemical reactions. Details of certain specific chemical transformations are provided in the Examples that follow. Those skilled in the art will be able to routinely modify and/or adapt the schemes to synthesize any compounds of the invention covered by Formula I.
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 mixtures thereof, including 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 hydrogen 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 diastereoisomeric forms can be obtained by separation of mixtures thereof in a conventional manner. For example, chromatographic separation may be employed; chiral chromatography may be performed to separate individual enantiomers.
Compound names were generated with ACDLab version 12.5; some intermediates' and reagents' names used in the examples were generated with softwares such as Chem Bio Draw Ultra version 12.0, ACDLab version 12.5 or Auto Nom 2000 from MDL ISIS Draw 2.5 SP1.
In general, characterization of the compounds was performed using NMR spectra, which were recorded on a 300 or 600 MHz Varian NMR spectrometer and acquired at room temperature. Chemical shifts are given in ppm referenced either to internal TMS or to the solvent signal. 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 Teledyne-ISCO CombiFlash with a silica column, unless noted otherwise.
The following abbreviations are used in the examples:
THF tetrahydrofuran
CD 3 OD deuterated methanol
RT room temperature
CH 2 Cl 2 dichloromethane
EtOAc ethyl acetate
EtOH ethanol
Et 3 N triethylamine
DMSO-D6 deuterated dimethylsulfonamide
K 2 CO 3 potassium carbonate
HCl hydrochloric acid
CD 3 CN deuterated acetonitrile
NaCNBH 3 sodium borohydride
EtOAc ethyl acetate
NaHCO 3 sodium bicarbonate
AcOH acetic acid
CDCl 3 deuterated chloroform
TLC thin layer chromatography
EDC 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide
HOBT 1H-benzotriazol-1-ol
LiOH lithium hydroxide
H 2 O water
KOH potassium hydroxide
Example 1
Intermediate 1
(E)-N-(4-Bromophenyl)-2-(2-methylpropylidene)hydrazinecarboxamide
A mixture of N-(4-bromophenyl)-hydrazinecarboxamide CAS#2646-26-6 (231 mg, 1 mmol), isobutyraldehyde CAS#78-84-2 (86 mg, 1.2 mmol), K 2 CO 3 (304 mg, 1.2 mmol) in THF (5 mL) was stirred for 2 h. The reaction mixture was diluted with EtOAc (15 mL), washed with dilute aq. HCl (0.5% solution, 5 mL). The EtOAc layer was dried and the solvent was removed. Intermediate 1 was isolated as a white solid.
1 HNMR (CD 3 CN) δ: 1.12 (d, J=7.0 Hz, 6H), 2.48-2.59 (m, 1H), 7.18 (d, J=4.98 Hz, 1H), 7.42-7.53 (m, 4H).
Intermediates 3, 5, 7 and 9 were prepared from the corresponding hydrazinecarboxamides and aldehydes, in a similar manner to the procedure described in Example 1 for Intermediate 1. The results are described below in Table 1.
TABLE 1
Interme-
diate
IUPAC name
Hydrazine
No.
Structure
carboxamide
Aldehyde
3
N-(4-bromo-2- fluorophenyl)- hydrazinecarboxamide CAS 1094561-48-4
Isobutyraldehyde CAS 78-84-2
5
N-[4-(trifluoromethyl) phenyl]- hydrazinecarboxamide CAS 131210-52-1
Isobutyraldehyde CAS 78-84-2
7
N-[4-(trifluoromethyl) phenyl]- hydrazinecarboxamide CAS 131210-52-1
Propanal CAS 123-38-6
9
N-(4-bromophenyl) hydrazinecarboxamide CAS 2646-26-6
Butanal CAS 123-72-8
Example 2
Intermediate 2
N-(4-Bromophenyl)-2-isobutylhydrazinecarboxamide
To a mixture of Intermediate 1 (580 mg, 2.05 mmol) and NaCNBH 3 (196 mg, 3.1 mmol) in THF (8 mL) was added AcOH (326 mg, 4.1 mmol) and stirred at RT for 6 h. All of the solvent was removed and the crude mixture was dissolved in EtOAc (50 mL), washed with aq. NaHCO 3 (10% solution, 10 mL), brine, dried and the solvent was removed. The crude mixture was purified by silica gel chromatography, using EtOAc in hexane as eluent. Intermediate 2 was isolated as a white solid.
1 HNMR (CD 3 CN) δ: 0.97 (d, J=6.7 Hz, 6H), 1.75-1.87 (m, 1H), 2.61 (d, J=6.7 Hz, 2H), 7.38 (s, 4H).
Intermediates 4, 6, 8 and 10 were prepared from in a similar manner to the procedure described in Example 2 for Intermediate 2. The results are described below in Table 2.
TABLE 2
From
Interm.
IUPAC name
Interm.
No.
Structure
No.
1 H NMR δ (ppm)
4
3
1 HNMR (CDCl 3 ): δ 0.98 (d, J = 6.1 Hz, 6H), 1.70- 1.85 (m, 1H), 2.68 (t, J = 6.1 Hz, 2H), 7.13-7.18 (m, 2H), 8.18 (t, J = 8.6 Hz, 1H).
6
5
1 HNMR (CD 3 OD): δ 0.96 (d, J = 6.7 Hz, 6H), 1.70-1.86 (m, 1H), 2.62 (d, J = 7.0 Hz, 2H), 7.50-7.66 (m, 4H).
8
7
1 HNMR (CD 3 OD): δ 1.05 (t, J = 7.0 Hz, 3H), 1.64-1.82 (m, 2H), 3.07-3.24 (m, 2H), 7.49-7.64 (m, 2H), 7.64-7.76 (m, 2H).
10
9
1 HNMR (CD 3 OD): δ 0.94 (t, J = 7.0 Hz, 3H), 1.30-1.60 (m, 4H), 2.80 (t, J = 7.0 Hz, 2H), 7.38 (s, 4H).
11
N-(4-bromo- 2-fluorophenyl)- hydrazine- carboxamide CAS 1094561- 48-4 Propanal CAS 123-38-6
1 HNMR (CD 3 OD): δ 0.98 (t, J = 7.5 Hz, 3H), 1.37-1.71 (m, 2H), 2.78 (t, J = 7.0 Hz, 2H), 7.07- 7.46 (m, 2H), 7.86 -8.17 (m, 1H).
Example 3
Compound 1
Ethyl 3-{2-[(4-bromophenyl)carbamoyl]hydrazinyl}-3-oxopropanoate
To a solution of N-(4-bromophenyl)hydrazinecarboxamide (CAS#2646-26-6; 100 mg, 0.44 mmol), and Et 3 N (88 mg, 0.88 mmol) in CH 2 Cl 2 (3 mL) and DMF (1 mL) was added 3-chloro-3-oxo-propanoic acid ethyl ester (CAS#36239-09-5; 75 mg, 0.5 mmol). The mixture was stirred at RT for 18 h; then the solvent was removed, and the crude mixture was purified by preparative TLC. Compound 1 was isolated as a white solid.
1 HNMR (CD 3 OD) δ: 1.35 (t, J=7.5 Hz, 3H), 3.31 (s, 2H), 4.25 (q, J=7.5 Hz, 2H), 7.40 (s, 4H).
Example 4
Compound 2
3-{2-[(4-Bromophenyl)carbamoyl]hydrazinyl}-2,2-dimethyl-3-oxopropanoic acid
A mixture of N-(4-bromophenyl)hydrazinecarboxamide (CAS#2646-26-6; 100 mg, 0.44 mmol), EDC (130 mg, 0.66 mmol), HOBT (90 mg, 0.66 mmol), 4-methyl morpholine (131 mg, 1.32 mmol) and dimethylmalonic acid (58 mg, 0.44 mmol) in CH 2 Cl 2 (5 mL) was stirred at RT for 18 h. The solvent was removed and the crude mixture was purified by preparative TLC. Compound 2 was isolated as a white solid.
1 HNMR (CD 3 OD) δ: 1.31 (s, 6H), 7.42 (brs, 4H).
Compounds 3, 4 and 6 were prepared in a similar manner to the procedure described in Example 4 for Compound 2. The results are shown below in Table 3.
TABLE 3
Cmpd.
IUPAC name
Starting
1 H NMR δ
No.
Structure
materials
(ppm)
3
N-(4- bromophenyl) hydrazine- carboxamide CAS 2646-26-6 2,2-dimethyl Butanedioic acid CAS 597-43-3
1 HNMR (CD 3 OD) δ: 1.38 (s, 6H), 2.68 (s, 2H), 7.35 (d, J = 8.2 Hz, 2H), 7.40 (d, J = 8.2 Hz, 2H). white solid
4
N-(4- bromophenyl) hydrazine- carboxamide CAS 2646-26-6 butanedioic acid, 2,2- dipropyl-,1- methyl ester CAS 664304-90-9
1 HNMR (CD 3 OD) δ: 0.91 (br s, 6H), 1.16-1.36 (m, 4H), 1.59-1.75 (m, 4H), 2.57 (s, 2H), 3.67 (s, 3H), 7.38 (s, 4H).
6
N-(4- bromophenyl) hydrazine- carboxamide CAS 2646-26-6 3,3- diethyldihydro- 2,5-Furandione CAS 2840-69-9
1 HNMR (CD 3 OD) δ: 0.91 (t, J = 7.5 Hz, 6H), 1.76 (q, J = 7.5 Hz, 2H), 2.53 (s, 2H), 7.37 (m, 4H).
Example 5
Compound 5
2-[2-(2-{[(4-Bromophenyl)amino]carbonyl}hydrazino)-2-oxoethyl]-2-propylpentanoic Acid
A mixture of Compound 4 (280 mg, 0.65 mmol) LiOH—H 2 O (1 M solution, 2, mL) and methanol (5 mL) was stirred for 5 h at RT. The reaction was quenched with 10% HCl solution (2 mL), extracted with EtOAC, the organic layer was washed with brine, dried and solvent removed. The crude product was purified by preparative TLC. Compound 5 was isolated as a light yellow solid.
1 HNMR (CD 3 OD) δ: 0.93 (br s, 6H), 1.29 (br s, 4H), 1.65 (br s, 4H), 2.70 (br s, 2H), 7.23-7.51 (m, 4H).
Example 6
Compound 7
Ethyl 4-{2-[(4-Bromophenyl)carbamoyl]-1-(2-methylpropyl)hydrazinyl}-4-oxobutanoate
To a cold (0° C.) mixture of Intermediate 2 (183 mg, 0.63 mmol), Et 3 N (77 mg, 0.77 mmol) in dioxane (4 mL) was added 4-chloro-4-oxo-butanoic acid ethyl ester (CAS#14794-31-1; 115 mg, 0.69 mmol). The mixture was stirred at RT for 2 h. The reaction was diluted with EtOAc (50 mL), washed with aq. NaHCO 3 (10 mL), dried and solvent removed. The crude product was recrystallized from hot methanol. Compound 7 was isolated as a white solid.
1 HNMR (CD 3 CN): δ 0.93 (br d, 6H), 1.23 (t, J=7.3 Hz, 3H), 1.82-1.95 (m, 1H), 2.54 (t, J=6.1 Hz, 2H), 2.62 (br. d, 2H), 2.78 (t, J=6.1 Hz, 2H), 4.12 (q, J=7.3 Hz, 2H), 7.37-7.49 (m, 4H).
Compounds 9, 11, 13, 15 and 16 were prepared in a similar manner to the procedure described in Example 6 for Compound 7. The results are described below in Table 4.
TABLE 4
Compound
IUPAC name
Interm.
1 H NMR δ
No.
Structure
No
(ppm)
9
4
1 HNMR (CD 3 OD): δ 0.91 (br. S, 6H), 1.21 (t, J = 7.2 Hz, 3H), 1.82-2.05 (m, 1H), 2.50-2.70 (br. S, 4H), 2.75-3.00 (br. s, 2H), 4.09 (q, J = 7.2 Hz, 2H), 7.20-7.35 (m, 2H), 7.90 (br. t, 1H).
11
6
1 HNMR (CD 3 OD): δ 0.93 (br. S, 6H), 1.23 (t, J = 7.2 Hz, 3H), 1.90-2.05 (m, 1H), 2.50-2.70 (br. S, 4H), 2.75-3.00 (br. s, 2H), 4.12 (q, J = 7.2 Hz, 2H), 7.47-7.75 (m, 4H)
13
8
1 HNMR (CD 3 OD): δ 0.92 (t, J = 7.3 Hz, 3H), 1.24 (t, J = 7.0 Hz, 3H), 1.45- 1.71 (m, 2H), 2.50-2.82 (br. s, 4H), 3.30-3.40 (br. s, 2H), 4.12 (q, J = 7.0 Hz, 2H), 7.46-7.74 (m, 4H).
15
10
1 HNMR (CD 3 OD): δ 0.93 (t, J = 7.2 Hz, 3H), 1.23 (t, J = 7.2 Hz, 3H), 1.30- 1.40 (m, 2H), 1.50-1.62 (m, 2H), 2.50-2.70 (br. s, 4H), 2.70-2.90 (br. s, 2H), 4.12 (q, J = 7.2 Hz, 2H), 7.40 (s, 4H).
16
Inter- mediate 11
1 HNMR (CD 3 OD): δ 0.91 (t, J = 7.3 Hz, 3H), 1.22 (t, J = 7.2 Hz, 3H), 1.55- 1.70 (m, 2H), 2.50-2.80 (br s, 4H), 3.20-3.40 (br s, 2H), 4.10 (q, J = 7.2 Hz, 2H), 7.26 (dd, J = 1.2, 8.8 Hz, 1H), 7.33 (dd, J = 2.1, 10.6 Hz, 1H), 7.87 (br s, 1H).
Example 7
Compound 8
4-{2-[(4-Bromophenyl)carbamoyl]-1-(2-methylpropyl)hydrazinyl}-4-oxobutanoic Acid
A mixture of Compound 7 (90 mg, 0.22 mmol), KOH—H 2 O (1 M solution, 1 mL), EtOH (1 mL) and dioxane (1 mL) was stirred at RT for 3 h. About 80% of the solvent was removed, the crude mixture cooled to −78° C. and acidified with aq. HCl. Compound 8 was collected as a white solid.
1 HNMR (DMSO-D 6 ): δ 0.93 (br s, 6H), 1.82-1.99 (m, 1H), 2.53 (br. s, 2H), 2.85 (br. s, 2H), 2.30 (br. s, 2H), 7.55 (s, 4H).
Compounds 10, 12, 14 and 17 were prepared in a similar manner to the procedure described in Example 7 for Compound 8. The results are described below in Table 5.
TABLE 5
Compound
IUPAC name
Starting
1 H NMR δ
No.
Structure
Compound
(ppm)
10
9
1 HNMR (CD 3 OD): δ0.91 (br. S, 6H), 1.94 (br. s, 1H), 2.57 (br. S, 4H), 2.98 (br. s, 2H), 7.20- 7.35 (m, 2H), 7.87 (br. t, 1H).
12
11
1 HNMR (CD 3 OD): δ 0.92 (br. s, 6H), 1.92- 2.02 (m, 1H), 2.45- 2.65 (br. s, 4H), 2.70- 2.80 (br. s, 2H), 7.54 (d, J = 8.2 Hz, 2H), 7.65 (d, J = 8.2 Hz, 2H).
14
13
1 HNMR (CD 3 OD): δ 0.92 (t, J = 7.3 Hz, 3H), 1.49-1.74 (m, 2H), 2.43-2.80 (br. s, 4H), 3.30-3.40 (br. s, 2H), 7.47-7.60 (m, 2H), 7.60-7.73 (m, 2H).
17
16
1 HNMR (CD 3 OD): δ 0.91 (t, J = 7.2 Hz, 3H), 1.55-1.70 (m, 2H), 2.50-2.80 (br s, 4H), 3.20-3.40 (br s, 2H), 7.28 (d, J = 8.8 Hz, 1H), 7.35 (dd, J = 1.9, 10.4 Hz, 1H), 7.85 (br s, 1H).
Biological Data
Compounds of Formula I modulate FPR activity. For example, the data set forth in Table 6 below show that compounds of Formula I modulate FPR2 activity. HEK-Gα16 and CHO-Gα16 cells stably expressing FPR2 were cultured in (F12, 10% FBS, 1% PSA, 400 μg/ml geneticin and 50 μg/ml hygromycin) and HEK-Gqi5 cells stable expressing FPR2 were cultured in (DMEM high glucose, 10% FBS, 1% PSA, 400 μg/ml geneticin and 50 μg/ml hygromycin). In general, the day before the experiment, 18,000 cells/well were plated in a 384-well clear bottom poly-D-lysine coated plate. The following day, the screening compound-induced calcium activity was assayed on the FLIPR Tetra®. The drug plates were prepared in 384-well microplates using the EP3 and the MuItiPROBE robotic liquid handling systems. Compounds were tested at concentrations ranging from 0.61 to 10,000 nM. Results are expressed as EC 50 (nM) and efficacy values.
TABLE 6
EC 50 nM
Compound IUPAC name
(% Efficacy)
ethyl 3-{2-[(4-bromophenyl)carbamoyl]hydrazinyl}-3-
750
(100)
oxopropanoate
3-{2-[(4-bromophenyl)carbamoyl]hydrazinyl}-2,2-
5212
(73)
dimethyl-3-oxopropanoic acid
4-{2-[(4-bromophenyl)carbamoyl]hydrazinyl}-2,2-
602
(86)
dimethyl-4-oxobutanoic acid
methyl 2-(2-{2-[(4-bromophenyl)carbamoyl]hydrazinyl}-
46
(89)
2-oxoethyl)-2-propylpentanoate
2-(2-{2-[(4-bromophenyl)carbamoyl]hydrazinyl}-2-
215
(87)
oxoethyl)-2-propylpentanoic acid
4-{2-[(4-bromophenyl)carbamoyl]hydrazinyl}-2,2-
421
(73)
diethyl-4-oxobutanoic acid
ethyl 4-{2-[(4-bromophenyl)carbamoyl]-1-(2-
31
(100)
methylpropyl)hydrazinyl}-4-oxobutanoate
4-{2-[(4-bromophenyl)carbamoyl]-1-(2-
12
(100)
methylpropyl)hydrazinyl}-4-oxobutanoic acid
ethyl 4-{2-[(4-bromo-2-fluorophenyl)carbamoyl]-1-(2-
3659
(76)
methylpropyl)hydrazinyl}-4-oxobutanoate
4-{2-[(4-bromo-2-fluorophenyl)carbamoyl]-1-(2-
339
(99)
methylpropyl)hydrazinyl}-4-oxobutanoic acid
ethyl 4-[1-(2-methylpropyl)-2-{[4-
57
(94)
(trifluoromethyl)phenyl]carbamoyl}hydrazinyl]-4-
oxobutanoate
4-[1-(2-methylpropyl)-2-{[4-
21
(98)
(trifluoromethyl)phenyl]carbamoyl}hydrazinyl]-4-
oxobutanoic acid
ethyl 4-oxo-4-(1-propyl-2-{[4-
35
(98)
(trifluoromethyl)phenyl]carbamoyl}hydrazinyl)butanoate
4-oxo-4-(1-propyl-2-{[4-
28
(97)
(trifluoromethyl)phenyl]carbamoyl}hydrazinyl)butanoic
acid
ethyl 4-{2-[(4-bromophenyl)carbamoyl]-1-
34
(100)
butylhydrazinyl}-4-oxobutanoate
ethyl 4-{2-[(4-bromo-2-fluorophenyl)carbamoyl]-1-
34
(100)
propylhydrazinyl}-4-oxobutanoate
4-{2-[(4-bromo-2-fluorophenyl)carbamoyl]-1-
29
(100)
propylhydrazinyl}-4-oxobutanoic acid
|
The present invention relates to carbamoyl hydrazine derivatives, processes for preparing them, pharmaceutical compositions containing them and their use as pharmaceuticals as modulators of the FPR receptor.
| 2
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority benefit from U.S. Provisional Patent Application No. 61/730,486 entitled “MULTISTAGE IONIZER FOR A COMBUSTION SYSTEM” filed Nov. 27, 2012; which, to the extent not inconsistent with the disclosure herein, is incorporated by reference.
The following U.S. Patent Applications, filed concurrently herewith, are directed to subject matter that is related to or has some technical overlap with the subject matter of the present disclosure, and are incorporated herein by reference, in their entireties: U.S. patent application Ser. No. 14/092,857; U.S. patent application Ser. No. 14/092,836; U.S. patent application Ser. No. 14/092,814; U.S. patent application Ser. No. 14/092,896; and U.S. patent application Ser. No. 14/092,876.
SUMMARY
According to an embodiment, an electrodynamic burner includes a fuel nozzle configured to provide fuel, an ionizer configured to output charged particles and positioned away from the fuel nozzle and the combustion reaction, and configured to apply corresponding charges to a combustion reaction supported by the fuel. An electrically conductive flame holder is positioned away from the fuel nozzle. The charge applied to the flame by the charged particles interacts with the flame holder to hold the combustion reaction proximate to the flame holder. A lift distance between the fuel nozzle and the conductive flame holder operates as a mixing zone to entrain air and/or flue gas into the fuel. The entrainment and dilution of the fuel in turn reduces combustion reaction temperature to reduce the production of oxides of nitrogen (NOx) by the burner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a combustion system with an ion flow upstream of a reaction front to control a combustion reaction, according to an embodiment.
FIG. 2A is a block diagram of an ionizer, according to an embodiment.
FIG. 2B is a block diagram of an ionizer, according to another embodiment.
FIG. 3 is a block diagram of a combustion system including an ion flow to control a combustion reaction, according to another embodiment.
FIG. 4A is a block diagram of a combustion system including a plurality of combustion reactions, according to an embodiment.
FIG. 4B is a block diagram of the system of FIG. 4A in which ion flows are of opposite polarities, according to an embodiment.
FIG. 5A is a block diagram of a combustion system, according to an embodiment.
FIG. 5B is a block diagram of the system of FIG. 5A in which the ion flows have opposite polarities, according to an embodiment.
FIG. 6 is a block diagram of a combustion system including a system for employing ion flows to control the interaction of adjacent combustion reactions, according to another embodiment.
FIG. 7 is a block diagram of a combustion system, according to another embodiment.
FIG. 8 is a flow diagram of a method for employing an ion flow to control a combustion reaction, according to an embodiment.
DETAILED DESCRIPTION
In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. Other embodiments may be used and/or other changes may be made without departing from the spirit or scope of the disclosure.
The inventors have recognized that electrodes in contact with, or in close proximity to the combustion reaction may be damaged by heat or reactive species from the combustion reaction, which can reduce the ability to control the combustion reaction. For example, electrodes with limited surface area, small radius of curvature, and/or sharp edges, such as may be employed for charge injection or corona electrodes, are frequently susceptible to such damage. Additionally, electrodes made from certain materials may be susceptible to such damage, in some cases so susceptible that such damage may discourage the use of otherwise desirable electrode materials for cost or practicality reasons. Moreover, electrode replacement is costly in terms of combustion reaction downtime, electrode materials, and/or labor, not to mention reduced control efficiency of such electrodes prior to replacement.
According to some embodiments, a combustion reaction charging system having “active”, or current-carrying parts in a combustion volume, may require a more extensive procedure to replace broken or worn parts and/or may require shutdown or large fuel turn-down to access the broken or worn parts. Accordingly, service and reliability can be positively affected by placing active parts outside the combustion volume.
The inventors propose providing an ionizer mechanism configured to create charged particles, which are then introduced to the combustion reaction as a means of applying an electrical charge to the combustion reaction. The charged particles can be drawn from any appropriate material or combination of materials, including, for example, components of the combustion reaction, such as oxidizer gas (e.g., air), fuel, flue gas, reactants, etc. According to an embodiment, the ionizer mechanism may include an ion beam generator, such as an electron beam source. According to another embodiment, the ionizer mechanism may include a corona electrode and counter electrode pair immersed in a flow of dielectric fluid, such as a gas, which is to be introduced into the combustion volume. The corona electrode and counter electrode pair are configured to create ions from (deposit charges on) molecules of the dielectric fluid, or from other donor substances carried by the fluid.
The ionizer may be provided as a module or modular system configured for field exchange or replacement.
The term combustion reaction is to be construed as referring to an exothermic oxidation reaction. In some cases a combustion reaction can include a stoichiometric (e.g., visible) surface. In other cases, the combustion reaction may be “flameless” such that no visible boundary exists.
Combustion components refers to elements that are to be introduced into the combustion volume, and that will be involved in the combustion process, such as fuel, oxidizer, EGR flue gases, modifiers, catalysts, and other substances that may be introduced. This term is not limited to reference to these elements as they are present within the combustion volume, but also prior to their introduction into the combustion volume.
Combustion volume refers to the space within which a combustion reaction occurs, and is delineated according to the circumstances of the particular application. For example, many systems include a firebox or other enclosure configured to contain the combustion reaction and its products, and/or to protect individuals from the reaction. In such cases, corresponding boundaries and dimensions of the combustion volume are defined by walls or surfaces of the enclosure, to the extent reasonable. Any barrier configured to protect an element positioned on one side of the barrier from thermal energy produced by a combustion reaction positioned on an opposite side of the barrier can define a respective boundary of the combustion volume. Thus, for example, a smaller enclosure positioned partially or wholly within a combustion volume and configured to protect a circuit or other device from heat produced by a combustion reaction effectively removes the volume defined by the smaller enclosure from the combustion volume.
Where an enclosure is not present, or where portions of an enclosure are far enough from the combustion reaction that they do not effectively constrain aspects of the combustion reaction, the combustion volume can be defined as the volume within which the ambient temperature is at least 400° F. The combustion volume also includes regions that are significantly hotter than 400° F. For example, a temperature of up to near the adiabatic flame temperature can be encountered in some practical combustion systems.
Generally, the opening, i.e., terminus, of a fuel nozzle or burner that is configured to support the combustion reaction defines a boundary or limit of the combustion volume, such that fuel flowing from the nozzle enters the combustion volume as it is emitted from the nozzle. Likewise, nozzles, openings, vents, etc. by which other components of a combustion reaction are introduced can define respective boundaries of a combustion volume. Another boundary is at the approximate point within an exhaust passage, such as a flue or chimney, at which the exothermic process is no longer self-sustaining.
Embodiments illustrating the use of charged particles for applying a charge to a combustion reaction are primarily described in the present disclosure with reference to ions and ionizers. However, this is merely illustrative. Other varieties of charged particles are well known, as are mechanisms for their production. The term charged particle, as used in the claims, is not limited to ions, but is to be construed broadly as reading on any type of charged particle, i.e., any particle that is not electrically neutral. In some cases, the charged particles may be present in the form of free- or loosely associated-electrons. In other cases, the charged particles can include at least a nucleus, as in a H+, and/or can include a charged atomic pair or charged molecule. It will be understood that descriptions related to the production of ions herein may also apply to the production of charged particles that are not ions per se (e.g., electrons).
FIG. 1 is a block diagram of system 100 for employing an ion flow 102 to control a combustion reaction 104 , according to an embodiment.
According to an embodiment, the system 100 includes an ionizer 106 , which is configured to provide an ion flow 102 to a first location 108 with respect to the opening of a nozzle or terminus 109 of a burner 110 supporting a combustion reaction 104 . The ion flow 102 has a first polarity. The ion flow 102 is configured to impart a net charge to the combustion reaction 104 , or a component thereof. A first electrode 114 can be positioned at a second location 115 that is downstream 111 of the first location 108 and at least intermittently separated from the combustion reaction 104 by an air gap 117 . A voltage source 118 is operatively coupled to the first electrode 114 . A controller 120 is operatively coupled to provide one or more electrical signals to the ionizer 106 and the voltage source 118 . The controller can be configured to control the combustion reaction 104 by selection of the one or more electrical signals. The first location 108 is at least intermittently upstream 113 with respect to a reaction front 112 of the combustion reaction 104 . According to embodiments, the controller 120 is configured to control the voltage supply and the ionizer 106 to maintain the air gap 117 between the combustion reaction 104 and the first electrode 114 . In other embodiments, the first electrode 114 can be electrically insulated, such as by a fused quartz glass. In other embodiments. The first electrode 114 can be in electrical continuity with the combustion reaction. Current flow through the combustion reaction can be controlled by maintaining resistance between the first electrode 114 and a voltage source for the first electrode, for example.
The terms upstream, indicated in the drawings by the arrow 111 , and downstream, indicated by arrow 113 , are with reference to a composite flow associated with a combustion reaction that includes, for example, a fuel flow, an oxidizer flow, a flow of reactants within the combustion reaction, and a flow of products of the combustion reaction, i.e., flue gas and its various components. Use of these terms without further modification or definition can be construed as referring to relative positions along this composite flow.
According to various embodiments, the ion flow 102 is selected to impart the charge and the first polarity to the combustion reaction 104 . Additionally or alternatively, the ion flow 102 may be selected to impart the charge and the first polarity to a fuel of the combustion reaction 104 . Additionally or alternatively, the ion flow 102 may be selected to impart the charge and the first polarity to an oxidizer of the combustion reaction 104 . Additionally or alternatively, the ion flow 102 may be selected to impart the charge and the first polarity to a carrier gas of the combustion reaction 104 . Additionally or alternatively, the ion flow 102 may be selected to impart the charge and the first polarity to a product of the combustion reaction 104 . Additionally or alternatively, the ion flow 102 may be selected to impart the charge and the first polarity to any combination thereof of the fuel, oxidizer, carrier gas, and/or product of the combustion reaction.
According to various embodiments, the controller 120 is configured to control the combustion reaction 104 by providing the one or more electrical signals carried by signal carriers 107 , such as wires. The one or more electrical signals carried by the signal carriers 107 may cause an increase or decrease in one or more of a height of the combustion reaction 104 or a surface area of the combustion reaction 104 . Additionally or alternatively, the one or more electrical signals carried by the signal carriers 107 may cause the combustion reaction 104 to be directed to a selected location or to be directed away from the selected location. For example, this can be use to affect heat transfer and/or affect another combustion reaction ignition location. Additionally or alternatively, the one or more electrical signals carried by the signal carriers 107 may cause an oscillation in the combustion reaction 104 . Additionally or alternatively, the one or more electrical signals carried by the signal carriers 107 may dynamically control a shape of the combustion reaction 104 or a movement of the combustion reaction 104 . Additionally or alternatively, the one or more electrical signals carried by the signal carriers 107 can affect the luminance of the combustion reaction 104 . Additionally or alternatively, the one or more electrical signals carried by the signal carriers 107 can be used to control a flame holding position; wherein a first flame holding position is proximal and a second flame holding position is distal.
The controller 120 is configured to cause the ionizer to instantaneously extract ions of a single polarity or add ions of a single polarity at the one or more first electrodes 114 from/to the combustion reaction 104 , according to an embodiment.
The first electrode 114 can be configured to affect various characteristics of the combustion reaction 104 such as, for example, shape, location, luminosity, reaction rate. Depending on resistance through the first electrode to an electrical potential different from the electrical potential imparted onto the combustion reaction 104 by the ionizer 106 , the first electrode can additionally or alternatively affect charge concentration in the combustion reaction 104 . The controller 120 , together with the voltage source 118 , can be configured to hold the combustion reaction 104 at a surface of the burner 110 . In the example of FIG. 1 , the “burner” 110 may be embodied as a fuel nozzle 109 and flame holder 114 (aka, the first electrode), and the flame holder can operate as a flame holding surface. Not shown, a distal flame holder can hold the combustion reaction 104 when the controller 120 does not cause the voltage source 118 to hold the combustion reaction at the flame holder/first electrode 114 .
According to an embodiment, the burner 110 is electrically isolated and/or insulated from electrical ground and from voltages other than those defined by the ionizer 106 and/or the first electrode 114 . According to various embodiments, the controller 120 is configured to apply the one or more electrical signals to the one or more first electrodes 114 . The controller 120 can cause a charge carried by the combustion reaction 104 to respond to the one or more electrical signals applied to the ionizer 106 and/or the first electrode 114 .
The controller 120 can be configured to operate the ionizer 106 to periodically or intermittently change a quantity or a concentration of charge in the ion flow 102 or in the combustion reaction 104 . Additionally or alternatively, the controller 120 can be configured to operate the ionizer 106 to periodically or intermittently change the first charge polarity in the ion flow 102 or in the combustion reaction 104 . The one or more electrical signals can be characterized by one or more voltages. Additionally or alternatively, the one or more electrical signals can be controlled to influence or control an electrical field adjacent to the combustion reaction 104 . The one or more electrical signals can include a time-varying signal configured to control the ionizer 106 to output a time-varying charge and/or control the first electrode 114 to deplete a charge carried by the combustion reaction 104 in a time-varying way. Additionally or alternatively, the one or more electrical signals can include a time-varying voltage. Additionally or alternatively, the one or more electrical signals can be switched to provide a time-varying electrical continuity to the ionizer 106 and/or the first electrode 114 .
The combustion reaction 104 can be embodied as a visible flame or can consist essentially of a flameless reaction, according to embodiments.
As previously noted, according to the embodiment of FIG. 1 , the ionizer 106 is configured to provide an ion flow 102 . As used herein, ion flow refers to a flow of ions (including precursor ions (e.g., ions that will subsequently be converted to charges carried by other particles), to the extent that they may be present) in some medium (theoretically, the medium could be comprised substantially 100% of ions, however typical ionizer technologies do not provide such a high charge carrying efficiency) through space to a combustion reaction 104 , with the ions carried by the ion flow then being substantially transferred to the combustion reaction 104 . An ion flow may be provided by ionizing a gas, and the gas may then flow through space to the combustion reaction 104 . The ionized gas can include a fuel, such as a hydrocarbon gas; or can include an oxidant flow, such as air. Additionally or alternatively, an ion flow may be provided by ionizing a gas in the form of a dielectric vapor. An ion flow may be provided by ionizing particles or droplets in an aerosol. An ion flow may be provided by ionizing molecules of a dielectric liquid. An ion flow may be provided by depositing ions on a particulate solid. Combinations of the above-described ion flows may become evident with further variations that fall within the scope of claims appended hereto.
In an embodiment, the ionizer 106 is configured to provide the ion flow 102 by contacting the ion flow 102 to at least one of air or a fuel. The ion flow 102 can be contacted to air or may consist essentially of combustion air to form a charged air flow. Additionally or alternatively, the ion flow 102 can be contacted to or consist essentially of fuel to form a charged fuel flow. Additionally or alternatively, the ion flow 102 is contacted to at least one of air or a fuel or can consist essentially of a fuel/air mixture to form a charged fuel/air mixture flow. In the case of charging a fuel/air mixture, care should be taken to prevent any inadvertent spark discharge that could cause detonation.
According to embodiments, the ionizer 106 can be configured to provide the ion flow 102 at a positive polarity. Additionally or alternatively, the ionizer 106 may configured to provide the ion flow 102 at a negative polarity.
According to an embodiment, the controller 120 is configured to control the combustion reaction 104 such that the first location 108 is substantially upstream 113 (e.g., averaged over time) with respect to the reaction front 112 of the combustion reaction 104 . For example, the first location can include a flow distance through which the ion flow 102 travels between the ionizer 106 and the combustion reaction 104 .
According to another embodiment, the ionizer 106 can output the ion flow 102 to the combustion reaction 104 above the lower reaction front 112 . For example, as shown in FIGS. 5A, 5B , the ionizer can output an ion flow to the combustion reaction 104 through a conduit 302 including at least a dielectric portion configured to guide the ion flow while maintaining electrical isolation of the combustion reaction 104 with respect to the ionizer body 106 .
FIG. 2A is a diagram of an ionizer 200 A, according to an embodiment. The ionizer 200 A includes a charge source, such as a corona electrode 204 configured to cooperate with a counter electrode 206 to produce an ion discharge.
According to embodiments, the ionizer 200 A is electrically isolated. According to various embodiments, the ionizer 200 A imparts charged particles, in the form of ions, to the ion flow 102 via a corona discharge. Additionally or alternatively, the ionizer 200 A may impart ions to the ion flow 102 via an electrospray ionization. Additionally or alternatively, the ionizer 200 A may impart ions to the ion flow 102 via a thermospray ionization. Additionally or alternatively, the ionizer 200 A may impart ions to the ion flow 102 via a field desorption ionization. Additionally or alternatively, the ionizer 200 A may impart ions to the ion flow 102 via a photoionization. Additionally or alternatively, the ionizer 200 A may impart ions to the ion flow 102 via a photoelectric ionization. Additionally or alternatively, the ionizer 200 A may impart ions to the ion flow 102 via a radioactive decay ionization. Additionally or alternatively, the ionizer 200 A may impart ions to the ion flow 102 via any combination thereof of the corona discharge, electrospray ionization, thermospray ionization, field desorption ionization, photoionization, photoelectric ionization, and/or radioactive decay ionization.
According to an embodiment, the ionizer 200 A imparts a charge to the ion flow 102 via ejection of generated ions (e.g. electrons) at corona electrode 204 to produce negatively charged ions. Additionally or alternatively, the ionizer 200 A may impart a charge to the ion flow 102 via extraction of charges (e.g., electrons) from neutral particles proximate the corona electrode 204 to produce positively charged ions. This is also referred to as charge ejection. A counter-electrode 206 applies an electric field to pull the ejected charges away from the corona electrode in a direction toward an entraining dielectric fluid flow and/or toward a location where the ion flow 102 leaves the ionizer body 106 . Other ionization modalities, referenced herein or known in the art, may replace the corona/counter electrode 204 / 206 arrangement shown in FIG. 2A . The ionizer 200 A may produce a net charge density at the ionizer 200 A of about 1 million charges per cubic centimeter or more, according to embodiments.
According to an embodiment, the controller 120 is configured to detect a short circuit at the corona electrode 204 in the ionizer 200 A. The controller 120 is configured to reduce or stop the voltage applied to the corona electrode 204 in the ionizer 200 A responsive to the short circuit at the corona electrode 204 .
According to embodiments, a fluid source 222 can be configured to provide a fluid 224 to the ionizer 200 A in the form of a gas. Additionally or alternatively, the fluid 224 may be provided to the ionizer 200 A in the form of a vapor. Additionally or alternatively, the fluid 224 may be provided to the ionizer 200 A in the form of a liquid aerosol. Additionally or alternatively, the fluid 224 may be provided to the ionizer 200 A in the form of a dielectric liquid stream. Additionally or alternatively, the fluid 224 may be provided to the ionizer 200 A in the form of any combination thereof of the gas, vapor, liquid aerosol, and/or liquid stream.
In an embodiment, the fluid source 222 is operatively coupled to provide the fluid 224 to the ionizer 200 A using a nebulizer. Additionally or alternatively, the fluid 224 may be provided to the ionizer 200 A using an atomizer. The fluid 224 may be provided to the ionizer 200 A using an injector. The fluid 224 may be provided to the ionizer 200 A using a steam generator. The fluid 224 may be provided to the ionizer 200 A using an ultrasonic humidifier. The fluid 224 may be provided to the ionizer 200 A using a vaporizer. The fluid 224 may be provided to the ionizer 200 A using an evaporator. The fluid 224 may be provided to the ionizer 200 A using a pump. Additionally or alternatively, the fluid 224 may be provided to the ionizer 200 A using any combination thereof of the nebulizer, atomizer, injector, steam generator, ultrasonic humidifier, vaporizer, evaporator, and/or pump.
According to various embodiments, the ionizer 200 A is configured to provide an ion flow 208 by ionizing a fluid 224 . The fluid 224 may include a buffer or may be functionalized to hold a charge, and can be impelled by any appropriate means, including, e.g., a pump, fan, compressor, etc. In other embodiments, the fluid source 222 is a combustion air 224 source, and may include either natural draft or forced draft aspects. In other embodiments, the fluid source 222 is a fuel source, such as a hydrocarbon gas source. According to an embodiment, the ionizer 200 A is positioned in series with a main fuel line of a combustion system, such that a flow of fuel to a burner of the combustion system passes through the ionizer and incorporates the ion flow 208 .
According to other embodiments, a valve 226 is operatively coupled to the fluid source 222 and the controller 120 . The controller 120 is configured to operate the valve 226 to control a flow of the fluid 224 from the fluid source 222 . The fluid source 222 is configured to supply the fluid 224 to the ionizer 200 A and maintain electrical isolation between the conductive and/or grounded parts of the fluid source 222 and the ionizer 200 A. The fluid source 222 includes a tank 228 to hold the fluid 224 . The tank 228 can be made of an electrically insulating material to isolate the fluid 224 from ground or another voltage. Additionally or alternatively, the tank 228 may be supported by electrical insulators to isolate the fluid 224 from ground or another voltage. An anti siphon 230 arrangement is configured to maintain electrical isolation between the fluid source 222 and the ionizer 200 A. However, since corona discharge ionization requires a charge separation across a dielectric layer adjacent to a corona electrode 204 (e.g., exhibited as electric field curvature around emission surfaces), most embodiments are contemplated as being based on a dielectric fluid 224 having a relatively high dielectric constant (i.e., being substantially non-conductive). Accordingly, the anti siphon arrangement 230 may be often embodied as simply a length of low conductivity material or an isolation distance between the corona electrode 204 and adjacent conductive components.
FIG. 2B is a sectional diagram of an ionizer 200 B, according to another embodiment. According to embodiments, the ionizer 200 B includes a body 250 defining a vaporization well 252 . Third and fourth electrodes 254 a , 254 b are operatively coupled to the voltage source 118 and are configured to apply a high voltage to a liquid at least temporarily resident in the vaporization well 252 . The voltage source 118 is configured to apply a voltage to vaporize the liquid to produce a vapor of the liquid. The vapor then carries charged particles from the ionizer. Additionally or alternatively, the voltage source 118 may be configured to apply a voltage to produce an aerosol or a mixed vapor and aerosol of the liquid, which, in either case, carries charged particles from the ionizer.
According to various embodiments, the liquid includes water. Additionally or alternatively, the liquid may include a buffer solution or may be at least partly functionalized to hold a charge.
The electrodes 254 a , 254 b are energized at a bias voltage to produce the polarity of the charges carried by the vapor or aerosol. For example, to produce positive charges, the electrode 254 a can be briefly energized with +40 kV while the electrode 254 b is energized or held at +20 kV. The 20 kV difference between the electrodes produces vaporization. The +30 kV average voltage operates as a bias voltage to produce positive charges in the ejected vapor/aerosol. In some embodiments, kinetic energy from the vaporization is sufficient to propel the ion flow 102 through the flow distance (e.g., see FIG. 1, 108 ) to the combustion reaction (not shown in FIG. 2B ) or to an entraining fluid stream. Optionally, a counter electrode 206 can be positioned to accelerate the charged particles toward their intended destination as an ion flow 102 .
FIG. 3 is a diagram of a system 300 for employing an ion flow to control a combustion reaction, according to an embodiment. The ionizer 106 is configured to provide at least a portion of the ion flow 102 , which is introduced upstream 113 of the terminus 109 of a burner or fuel source 110 . For example, the ionizer 106 can be configured to provide at least a portion of the ion flow 102 through the burner or fuel source 110 . In an alternative embodiment (see, e.g., FIGS. 4A and 4B ), the ionizer 106 is configured to provide at least a portion of the ion flow 102 downstream 111 from the terminus 109 and upstream 113 from the reaction front 112 .
According to embodiments, a conduit 302 is configured to convey the ion flow 102 from the ionizer 106 to the first location 108 . The conduit 302 can be electrically isolated. The conduit 302 may include a conduit electrode operatively coupled to the voltage supply, in which case, the controller 120 can be configured to control the voltage supply to apply a voltage at the first polarity to the conduit electrode. The maximum charge density output of the ionizer 106 can be within about 10 centimeters of a downstream 111 terminus of the burner or fuel source 110 . The conduit 302 preferably includes a material that resists reaction with the ion flow 102 .
The conduit 302 is thermally insulated, according to various embodiments. For example, a portion of the conduit 302 or an opening of the conduit 302 can be shielded from the combustion reaction 104 by a shroud (not shown) located at least in part upstream 113 of the first location 108 . The shroud may be thermally reflective. A cooling apparatus (not shown) may be operatively coupled to the conduit 302 to cool the conduit 302 .
Referring again to FIG. 3 , according to various embodiments, a system 300 may include a flow control valve 306 operatively coupled to the controller 120 and the burner or fuel source 110 . The controller 120 is configured to operate the ionizer 106 , the voltage source 118 , and the flow control valve 306 to control the combustion reaction 104 .
According to various embodiments, a system 300 may include a waveform generator 304 that is operatively coupled to the controller 120 and the voltage supply. The waveform generator 304 is configured to generate one or more waveforms. The waveform generator 304 is configured together with the controller 120 to drive the ionizer 106 or the one or more first electrodes 114 with the one or more waveforms. The one or more electrical signals may include the one or more waveforms.
According to embodiments, the waveform generator 304 is configured to generate an alternating current (AC) voltage waveform. Additionally or alternatively, the waveform generator 304 may be configured to generate a sinusoidal waveform. The waveform generator 304 may generate a square waveform. The waveform generator 304 may generate a sawtooth waveform. The waveform generator 304 may generate a triangular waveform. The waveform generator 304 may generate a wavelet waveform. The waveform generator 304 may generate a logarithmic waveform. The waveform generator 304 may generate an exponential waveform. The waveform generator 304 may generate a truncated waveform. The waveform generator 304 may generate a combination of one or more waveform thereof.
FIG. 4A is a block diagram of a system 400 for employing a plurality of ion flows to control the interaction of adjacent combustion reactions, according to an embodiment. The system 400 includes a pair of burners 110 a , 110 b , and corresponding second electrodes 116 a , 116 b operatively coupled to the voltage source 118 . An ionizer 106 includes first and second conduits 302 a , 302 b configured to deliver respective ion flows 102 a , 102 b to the corresponding combustion reactions 104 a , 104 b . As shown in FIG. 4A , the conduits 302 a , 302 b are positioned and configured to introduce the ion flows 102 upstream from the opening or terminus of the burner 110 .
In the claims, the term sub-flow is used where a plurality of flows of charged particles are introduced to one or more combustion reactions within a same combustion volume. Thus, the ion flows 102 a , 102 b of FIG. 4A can also be referred to as sub-flows that together form a single ion flow.
A controller 120 is configured to control the ionizer 106 , first electrodes (not shown) and the second electrodes 116 to control the combustion reaction 104 . The second electrodes 116 electrically isolated.
The controller 120 is operatively coupled to provide electrical signals to the ionizer 106 and the voltage source 118 to independently control polarity and volume of the ion flows 102 a , 102 b . The controller 120 is configured to control the combustion reactions 104 by applying charges to the combustion reactions via the ion flows 102 . The controller 120 may also be configured to further control the combustion reactions 104 by applying electrical energy via first electrodes 114 , as described above with reference to FIG. 1 .
According to one method of operation, the controller is configured to produce an electrostatic repulsion 402 between the first and second instance combustion reactions 104 a , 104 b , by controlling the ionizer 106 to produce ion flows 102 a , 102 b , having a same polarity, as shown in FIG. 4A . The corresponding net charge applied to the combustion reactions 104 a , 104 b causes the combustion reactions to be mutually repulsive.
FIG. 4B is a block diagram of the system 400 illustrating a second method of operation, according to an embodiment.
As shown, the controller 120 is configured to control the first and second ion flows 102 a , 102 b to have opposite polarities, which produces an electrostatic attraction 404 between the first and second combustion reactions 104 a , 104 b . The controller 120 can be configured to control the electrostatic attraction 404 to cause mixing between the first combustion reaction 104 a and the second combustion reaction 104 b.
FIG. 5A is a block diagram of a combustion system 500 , according to an embodiment. In most respects, the system 500 is substantially identical to the system 400 of FIGS. 4A and 4B . However, where the system 400 is configured to introduce the ion flows 102 a , 102 b upstream of the burners 110 a , 110 b , the system 500 is configured to introduce the ion flows 102 downstream of the burners 110 .
In FIG. 5A , the ion flows 102 a , 102 b are have a same polarity, similarly to the operation of the system 400 described with reference to FIG. 4A . As a result of the common polarity of the ion flows 102 , the combustion reactions 104 a , 104 b are electrically repulsed.
FIG. 5B shows the system 500 of FIG. 5A , with the ionizer 106 controlled to produce the ion flows 102 a , 102 b at opposite polarities. As a result, the combustion reactions 104 are attracted to each other, substantially as described with reference to FIG. 4B . In an embodiment, the system 500 can include a second ionizer 106 configured to provide the second ion flow 102 b having a second polarity to the third location 108 b downstream 113 of a second reaction front 112 b of the second combustion reaction 104 b . The controller 120 can be configured to independently control the first and second instances of the combustion reaction 104 a , 104 b . The controller 120 can be further configured to control an electrostatic repulsion 402 between the first instance of the combustion reaction 104 a and the second instance of the combustion reaction 104 b by causing the first polarity and the second polarity to be the same. The controller 120 can be further configured to control an electrostatic attraction 404 between the first instance of the combustion reaction 104 a and the second instance of the combustion reaction 104 b by causing the first polarity and the second polarity to be different. The controller 120 can be further configured to control the electrostatic attraction 404 to cause mixing between the first instance of the combustion reaction 104 a and the second instance of the combustion reaction 104 b.
According to an embodiment, the burner or fuel source 110 can be electrically insulated, electrically isolated, or electrically insulated and isolated. The controller 120 can be configured to operate the ionizer 106 to periodically and/or intermittently change a quantity and/or a concentration of charge in the ion flow 102 . The controller 120 can be configured to operate the ionizer 106 to periodically and/or intermittently change a quantity and/or a concentration of charge in the combustion reaction 104 . And/or the controller 120 can be configured to operate the ionizer 106 to periodically and/or intermittently change the first charge polarity in the ion flow 102 and/or in the combustion reaction 104 .
According to an embodiment, the controller 120 can be configured to apply the one or more electrical signals to the one or more first electrodes 114 to cause a charge of the combustion reaction 104 to respond to the one or more electrical signals. The one or more electrical signals can include a charge, a voltage, an electrical field, or a combination thereof. Additionally, the one or more electrical signals can include one or more of a time-varying charge, a time-varying voltage, a time varying electric field, or a combination thereof. A waveform generator 304 can be included, according to an embodiment. The waveform generator 304 can be operatively coupled to the controller 120 and the power supply 118 . The waveform generator 304 can be configured to generate one or more waveforms. The waveform generator 304 can be configured together with the controller 120 to drive the ionizer 106 and/or the one or more first electrodes 114 with the one or more waveforms such that the one or more electrical signals can include the one or more waveforms. The waveform generator 304 can be configured to generate one or more of an alternating current (AC) voltage waveform, a sinusoidal waveform, a square waveform, a sawtooth waveform, a triangular waveform, a wavelet waveform, a logarithmic waveform, an exponential waveform, a truncated waveform, or a combination waveform thereof.
FIG. 6 is a block diagram of a system 600 for employing ion flows to control the interaction of adjacent combustion reactions, according to another embodiment. The system 600 is substantially similar to the system 100 of FIG. 1 , except that the ionizer 106 is configured to introduce a plurality of ion flows 102 to the combustion reaction 104 . In the embodiment shown, a first ion flow 102 is introduced at a first location 108 that is upstream 113 relative to a reaction front 112 of the combustion reaction 104 . A second ion flow 102 ′ is introduced at a second location 108 ′ that is upstream 113 relative to the first location 108 . The second location 108 ′ may be positioned upstream 113 or downstream 111 relative to the reaction front 112 . According to an embodiment, both locations 108 , 108 ′ are at least intermittently upstream of the reaction front 112 . According to another embodiment, the first location 108 is positioned upstream with respect to the terminus 109 of the burner 110 .
The first and second ion flows 102 , 102 ′ can be provided by a single ionizer 106 , as shown, or by separate ionizers.
In an embodiment, the ionizer 106 is configured to provide the first and second ion flows 102 , 102 ′ at first and second polarities effective to cause mixing of the first and second charged ion flows 102 , 102 ′. For example, the opposing first and second polarities can be configured to cause an electrostatic attraction that facilitates mixing of the first and second ion flows 102 a , 102 b , and consequently promotes improved mixing of components of the combustion reaction 104 .
According to an embodiment, the ionizer 106 is configured to provide the first and second charged ion flows 102 , 102 ′ in unequal respective first and second charge quantities or strengths, resulting in a net charge 103 of the combustion reaction 104 . By selection of the polarities and strengths of the respective ion flows, the combustion reaction 104 can be further controlled as described with reference to previous embodiments.
FIG. 7 is a block diagram of a system 600 that includes first and second burners 110 a , 110 b , each configured to support a respective combustion reaction 104 a , 104 b . Each of the first and second burners 110 is associated with respective first and second ion flows 102 a , 102 a ′ and 102 b , 102 b ′. Each of the first and second burners 110 a , 110 b and associated elements operates substantially as described with reference to the system 600 of FIG. 6 . Jointly, the combustion reactions 104 a , 104 b can be manipulated, by selection of strengths and polarities of the respective ion flows, to function as described with reference to the combustion reactions 104 a , 104 b of FIGS. 4A, 4B, 5A, and 5B .
FIG. 8 is a flow diagram of a method 500 for employing an ion flow downstream of a reaction front to control a combustion reaction, according to an embodiment. In an embodiment, a method is provided for employing an ion flow to control a combustion reaction. The method includes 802 supporting a combustion reaction at a burner. The method also includes 804 generating an ion flow having a first polarity. The method may further include 806 introducing the ion flow to the combustion reaction or a component of the combustion reaction at a first location. The first location is, according to an embodiment, at least intermittently upstream with respect to at least a portion of a reaction front of the combustion reaction. The method additionally includes 808 imparting a charge to the combustion reaction via the ion flow. The method shown includes 810 controlling the combustion reaction by applying one or more electrical signals to respective electrodes positioned at locations that are downstream of the first location, causing the combustion reaction to respond due to the imparted charge. The one or more electrodes thus control aspects of the combustion reaction by application of the one or more electrical signals.
In an embodiment, imparting the charge can include selecting the ion flow to impart the charge and the first charge polarity to the combustion reaction, a fuel of the combustion reaction, an oxidizer of the combustion reaction, a carrier gas of the combustion reaction, a product of the combustion reaction, another component of the combustion reaction, a combination of components of the combustion reaction, etc.
In an embodiment of the method, controlling the combustion reaction may include extracting ions of a single polarity at the one or more electrodes from the combustion reaction. Generating the ion flow may also include providing a ion flow, such as by ionizing a gas, a vapor, a liquid aerosol, a dry aerosol, a particulate solid, or a combination of elements. Generating the ion flow may also include contacting an ion flow to air or a fuel to form a charged air flow, a charged fuel flow, or a charged air-fuel mixture flow.
In an embodiment, the method can include providing the ion flow at a positive polarity, a negative polarity, or, where multiple ion flows (i.e., sub-flows) are used, both.
In an embodiment, the method may include controlling the combustion reaction such that the first location is substantially upstream over time with respect to the reaction front of the combustion reaction. The method may also include providing at least a portion of the ion flow upstream of the burner or fuel source. The method may further include providing at least a portion of the ion flow through the burner or fuel source. The method may, alternatively, include providing at least a portion of the ion flow downstream from the burner or fuel source and upstream from the reaction front.
In an embodiment, the method may include providing the ion flow by ionizing a gas, a vapor, an aerosol, a particulate solid, an oxidant or a fuel of the combustion reaction, combinations of elements, etc.
In an embodiment, the method may include electrically isolating the ionizer. The method may include imparting ions to the ion flow via a corona discharge. The method may include imparting ions to the ion flow via an electrospray ionization, a thermospray ionization, a field desorption ionization, via a photoionization, a photoelectric ionization, a radioactive decay ionization, etc.
In an embodiment, the method may include imparting a charge to the ion flow via generating and injecting ions, selectively extracting preexisting ions, or a combination thereof. Applying electrical signals to the ionizer to generate the ion flow may include producing a net charge density at the ionizer of at least about 1 million charges per cubic centimeter.
In an embodiment, applying electrical signals to the ionizer to generate the ion flow may include employing a corona electrode and a counter electrode to generate ions in the ionizer. Applying the one or more electrical signals to the ionizer to generate the ion flow may also include detecting a short at the corona electrode in the ionizer. The method may further include reducing the voltage applied to the corona electrode in the ionizer responsive to the short at the corona electrode.
In an embodiment, applying the one or more electrical signals to the ionizer to generate the ion flow may include providing a fluid to the ionizer in the form of a gas, a vapor, an aerosol, a dielectric liquid stream, etc.
In an embodiment, the method may include providing the fluid to the ionizer using a nebulizer, an atomizer, an injector, a steam generator, an ultrasonic humidifier, a vaporizer, an evaporator, a pump, etc.
In an embodiment, applying electrical signals to the ionizer to generate the ion flow may include preparing an ion flow by ionizing a gas, a vapor, a liquid aerosol, a dry aerosol, a liquid, a particulate solid, etc. Applying electrical signals to the ionizer to generate the ion flow may also include forming the ion flow by contacting the ion flow to water, in the form of a vapor, a steam, a liquid, a liquid aerosol, etc. The fluid may include a buffer or be functionalized to hold a charge. The method may also include controlling a flow of the fluid to an ionizer. Applying electrical signals to the ionizer to generate the ion flow may also include supplying the fluid to the ionizer and maintaining electrical isolation between the fluid source and the ionizer. Applying electrical signals to the ionizer to generate the ion flow may also include electrically isolating the fluid from ground or another voltage. Additionally or alternatively, generating an ion flow in step 204 can include attracting ions away from an ion source and toward a desired flow direction can include attracting the ions with a counter-electrode. In the cases where an ion source other than a corona electrode is used, the counter-electrode may be referred to as a propulsion electrode.
In an embodiment, applying electrical signals to the ionizer to generate the ion flow may include applying a voltage to a liquid to vaporize the liquid to produce a vapor, aerosol, or vapor and aerosol of the liquid to carry charged particles. The liquid may include a buffer solution or may be at least partly functionalized to hold a charge.
In an embodiment, introducing the ion flow at the first location may include conveying the ion flow from the ionizer to the first location using a conduit. Introducing the ion flow at the first location may also include electrically isolating the conduit. Generally speaking, the conduit is formed at least partially from a dielectric material selected to maintain electrical insulation between the combustion reaction and the ionizer. The use of a dielectric conduit can prevent the conduit from acting as an immersed electrode in direct contact with the combustion reaction. In an embodiment, the conduit can be formed from fused quartz glass or other ceramic material that maintains relatively high electrical resistivity at temperatures encountered in the combustion volume. The method may include applying a voltage at the first polarity to the conduit electrode. Introducing the ion flow at the first location may further include providing a maximum charge density output of the ionizer within about 10 centimeters of a downstream terminus of the burner or fuel source. Introducing the ion flow at the first location may also include employing a conduit material that resists reaction with the ion flow. Introducing the ion flow at the first location may further include thermally insulating the conduit or cooling the conduit.
In an embodiment, the method may also include electrically isolating the one or more electrodes from ground or another voltage. Controlling the combustion reaction may include at least intermittently separating the one or more electrodes from the combustion reaction by an air gap. Controlling the combustion reaction may also include controlling the voltage supply and the ionizer to maintain the air gap between the combustion reaction and the one or more first electrodes. Controlling the combustion reaction may further include at least intermittently holding the combustion reaction at the burner or fuel source.
In an embodiment, controlling the combustion reaction may include controlling two or more combustion reactions. Controlling the combustion reaction may include causing an electrostatic repulsion between the first combustion reaction and the second combustion reaction by charging the first combustion reaction and the second combustion reaction at the first polarity. Controlling the combustion reaction may also include causing an electrostatic attraction between the first combustion reaction and the second combustion reaction by charging the first combustion reaction at the first polarity and charging the second combustion reaction at a second polarity opposite the first polarity. Controlling the combustion reaction may further include controlling the electrostatic attraction to cause mixing between the first combustion reaction and the second combustion reaction.
In an embodiment, the method may include electrically isolating the burner or fuel source. Controlling the combustion reaction may include operating a flow valve operatively coupled to the burner or fuel source. Controlling the combustion reaction may also include periodically or intermittently changing a quantity or a concentration of ions in the ion flow or in the combustion reaction. Controlling the combustion reaction may further include periodically or intermittently changing the polarity of the ion flow or the combustion reaction.
In an embodiment, controlling the combustion reaction may include applying the one or more electrical signals including a charge, a voltage, an electrical field, or a combination thereof. Controlling the combustion reaction may also include applying the one or more electrical signals including one or more of: a time-varying charge, a time-varying voltage, a time varying electric field, or a combination thereof. Controlling the combustion reaction may further include generating one or more waveforms. Controlling the combustion reaction may also include driving the ionizer or the one or more electrodes with the one or more waveforms such that the one or more electrical signals include the one or more waveforms. Generating one or more waveforms may include generating one or more of: an alternating current (AC) voltage waveform, a sinusoidal waveform, a square waveform, a sawtooth waveform, a triangular waveform, a wavelet waveform, a logarithmic waveform, an exponential waveform, a truncated waveform, a DC offset voltage, etc.
The method may also include supporting the combustion reaction to include a flame.
According to embodiments, the combustion reaction can be supported by either a diffusion, partial premix, or premixed burner.
According to a premixed burner embodiment, the ion (or charged particle) flow 102 can be introduced to the combustion reaction through a premixing chamber. For example, a charged particle source such as a corona electrode 204 and counter electrode 206 pair can be disposed in the premixing chamber, and the premixing chamber and any flame arrestor can be held or allowed to float to a voltage that allows the charged particle flow 102 to pass through the flame arrestor and into the combustion reaction. In another example, a charged particle delivery conduit 302 can deliver the charged particle flow 102 from a charged particle source into the premixing chamber.
In another premixed burner embodiment, the charged particle flow 102 can be introduced above a flame arrestor and below a flame holder into a premixed fuel/air flow. The charged particle flow can be generated by a charged particle source such as a corona electrode 204 and counter electrode 206 pair can be disposed in the premixed fuel/air flow between the flame arrestor and below the flame holder, and the flame arrestor or other conductive surface past which the charged particles may flow (e.g., the flame holder) can be held or allowed to float to a voltage that allows the charged particle flow 102 to pass through the flame holder and into the combustion reaction 104 . In another example, a charged particle delivery conduit 302 can deliver the charged particle flow 102 from a charged particle source into the premixed fuel/air flow between the flame arrestor and below the flame holder. Of course, if it is desired to cause the fuel/air flow to support a combustion reaction that is held by the flame holder, then the flame holder can optionally be configured as the first electrode 114 (and be held at a voltage different from a voltage that would allow the charged particle flow 102 to pass by the flame holder. In the case of an aerodynamic flame holder, the flame holder can be formed from an electrically insulating material or can be held or allowed to float to an equilibrium voltage. In this case, the resultant charge concentration in the combustion reaction 104 can be used for purposes other than holding the combustion reaction.
In another premixed burner embodiment, the ion flow 102 can be introduced above a flame holder into a premixed fuel/air flow and/or into a combustion reaction above a flame holder. The ion flow can be generated by a charged particle source, such as a corona electrode 204 and counter electrode 206 pair, can be disposed outside the combustion volume. A charged particle delivery conduit 302 can deliver the charged particle flow 102 from the charged particle source into the fuel/air flow or into the combustion reaction 104 .
While various aspects and embodiments have been disclosed herein, other aspects and embodiments are contemplated. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
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An ionizer provides charged particles to charge a combustion reaction. A conductive flame holder cooperates with the charged combustion reaction to hold the combustion reaction away from a fuel nozzle. Dilution and/or premixing of the fuel in the region between the fuel nozzle and the conductive flame holder results in a reduced flame temperature. The reduced flame temperature results in a reduced output of oxides of nitrogen (NOx).
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CROSS-REFERENCE TO OTHER APPLICATION
[0001] This application claims priority from No. 60/098,442 filed Aug. 31 1998, which is hereby incorporated by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates generally to the drilling of oil and gas wells, or similar drilling operations, and in particular to orientation of tooth angles on a roller cone drill bit.
[0003] Background: Rotary Drilling
[0004] Oil wells and gas wells are drilled by a process of rotary drilling, using a drill rig such as is shown in FIG. 10. In conventional vertical drilling, a drill bit 10 is mounted on the end of a drill string 12 (drill pipe plus drill collars), which may be more than a mile long, while at the surface a rotary drive (not shown) turns the drill string, including the bit at the bottom of the hole.
[0005] Two main types of drill bits are in use, one being the roller cone bit, an example of which is seen in FIG. 11. In this bit a set of cones 16 (two are visible) having teeth or cutting inserts 18 are arranged on rugged bearings on the arms of the bit. As the drill string is rotated, the cones will roll on the bottom of the hole, and the teeth or cutting inserts will crush the formation beneath them. (The broken fragments of rock are swept uphole by the flow of drilling fluid.) The second type of drill bit is a drag bit, having no moving parts, seen in FIG. 12.
[0006] Drag bits are becoming increasingly popular for drilling soft and medium formations, but roller cone bits are still very popular, especially for drilling medium and medium-hard rock. There are various types of roller cone bits: insert-type bits, which are normally used for drilling harder formations, will have teeth of tungsten carbide or some other hard material mounted on their cones. As the drill string rotates, and the cones roll along the bottom of the hole, the individual hard teeth will induce compressive failure in the formation.
[0007] The bit's teeth must crush or cut rock, with the necessary forces supplied by the “weight on bit” (WOB) which presses the bit down into the rock, and by the torque applied at the rotary drive. While the WOB may in some cases be 100,000 pounds or more, the forces actually seen at the drill bit are not constant: the rock being cut may have harder and softer portions (and may break unevenly), and the drill string itself can oscillate in many different modes. Thus the drill bit must be able to operate for long periods under high stresses in a remote environment.
[0008] When the bit wears out or breaks during drilling, it must be brought up out of the hole. This requires a process called “tripping”: a heavy hoist pulls the entire drill string out of the hole, in stages of (for example) about ninety feet at a time. After each stage of lifting, one “stand” of pipe is unscrewed and laid aside for reassembly (while the weight of the drill string is temporarily supported by another mechanism). Since the total weight of the drill string may be hundreds of tons, and the length of the drill string may be tens of thousands of feet, this is not a trivial job. One trip can require tens of hours and is a significant expense in the drilling budget. To resume drilling the entire process must be reversed. Thus the bit's durability is very important, to minimize round trips for bit replacement during drilling.
[0009] Background: Drill String Oscillation
[0010] The individual elements of a drill string appear heavy and rigid. However, in the complete drill string (which can be more than a mile long), the individual elements are quite flexible enough to allow oscillation at frequencies near the rotary speed. In fact, many different modes of oscillation are possible. (A simple demonstration of modes of oscillation can be done by twirling a piece of rope or chain: the rope can be twirled in a flat slow circle, or, at faster speeds, so that it appears to cross itself one or more times.) The drill string is actually a much more complex system than a hanging rope, and can oscillate in many different ways; see WAVE PROPAGATION IN PETROLEUM ENGINEERING, Wilson C. Chin, (1994).
[0011] The oscillations are damped somewhat by the drilling mud, or by friction where the drill pipe rubs against the walls, or by the energy absorbed in fracturing the formation: but often these sources of damping are not enough to prevent oscillation. Since these oscillations occur down in the wellbore, they can be hard to detect, but they are generally undesirable. Drill string oscillations change the instantaneous force on the bit, and that means that the bit will not operate as designed. For example, the bit may drill oversize, or off-center, or may wear out much sooner than expected. Oscillations are hard to predict, since different mechanical forces can combine to produce “coupled modes”; the problems of gyration and whirl are an example of this.
[0012] Background: Roller Cone Bit Design
[0013] The “cones” in a roller cone bit need not be perfectly conical (nor perfectly frustroconical), but often have a slightly swollen axial profile. Moreover, the axes of the cones do not have to intersect the centerline of the borehole. (The angular difference is referred to as the “offset” angle.) Another variable is the angle by which the centerline of the bearings intersects the horizontal plane of the bottom of the hole, and this angle is known as the journal angle. Thus as the drill bit is rotated, the cones typically do not roll true, and a certain amount of gouging and scraping takes place. The gouging and scraping action is complex in nature, and varies in magnitude and direction depending on a number of variables.
[0014] Conventional roller cone bits can be divided into two broad categories: Insert bits and steel-tooth bits. Steel tooth bits are utilized most frequently in softer formation drilling, whereas insert bits are utilized most frequently in medium and hard formation drilling.
[0015] Steel-tooth bits have steel teeth formed integral to the cone. (A hardmetal is typically applied to the surface of the teeth to improve the wear resistance of the structure.) Insert bits have very hard inserts (e.g. specially selected grades of tungsten carbide) pressed into holes drilled into the cone surfaces. The inserts extend outwardly beyond the surface of the cones to form the “teeth” that comprise the cutting structures of the drill bit.
[0016] The design of the component elements in a rock bit are interrelated (together with the size limitations imposed by the overall diameter of the bit), and some of the design parameters are driven by the intended use of the product. For example, cone angle and offset can be modified to increase or decrease the amount of bottom hole scraping. Many other design parameters are limited in that an increase in one parameter may necessarily result in a decrease of another. For example, increases in tooth length may cause interference with the adjacent cones.
[0017] Background: Tooth Design
[0018] The teeth of steel tooth bits are predominantly of the inverted “V” shape. The included angle (i.e. the sharpness of the tip) and the length of the tooth will vary with the design of the bit. In bits designed for harder formations the teeth will be shorter and the included angle will be greater. Gage row teeth (i.e. the teeth in the outermost row of the cone, next to the outer diameter of the borehole) may have a “T” shaped crest for additional wear resistance.
[0019] The most common shapes of inserts are spherical, conical, and chisel. Spherical inserts have a very small protrusion and are used for drilling the hardest formations. Conical inserts have a greater protrusion and a natural resistance to breakage, and are often used for drilling medium hard formations.
[0020] Chisel shaped inserts have opposing flats and a broad elongated crest, resembling the teeth of a steel tooth bit. Chisel shaped inserts are used for drilling soft to medium formations. The elongated crest of the chisel insert is normally oriented in alignment with the axis of cone rotation. Thus, unlike spherical and conical inserts, the chisel insert may be directionally oriented about its center axis. (This is true of any tooth which is not axially symmetric.) The axial angle of orientation is measured from the plane intersecting the center of the cone and the center of the tooth.
[0021] Background: Rock Mechanics and Formations
[0022] There are many factors that determine the drillability of a formation. These include, for example, compressive strength, hardness and/or abrasivity, elasticity, mineral content (stickiness), permeability, porosity, fluid content and interstitial pressure, and state of under-ground stress.
[0023] Soft formations were originally drilled with “fish-tail” drag bits, which sheared the formation away. Roller cone bits designed for drilling soft formations are designed to maximize the gouging and scraping action. To accomplish this, cones are offset to induce the largest allowable deviation from rolling on their true centers. Journal angles are small and cone-profile angles will have relatively large variations. Teeth are long, sharp, and widely-spaced to allow for the greatest possible penetration. Drilling in soft formations is characterized by low weight and high rotary speeds.
[0024] Hard formations are drilled by applying high weights on the drill bits and crushing the formation in compressive failure. The rock will fail when the applied load exceeds the strength of the rock. Roller cone bits designed for drilling hard formations are designed to roll as close as possible to a true roll, with little gouging or scraping action. Offset will be zero and journal angles will be higher. Teeth are short and closely spaced to prevent breakage under the high loads. Drilling in hard formations is characterized by high weight and low rotary speeds.
[0025] Medium formations are drilled by combining the features of soft and hard formation bits. The rock breaks away (is failed) by combining compressive forces with limited shearing and gouging action that is achieved by designing drill bits with a moderate amount of offset. Tooth length is designed for medium extensions as well. Drilling in medium formations is most often done with weights and rotary speeds between that of the hard and soft formations. Area drilling practices are evaluated to determine the optimum combinations.
[0026] Background: Roller Cone Bit Interaction with the Formation
[0027] In addition to improving drilling efficiency, the study of bottom hole patterns has allowed engineers to prevent detrimental phenomena such as those known as tracking, and gyration. The impressions a tooth makes into the formation depend largely on the design of the tooth, the tangential and radial scraping motions of the tooth, the force and speed with which the tooth impacts the formation, and the characteristics of the formation. Tracking occurs when the teeth of a drill bit fall into the impressions in the formation formed by other teeth at a preceding moment in time during the revolution of the drill bit. Gyration occurs when a drill bit fails to drill on-center. Both phenomena result in slow rates of penetration, detrimental wear of the cutting structures and premature failure of bits. Other detrimental conditions include excessive uncut rings in the bottom hole pattern. This condition can cause gyration, result in slow rates of penetration, detrimental wear of the cutting structures and premature failure of the bits. Another detrimental phenomenon is bit lateral vibration, which can be caused by radial force imbalances, bit mass imbalance, and bit/formation interaction among other things. This condition includes directional reversals and gyration about the hole center often known as whirl. Lateral vibration results in poor bit performance, overgage hole drilling, out-of-round, or “lobed” wellbores, and premature failure of both the cutting structures and bearing systems of bits. (Kenner and Isbell, DYNAMIC ANALYSIS REVEALS STABILITY OF ROLLER CONE ROCK BITS, SPE 28314, 1994).
[0028] Background: Bit Design
[0029] Currently, roller cone bit designs remain the result of generations of modifications made to original designs. The modifications are based on years of experience in evaluating bit records, dull bit conditions, and bottom hole patterns.
[0030] One method commonly used to discourage bit tracking is known as a staggered tooth design. In this design the teeth are located at unequal intervals along the circumference of the cone. This is intended to interrupt the recurrent pattern of impressions on the bottom of the hole. Examples of this are shown in U.S. Pat. No. 4,187,922 and UK application 2,241,266.
[0031] Background: Shortcomings of Existing Bit Designs
[0032] The economics of drilling a well are strongly reliant on rate of penetration. Since the design of the cutting structure of a drill bit controls the bit's ability to achieve a high rate of penetration, cutting structure design plays a significant role in the overall economics of drilling a well. Current bit designs have not solved the issue of tracking. Complex mathematical models can simulate bottom hole patterns to a limited extent, but they do not suggest a solution to the ever-present problem of tracking. The known angular orientations of teeth designed to improve tooth impact strength leave excessive uncut bottom hole patterns and do not solve the problem of tracking. The known angular orientations of teeth designed to increase bottom hole coverage, fail to optimize tooth orientation and do not solve the problem of tracking. Staggered tooth designs do not prevent tracking of the outermost rows of teeth. On the outermost rows of each cone, the teeth are encountering impressions in the formation left by teeth on other cones. The staggered teeth are just as likely to track an impression as any other tooth. Another disadvantage to staggered designs is that they may cause fluctuations in cone rotational speed, resulting in fluctuations in tooth impact force and increased bit vibration. Bit vibration is very harmful to the life of the bit and the life of the entire drill string.
[0033] Background: Cutting Structure Design
[0034] In the publication A NEW WAY TO CHARACTERIZE THE GOUGING-SCRAPING ACTION OF ROLLER CONE BITS (Ma, Society of Petroleum Engineers No. 19448, 1989), the author determines that a tooth in the first (heel or gage) row of the drill bit evaluated contacts the formation at −22 degrees (measured with respect to rotation of the cone about its journal) and begins to separate at an angle of −6 degrees. The author determines that the contacting range for the second row of the same cone is from −26 degrees to 6 degrees. The author states that “because the crest of the chisel inserts are always in the parallel direction with the generatrix of the roller cone . . . radial scraping will affect the sweep area only slightly.” The author concludes that scraping distance is a more important than the velocity of the cutter in determining performance.
[0035] In U.S. Pat. No. 5,197,555, Estes discloses a roller cone bit having opposite angular axial orientation of chisel shaped inserts in the first and second rows of a cone. This invention is premised on the determination that inserts scrape diagonally inboard and either to the leading side (facing in the direction of rotation) or to the trailing side (facing opposite to the direction of rotation). It is noted that the heel row inserts engage the formation to the leading side, while the second row inserts engage the formation to the trailing edge. In one embodiment, the inserts in the heel row are axially oriented at an angle between 30 degrees and 60 degrees, while the inserts in the second row are axially oriented between 300 degrees and 330 degrees. This orientation is designed to provide the inserts with a higher resistance to breakage. In an alternative embodiment, the inserts in the heel row are oriented at an axial angle between 300 degrees and 330 degrees, while the inserts in the second row are axially oriented between 30 degrees and 60 degrees. This orientation is designed to provide the inserts with a broader contact area with the formation for increased formation removal, and thereby an increased rate of penetration of the drill bit into the formation.
[0036] Summary: Roller-Cone Bits, Systems, Drilling Methods, and Design Methods with Optimization of Tooth Orientation
[0037] The present application describes bit design methods (and corresponding bits, drilling methods, and systems) in which tooth orientation is optimized jointly with other parameters, using software which graphically displays the linearized trajectory of each tooth row, as translated onto the surface of the cone. Preferably the speed ratio of each cone is precisely calculated, as is the curved trajectory of each tooth through the formation. However, for quick feedback to a design engineer, linear approximations to the tooth trajectory are preferably displayed.
[0038] The disclosed innovations, in various embodiments, provide one or more of at least the following advantages:
[0039] The disclosed methods provide a very convenient way for designers to take full advantage of the precision of a computer-implemented calculation of geometries. (The motion over hole bottom of roller cone bit teeth is so complex that only a complex mathematical model and associated computer program can provide accurate design support.)
[0040] The disclosed methods provide convenient calculation of tooth trajectory over the hole bottom during the period when the tooth engages into and disengages from the formation.
[0041] The disclosed methods permit the orientation angle of teeth in all rows to be accurately determined based on the tooth trajectory.
[0042] The disclosed methods permit the influence of tooth orientation changes on bit coverage ratio over the hole bottom to be accurately estimated and compensated.
[0043] The disclosed methods also permit designers to optimally select different types of teeth for different rows, based on the tooth trajectory.
[0044] The following patent application describes roller cone drill bit design methods and optimizations which can be used separately from or in synergistic combination with the methods disclosed in the present application. That application, which has common ownership, inventorship, and effective filing date with the present application, is:
[0045] application Ser. No. ______, filed Aug. 31, 1999, entitled “Force-Balanced Roller-Cone Bits, Systems, Drilling Methods, and Design Methods” (atty. docket no. SC-9825), claiming priority from U.S. provisional application No. 60/098,466 filed Aug. 31, 1998.
[0046] That nonprovisional application, and its provisional priority application, are both hereby incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWING
[0047] The disclosed inventions will be described with reference to the accompanying drawings, which show important sample embodiments of the invention and which are incorporated in the specification hereof by reference, wherein:
[0048] FIGS. 1 A- 1 C shows a sample embodiment of a bit design process, using the teachings of the present application.
[0049] [0049]FIG. 2 shows the tangential and radial velocity components of tooth trajectory, viewed through the cutting face (i.e. looking up).
[0050] [0050]FIGS. 3A, 3B, 3 C, and 3 D show plots of planar tooth trajectories for teeth in four rows of a single cone, referenced to the XY coordinates of FIG. 2.
[0051] [0051]FIGS. 4A and 4B show tangential and radial distances, respectively, for the four tooth trajectories shown in FIGS. 3 A- 3 D.
[0052] [0052]FIG. 5 is a sectional view of a cone (normal to its axis), showing how the tooth orientation is defined.
[0053] [0053]FIG. 6 shows time-domain plots of tooth tangential speed, for the five rows of a sample cone, over the duration of the trajectory for each row.
[0054] [0054]FIGS. 7A and 7B show how optimization of tooth orientation can perturb the width of uncut rings on the hole bottom.
[0055] [0055]FIGS. 8A and 8B show how optimization of tooth orientation can disturb the tooth clearances.
[0056] [0056]FIGS. 9A, 9B and 9 C show the screen views which a skilled bit designer would see, according to some embodiments of the invention, while working on a bit optimization which included optimization of tooth orientation.
[0057] [0057]FIG. 10 shows a drill rig in which bits optimized by the teachings of the present application can be advantageously employed.
[0058] [0058]FIG. 11 shows a conventional roller cone bit, and
[0059] [0059]FIG. 12 shows a conventional drag bit.
[0060] [0060]FIG. 13 shows a sample XYZ plot of a non-axisymmetric tooth tip.
[0061] [0061]FIG. 14 shows axial and sectional views of the i-th cone, and illustrates the enumeration of rows and teeth.
[0062] FIGS. 15 A- 15 D show how the planarized tooth trajectories vary as the offset is increased.
[0063] FIGS. 16 A- 16 D show how the ERSD and ETSD values vary for all rows of a given cone as offset is increased.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0064] The numerous innovative teachings of the present application will be described with particular reference to the presently preferred embodiment (by way of example, and not of limitation).
[0065] Overview of Sample Design Process
[0066] FIGS. 1 A- 1 C show a sample embodiment of a bit design process, using the teachings of the present application. Specifically, FIG. 1A shows an overview of the design process, and FIGS. 1B and 1C expand specific parts of the process.
[0067] First, the bit geometry, rock properties, and bit operational parameters are input (step 102 ). Then the 3D tooth shape, cone profile, cone layout, 3D cone, 3D bit, and 2D hole profile are displayed (step 104 ).
[0068] Since there are two types of rotation relevant to the calculation of the hole bottom (cone rotation and bit rotation), transformation matrices from cone to bit coordinates must be calculated (step 106 ). (See FIG. 1B.) The number of bit revolutions is input (step 108 ), and each cone is counted (step 110 ), followed by each row of teeth for each cone (step 112 ). Next, the type of teeth of each row is identified (step 114 ), and the teeth are counted (step 116 ). Next, a time interval delta is set (step 118 ), and the position of each tooth is calculated at this time interval (step 120 ). If a given tooth is not “cutting” (i.e., in contact with the hole bottom), then the algorithm continues counting until a cutting tooth is reached (step 122 ). The tooth trajectory, speed, scraping distance, crater distribution, coverage ratio and tracking ratios for all rows, cones, and the bit are calculated (step 124 ). This section of the process (depicted in FIG. 1B) gives the teeth motion over the hole bottom, and displays the results (step 126 ).
[0069] Next the bit mechanics are calculated. (See FIG. 1C.) Again transformation matrices from cone to bit coordinates are calculated (step 128 ), and the number of bit revolutions and maximum time steps, delta, are input (step 130 ). The cones are then counted (step 132 ), the bit and cone rotation angles are calculated at the given time step (step 134 ), and the rows are counted (step 136 ). Next, the 3D tooth surface matrices for the teeth on a given row are calculated (step 138 ). The teeth are then counted (step 140 ), and the 3D position of the tooth on the hole bottom is calculated at the given time interval (step 142 ). If a tooth is not cutting, counting continues until a cutting tooth is reached (step 144 ). The cutting depth, area, volume and forces for each tooth are calculated, and the hole bottom model is updated (based on the crater model for the type of rock being drilled). Next the number of teeth cutting at any given time step is counted. The tooth force is projected into cone and bit coordinates, yielding the total cone and bit forces and moments. Finally the specific energy of the bit is calculated (step 146 ).
[0070] Finally, all results are outputted (step 148 ). The process can then be reiterated if needed.
[0071] Four Coordinate Systems
[0072] Four coordinate systems are used, in the presently preferred embodiment, to define the crest point of a tooth in three dimensional space. All the coordinate system obey the “Right Hand Rule”. These coordinate systems—tooth, cone, bit, and hole—are described below.
[0073] Local Tooth Coordinates
[0074] [0074]FIG. 13 shows a sample XYZ plot of a tooth tip (in tooth local coordinates). Tooth coordinates will be indicated here by the subscript t. (Of course, each tooth has its own tooth coordinate system.) The center of the X t Y t Z t coordinate system, in the presently preferred embodiment, is located at the tooth center. The coordinate of a tooth's crest point P t will be defined by parameters of the tooth profile (e.g. tooth diameter, extension, etc.).
[0075] Cone Coordinates
[0076] [0076]FIG. 14 shows axial and sectional views of the i-th cone, and illustrates the enumeration of rows and teeth. Cone coordinates will be indicated here by the subscript c. The center of the cone coordinates is located in the center of backface of the cone. The cone body is fixed with respect to these coordinates, and hence THESE COORDINATES ROTATE WITH THE CONE. (Of course, each cone has its own cone coordinate system.) The axis Z c coincides with the cone axis, and is oriented towards to the bit center. Cone axes Y c and X c , together with axis Z c , follow the right hand rule. As shown in FIG. 13, four parameters are enough to completely define the coordinate of the crest point of a tooth on cone profile. These four parameters are H c , R c , φ c and θ c . For all the teeth on the same row, H c , R c , and φ c are the same.
[0077] Bit Coordinates
[0078] Similarly, a set of bit axes X b Y b Z b , indicated by the subscript b, is aligned to the bit. The bit is fixed with respect to these coordinates, and hence THESE COORDINATES ROTATE WITH THE BIT. Axis Z b preferably points toward the cutting face, and axes X b and Y b are normal to Z b (and follow the right-hand rule).
[0079] Hole Coordinates
[0080] The simplest coordinate system is defined by the hole axes X h Y h Z h , which are fixed in space. Note however that axes Z b and Z h may not be coincident if the bit is tilted. FIG. 2 shows the tangential and radial velocity components of tooth trajectory, viewed through the cutting face (i.e. looking up). Illustrated is a small portion of a tooth trajectory, wherein a tooth's crest (projected into an X h Y h plane which approximates the bottom of the hole) moves from point A to point B, over an arc distance ds and a radial distance dr.
[0081] Transformations
[0082] Since all of these coordinate systems are xyz systems, they can be interrelated by simple matrix transformations.
[0083] Both the bit and the cones are rotating with time. In order to calculate the position on hole bottom where the crest point of a tooth engages into formation, and the position that the crest point of a tooth disengages from formation, all the teeth positions at any time must be described in hole coordinate system XhYhZh.
[0084] The transformation from tooth coordinates X t Y t Z t to cone coordinates X c Y c Z c can be defined by a matrix Rtc, which is a matrix function of teeth parameters:
Rtc=f ( H c , R c , θ c , φ c ),
[0085] so that any point P t in X t Y t Z t can be transformed into local cone coordinates X c Y c Z c by:
P c =R tc *P t .
[0086] At time t=0, it is assumed that the plane X c O c Z c is parallel to the bit axis. At time t, the cone has a rotation angle λ around its negative axis (−Z c ). Any point on the cone moves to a new position due to this rotation. The new position of P c in X c Y c Z c can be determined by combining linear transforms.
[0087] The transform matrix due to cone rotation is R cone :
R cone =cos(λ) I+ (1−cos(λ)) NcNc′+ sin(λ) Mc,
[0088] where N c is the rotation vector and M c is a 3*3 matrix defined by N c .
[0089] Therefore, the new position P crot of P c due to cone rotation is:
P
crot
=R
cone
*P
c
[0090] Let R cb1 , R cb2 , and R cb3 be respective transformation matrices (for cones 1, 2, and 3) from cone coordinate to bit coordinates. (These matrices will be functions of bit parameters such as pin angle, offset, and back face length.) Any point P ci in cone coordinates can then be transformed into bit coordinates by:
P b =R cbi *P ci +P c0i for i= 1, 2, or 3,
[0091] where P c0i is the origin of cone coordinates in the bit coordinate system.
[0092] The bit is rotating around its own axis. Let us assume that the bit axes and hole axes are coincident at time t=0. At time t, the bit has a rotation angle β. The transform matrix due to bit rotation is:
Rbh= cos(β) I+ (1−cos(β)) NbNb′+ sin(β) Mb
[0093] where Nb is the rotation vector and Mb is a 3*3 matrix defined by Nb. Therefore, any point Pb in bit coordinate system can be transformed into the hole coordinate system X h Y h Z h by:
Ph=Rbh*Pb.
[0094] Therefore, the position of the crest point of any tooth at any time in three dimensional space has been fully defined by the foregoing seven equations. In order to further determine the engage and disengage point the formation is modeled, in the presently preferred embodiment, by multiple stepped horizontal planes. (The number of horizontal planes depends on the total number of rows in the bit.) In this way, the trajectory of any tooth on hole bottom can be determined.
[0095] Calculation of Trajectories in Bottomhole Plane
[0096] With the foregoing transformations, the trajectory of the tooth crest across the bottom of the hole can be calculated. FIGS. 3A, 3B, 3 C, and 3 D show plots of planar tooth trajectories, referenced to the hole coordinates X h Y h , for teeth on four different rows of a particular roller cone bit. The teeth on the outermost row (first row) scrapes toward the leading side of the cone. Its radial and tangential scraping distances are similar, as can be seen by comparing the first bar in FIG. 4A with the first bar in FIG. 4B. However for teeth on the second row the radial scraping motion is much larger than the tangent motion. The teeth on the third row scrape toward the trailing side of the cone, and the teeth on the forth row scrape toward the leading side of the cone.
[0097] [0097]FIGS. 4A and 4B show per-bit-revolution tangential and radial distances, respectively, for the four tooth trajectories shown in Figures 3 A- 3 D. Note that, in this example, the motion of the second row is almost entirely radial, and not tangential.
[0098] Projection of Trajectories into Cone Coordinates
[0099] The tooth trajectories described above are projected on the hole bottom which is fixed in space. In this way it is clearly seen how the tooth scrapes over the bottom. However for the bit manufacturer or bit designer it is necessary to know the teeth orientation angle on the cone coordinate, in order either to keep the elongate side of the tooth perpendicular to the scraping direction (for maximum cutting rate in softer formations) or to keep the elongate side of the tooth in line with the scraping direction (for durability in harder formations). To this end the tooth trajectories are projected to the cone coordinate system. Let P 1 ={x 1 , y 1 , z 1 } c and P 2 ={x 2 , y 2 , z 2 } c be the engage and disengage points on cone coordinate system, respectively, and approximate the tooth trajectory P 1 -P 2 as a straight line. Then the scraping angle in cone coordinates is:
R s ={square root}{square root over (( x 2 −x 1 ) 2 +( y 1 +y 2 ) 2 )}
[0100] and
γ s = tan - 1 ( R s z 2 - z 1 )
[0101] The teeth can then be oriented appropriately with respect to this angle gamma. For example, for soft formation drilling the tooth would preferably be oriented so that its broad side is perpendicular to the scraping direction, in order to increase its rate of rock removal. In this case, the direction γ c of the elongate crest of the tooth, in cone coordinates, is normal to γ s , i.e. γ c =γ s +π/2. Conversely, for drilling harder formations with a chisel-shaped tooth it might be preferable to orient the tooth with minimum frontal area in the direction of scraping, i.e. with γ c =γ s .
[0102] Derivation of Equivalent Radial and Tangential Scraping
[0103] There are numerous parameters in roller cone design, and experienced designers already know, qualitatively, that changes in cone shape (cone angle, heel angle, third angle, and oversize angle) as well as offset and journal angle will affect the scraping pattern of teeth in order to get a desired action-on-bottom. One problem is that it is not easy to describe a desired action-on-bottom quantitatively. The present application provides techniques for addressing this need.
[0104] Two new parameters have been defined in order to quantitatively evaluate the cone shape and offset effects on tooth scraping motion. Both of these parameters can be applied either to a bit or to individual cones.
[0105] (1) Equivalent Tangent Scraping Distance (ETSD) is equal to the total tangent scraping distance of all teeth on a cone (or bit) divided by the total number of the teeth on the cone (or bit).
[0106] (2) Equivalent Radial Scraping Distance (ERSD) is equal to the total radial scraping distance of all teeth on a cone (or bit) divided by the total number of the teeth on the cone (or bit).
[0107] Both of these two parameters they have much more clear physical meaning than the offset value and cone shape.
[0108] Surprisingly, the arcuate (or bulged) shape of the cone primarily affects the ETSD value, and the offset determines the ERSD value. Also surprisingly, the ERSD is not equal to zero even at zero offset. In other words, the teeth on a bit without offset may still have some small radial scraping effects.
[0109] The radial scraping direction for all teeth is always toward to the hole center (positive). However, the tangential scraping direction is usually different from row to row.
[0110] In order to use the scraping effects fully and effectively, the leading side of the elongated teeth crest should be orientated at an angle to the plane of the cone's axis, which is calculated as described above for any given row.
[0111] [0111]FIG. 2 shows the procedure in which a tooth cuts into (point A) and out (point B) the formation. Due to bit offset, arcuate cone shape and bit and cone rotations, the motion from A to B can be divided into two parts: tangent motion ds and radial motion dr. Notice the tangent and radial motions are defined in hole coordinate system XhYh. Because ds and dr vary from row to row and from cone to cone, we derive an equivalent tangent scraping distance (ETSD) and an equivalent radial scraping distance (ERSD) for a whole cone (or for an entire bit).
[0112] For a cone, we have
E T S D = ∑ j N r d s j N t j N c a n d E R S D = ∑ j N r d r j N t j N c
[0113] where Nc is the total tooth count of a cone and Nr is the number of rows of a cone.
[0114] Similarly for a bit, we have
E T S D = ∑ i 3 ∑ j N r d s ij N t ij N b a n d E R S D = ∑ i 3 ∑ j N r d r ij N t ij N b
[0115] where Nb is the total tooth count of the bit.
[0116] FIGS. 15 A- 15 D show how the planarized tooth trajectories vary as the offset is increased. These figures clearly show that with the increase of the offset value, the radial scraping distance is increased. Surprisingly, the radial scraping distance is not equal to zero even if the offset is zero. This is due to the arcuate shape of the cone.
[0117] FIGS. 16 A- 16 D show how the ERSD and ETSD values vary for all rows of a given cone as offset is increased. From these Figures, it can be seen that the tangent scraping distance of the gage row, while very small compared to other rows but is not equal to zero. It means that there is a sliding even for the teeth on the driving row. This fact may be explained by looking at the tangent speed during the entry and exit of teeth into and out of the rock. (FIG. 6 shows time-domain plots of tooth tangential speed, for the five rows of a sample cone, over the duration of the trajectory for each row.) During the cutting procedure the tangent speed is not equal to zero except for one instant. Because the sliding speed changes with time, the instantaneous speed is not the best way to describe the teeth/rock interaction.
[0118] Note that the tangent scraping directions are different from row to row for the same cone. FIG. 5 is a sectional view of a cone (normal to its axis), showing how the tooth orientation is defined in the present application: the positive direction is defined as the same direction as the bit rotation. This means that the leading side of tooth on one row may be different from that on another row.
[0119] The ERSD increases almost proportionally with the increase of the bit offset. However, ERSD is not zero even if the bit offset is zero. This is because the radial sliding speed is not always zero during the procedure of tooth cutting into and cutting out the rock.
[0120] Calculation of Uncut Rings, and Row Position Adjustment
[0121] [0121]FIGS. 7A and 7B show how optimization of tooth orientation can perturb the width of uncut rings on the hole bottom. The width of uncut rings is one of the design constraints: a sufficiently narrow uncut ring will be easily fractured by adjacent cutter action and mud flows, but too large an uncut ring will slow rate of penetration. Thus one of the significant teachings of the present application is that tooth orientation should not be adjusted in isolation, but preferably should be optimized jointly with the width of uncut rings.
[0122] Interference Check
[0123] Another constraint is tooth interference. In the crowded geometries of an optimized roller cone design, it is easy for an adjustment to row position to cause interference between cones. FIGS. 8A and 8B graphically show how optimization of tooth orientation can disturb the tooth clearances. Thus optimization of tooth orientation is preferably followed by an interference check (especially if row positions are changed).
[0124] Iteration
[0125] Preferably multiple iterations of the various optimizations are used, to ensure that the various constraints and/or requirements are all jointly satisfied according to an optimal tradeoff.
[0126] Graphic Display
[0127] The scraping motion of any tooth on any row is visualized on the designer's computer screen. The bit designer has a chance to see quantitatively how large the motion is and in which direction if bit geometric parameters like cone shape and offset are changed.
[0128] [0128]FIGS. 9A, 9B and 9 C show the screen views which a skilled bit designer would see, according to some embodiments of the invention, while working on a bit optimization which included optimization of tooth orientation. These three views show representations of tooth orientation and scraping direction for each tooth row on each of the three cones. This simple display allows the designer to get a feel for the effect of various parameter variations
[0129] Calculation of Cone/Bit Rotation Ratio
[0130] The present application also teaches that the ratio between the rotational speeds of cone and bit can be easily checked, in the context of the detailed force calculations described above, simply by calculating the torques about the cone axis. If these torques sum to zero (at a given ratio of cone and bit speed), then the given ratio is correct. If not, an iterative calculation can be performed to find the value of this ratio.
[0131] However, it should be noted that the exact calculation of the torque on the cones is dependent on use of a solid-body tooth model, as described above, rather than a mere point approximation.
[0132] Previous simulations of roller cone bits have assumed that the gage row is the “driving” row, which has no tangential slippage against the cutting face. However, this is a simplification which is not completely accurate. Accurate calculation of the ratio of cone speed to bit speed shows that it is almost never correct, if multiple rows of teeth are present, to assume that the gage row is the driver.
[0133] Changes in the tooth orientation angle will not themselves have a large immediate effect on the cone speed ratio. However, the tooth orientation affects the width of uncut rings, and excessive uncut ring width can require the spacing of tooth rows to be changed. Any changes in the spacing of tooth rows will probably affect the cone speed ratio.
[0134] Definitions:
[0135] Following are short definitions of the usual meanings of some of the technical terms which are used in the present application. (However, those of ordinary skill will recognize whether the context requires a different meaning.) Additional definitions can be found in the standard technical dictionaries and journals.
[0136] Drag bit: a drill bit with no moving parts that drills by intrusion and drag.
[0137] Mud: the liquid circulated through the wellbore during rotary drilling operations, also referred to as drilling fluid. Originally a suspension of earth solids (especially clays) in water, modern “mud” is a three-phase mixture of liquids, reactive solids, and inert solids.
[0138] Nozzle: in a passageway through which the drilling fluid exits a drill bit, the portion of that passageway which restricts the cross-section to control the flow of fluid.
[0139] Orientation: the angle of rotation with which a non-axisymmetric tooth is inserted into a cone. Note that a tooth which is axisymmetric (e.g. one having a hemispherical tip) cannot have an orientation.
[0140] Roller cone bit: a drilling bit made of two, three, or four cones, or cutters, that are mounted on extremely rugged bearings. Also called rock bits. The surface of each cone is made up of rows of steel teeth (generally for softer formations) or rows of hard inserts (typically of tungsten carbide) for harder formations.
[0141] According to a disclosed class of innovative embodiments, there is provided: A method of designing a roller cone bit, comprising the steps of: adjusting the orientation of at least one tooth on a cone, in dependence on an expected trajectory of said tooth through formation material at the cutting face, in dependence on an estimated ratio of cone rotation to bit rotation; recalculating said ratio, if the location of any row of teeth on said cone changes during optimization; recalculating the trajectory of said tooth in accordance. with a recalculated value of said cone speed; and adjusting the orientation of said tooth again, in accordance with a recalculated value of said tooth trajectory.
[0142] According to another disclosed class of innovative embodiments, there is provided: A method of designing a roller cone bit, comprising the steps of: calculating the trajectory of at least one tooth on each cone through formation material at the cutting face; and jointly optimizing both the orientations of said teeth and the width of uncut rings on said cutting face, in dependence on said trajectory.
[0143] According to another disclosed class of innovative embodiments, there is provided: A method of designing a roller cone bit comprising the steps of: a) adjusting the orientation of at least one row of teeth on a cone, in dependence on an expected trajectory of said tooth through formation material at the cutting face; b) calculating the width of uncut rings of formation material, in dependence on the orientation of said row of teeth, and adjusting the position of said row of teeth in dependence on said calculated width; and c) recalculating the rotational speed of said cone, if the position of said row is changed, and accordingly recalculating said trajectory of teeth in said row.
[0144] According to another disclosed class of innovative embodiments, there is provided: A method of designing a roller cone bit, comprising the steps of: calculating the respective trajectories, of at least two non-axisymmetric teeth in different rows of a roller cone bit, through formation material at the cutting face; and graphically displaying, to a design engineer, both said trajectories and also respective orientation vectors of said teeth, as the engineer adjusts design parameters.
[0145] According to another disclosed class of innovative embodiments, there is provided: A method of designing a roller cone bit, comprising the steps of: calculating the curved trajectory of a non-axisymmetric tooth through formation material at the cutting face, as the bit and cones rotate; calculating a straight line approximation to said curved trajectory; and orienting said tooth with respect to said approximation, and not with respect to said curved trajectory.
[0146] According to another disclosed class of innovative embodiments, there is provided: A roller cone drill bit designed by any of the methods described above, singly or in combination.
[0147] According to another disclosed class of innovative embodiments, there is provided: A rotary drilling system, comprising: a roller cone drill bit designed by any of the methods described above, singly or in combination. a drill string which is mechanically connected to said bit; and a rotary drive which rotates at least part of said drill string together with said bit.
[0148] According to another disclosed class of innovative embodiments, there is provided: A method for rotary drilling, comprising the actions of: applying weight-on-bit and rotary torque, through a drill string, to a drill bit designed in accordance with any of the methods described above, singly or in combination.
[0149] Modifications and Variations
[0150] As will be recognized by those skilled in the art, the innovative concepts described in the present application can be modified and varied over a tremendous range of applications, and accordingly the scope of patented subject matter is not limited by any of the specific exemplary teachings given.
[0151] For example, the various teachings can optionally be adapted to two-cone or four-cone bits.
[0152] In the example of FIGS. 9 A- 9 C the crest profiles of all rows except the gage rows are shown as identical (and their crest orientations are indicated by simple ellipses). However, this is not necessary: optionally the designer can be allowed to plug in different tooth profiles for different rows, and the optimization routines can easily substitute various tooth profiles as desired. In particular, various tooth shapes can be selected from a library of profiles, to fit the scraping motion of each row.
[0153] In one contemplated class of alternative embodiments, the orientations of teeth can be perturbed about the optimal value, to induce variation between the gage rows of different cones (or within an inner row of a single cone), to provide some additional resistance to tracking.
[0154] Of course the bit will also normally contain many other features besides those emphasized here, such as gage buttons, wear pads, lubrication reservoirs, etc. etc.
[0155] Additional general background, which helps to show the knowledge of those skilled in the art regarding implementations and the predictability of variations, may be found in the following publications, all of which are hereby incorporated by reference: A PPLIED D RILLING E NGINEERING , Adam T. Bourgoyne Jr. et al., Society of Petroleum Engineers Textbook series (1991), O IL AND G AS F IELD D EVELOPMENT T ECHNIQUES : D RILLING , J.-P. Nguyen (translation 1996, from French original 1993), M AKING H OLE (1983) and D RILLING M UD (1984), both part of the Rotary Drilling Series, edited by Charles Kirkley.
[0156] None of the description in the present application should be read as implying that any particular element, step, or function is an essential element which must be included in the claim scope: THE SCOPE OF PATENTED SUBJECT MATTER IS DEFINED ONLY BY THE ALLOWED CLAIMS. Moreover, none of these claims are intended to invoke paragraph six of 35 USC section 112 unless the exact words “means for” are followed by a participle.
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A novel and improved roller cone drill bit and method of design are disclosed. A roller cone drill bit for drilling through subterranean formations having an upper connection for attachment to a drill string, and a plurality cutting structures rotatably mounted on arms extending downward from the connection. A number of teeth are located in generally concentric rows on each cutting structure. The actual trajectory by which the teeth engage the formation is mathematically determined. A straight-line trajectory is calculated based on the actual trajectory. The teeth are positioned in the cutting structures such each tooth having a designed engagement surface is oriented perpendicular to the calculated straight-line trajectory.
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This invention is a process for producing wrinkle-resistant cellulosic textile materials, and the materials obtained thereby.
Fibrous cellulosic textile materials, such as cotton cloth, have been rendered wrinkle resistant in the past by treatment with a cross-linking agent, particularly with compounds containing two, or more, N-methylol, or N-alkoxymetnyl, groups.
However, compounds containing N-methylol groups, or N-alkoxymethyl groups, have a disadvantage in that on curing by heating they give off formaldehyde fumes which create environmental problems. There is a need, therefore, for wrinkle-resistant finishes for fibrous cellulosic textile materials which do not contain groups that liberate formaldehyde on heating.
It is known that fibrous cellulosic textile materials can be impregnated with a solution of cyanamide and phosphoric acid in water, according to U.S. Pat. No. 2,530,261, to impart improved wrinkle resistance to the treated material. This phenomenon is also described by O'Brien in "Cyanamide-Based Durable Flame-Retardant Finish for Cotton," Textile Research Journal, March, 1968, pp 263-264. However, it has been found that pad baths of cyanamide and phosphoric acid are unstable, and the tensile strength losses incurred are high.
It is also known that wrinkle resistance can be imparted to fibrous cellulosic textile materials by treating said materials with an aqueous solution of a phosphonic acid and cyanamide, and further treating the material with a solution of cyanamide, as disclosed in U.S. Pat. No. 3,892,906. However, pad bath instability is also a problem in this system. Other disadvantages include the relatively high costs of the cyanamide and phosphoric acids.
The invention is a process whereby a fibrous cellulosic textile material is rendered wrinkle resistant by impregnating the material with an aqueous mixture of urea and at least one phosphoric acid, wherein the mole ratio of urea to phosphoric acid is about 4:1 to 8:1, to deposit thereon about 7.0-35% by weight of urea, and about 3.0-9.0% by weight of the phosphoric acid, based on the weight of the untreated material; heating the treated material to obtain a phosphorylated material; contacting the phosphorylated material with an aqueous solution of cyanamide to deposit thereon about 0.75-13.5% by weight of cyanamide, based on the weight of the phosphorylated material; and, heating the treated material to impart wrinkle resistance thereto.
In the preferred embodiment, the mole ratio of urea to the phosphoric acid is about 5:1 to 7:1, and the urea and phosphoric acid deposited on the fabric are 15-30%, and 5.0-8.0%, respectively; the aqueous solution of cyanamide contains about 1.0-8.0% by weight of cyanamide, and the cyanamide deposited on the phosphorylated material is about 0.7-6.5% by weight.
In accordance with the invention, there are also provided wrinkle-resistant fibrous cellulosic textile materials obtained by the process of the invention.
The invention affords the following advantages:
1. The solution applied and the finished fabric contain no formaldehyde.
2. The problem of pad bath instability, inherent in the cyanamide/phosphoric acid, and cyanamide/phosphonic acid systems, is eliminated.
3. The level of wrinkle resistance is greatly improved over that obtained by usage of a corresponding mixture of cyanamide and phosphoric acid.
DESCRIPTION OF PREFERRED EMBODIMENTS
In carrying out the process of the invention, a solution of a phosphoric acid and urea in water, hereafter referred to as "Solution A," is prepared, containing a mole ratio of urea to phosphoric acid of about 4/1-8/1, preferably about 5/1-7/1.
Solution A can be prepared by adding urea to an aqueous solution of orthophosphoric acid, for example, at ambient temperature to provide a reaction mixture containing about 3.8-13.0%, preferably about 5.0-10.5%, by weight of orthophosphoric acid, and about 9.0-50.0%, preferably about 20.0-40.0%, by weight of urea.
Suitable phosphoric acids which may be used include the following:
orthophosphoric acid,
pyrophosphoric acid,
metaphosphoric acid,
and mixtures thereof.
Solution A is applied to a cellulosic textile material by any of the conventional methods of application, such as padding, spraying, dipping, and the like. Suitable cellulosic textile materials include cotton, rayon, and linen fabrics, as well as blends of these materials with hydrophobic fibers such as polyesters, nylon, polyacrylates, and the like. The preferred fabric is 100% cotton.
In carrying out the invention, the textile material is passed through a pad bath of Solution A, and passed between squeeze rolls to remove excess solution and obtain a wet pick-up of about 70-80%, preferably about 74-76%, by weight of Solution A, based on the weight of the untreated textile material. The treated material is then dried at about 80°-120° C. for about 1-15 minutes, preferably at about 100°-110° C. for about 2-6 minutes. The dried fabric contains about 3.0-9.0%, preferably about 5.0-8.0%, by weight of the phosphoric acid, and about 7.0-35.0%, preferably about 15.0-30.0%, by weight of urea, based on the weight of the dried material. After drying, the treated material is cured at about 140°-190° C. for about 1-6 minutes, preferably at about 160°-175° C. for about 1-4 minutes.
Preferably, Solution A also contains about 0.1% by weight of a surfactant which may be cationic, anionic, or nonionic. Preferably, the surfactant is nonionic.
Illustrative examples of suitable surfactants include the following:
nonylphenol-ethylene oxide polyether alcohols,
trimethylnonyl polyethylene glycol ether,
octylphenoxy polyethoxy ethanol,
isooctylphenoxy polyethoxy ethanol, and the
dihexyl ester of sodium sulfosuccinic acid.
The preferred surfactant is trimethylnonyl polyethylene glycol ether.
Solution B is prepared by adding cyanamide to water at ambient temperature to provide a solution containing about 2.0-17.0%, preferably about 3.0-8.0%, by weight of cyanamide.
The cured phosphorylated material is then rinsed with water and dried by conventional methods, preferably by frame drying, and treated with Solution B in the manner described above. The expression is such that wet pickup of Solution B is about 60-80%, preferably about 65-75%, by weight, based on the weight of the phosphorylated material. The treated material is dried, in the manner described above, to provide a material containing about 0.75-13.5%, preferably about 1.2-6.0% by weight of cyanamide, based on the weight of the dried material. After drying, the treated material is cured at about 140°-190° C. for about 1-6 minutes, preferably at about 160°-175° C. for about 1-4 minutes.
The following examples illustrate the process of the present invention. All parts are by weight unless otherwise indicated.
EXAMPLES 1 AND 2
A pad-bath solution is prepared containing 16.5% by weight of urea and 6.7% by weight of orthophosphoric acid in water to provide an application solution containing 4 moles of urea per mole of phosphoric acid.
A second pad-bath solution is prepared containing 24.7% by weight of urea and 6.7% by weight of orthophosphoric acid in water to provide an application solution containing 6 moles of urea per mole of phosphoric acid.
The solutions of the above pad baths are applied to 100% cotton broadcloth by padding, two dips and two nips, to obtain wet pickups of 77.3% and 79.8%, respectively, based on the weight of the untreated fabric. The treated fabrics are dried for 3 minutes at 107° C., and cured for 3 minutes at 171° C. The fabrics are then rinsed in water at 25° C. and dried for 3 minutes at 107° C. The fabric treated with the first pad-bath solution is labeled Fabric A and the one treated with the second pad-bath solution is labeled Fabric B.
A pad-bath solution, containing 3.75% by weight of cyanamide in water, is prepared and applied to Fabrics A and B by padding to obtain wet pickups of 66.6% and 68.7%, respectively, based on the weights of Fabrics A and B. The treated fabrics are then dried for 3 minutes at 107° C., and cured for one minute at 171° C.
The treated and untreated fabrics are tested for wrinkle recovery (American Association of Textile Chemists and Colorists Test Method 166-1975), and fill tensile strength (American Society for Testing Materials Test Method D-1682-64/R 1970).
The results obtained are shown below:
______________________________________ Wrinkle Recovery Tensile StrengthExample Fabric (degrees) (lbs)______________________________________1 A 254 282 B 257 26 Untreated 146 47______________________________________
EXAMPLES 3 AND 4
Pad-bath solutions are prepared in the manner of Examples 1 and 2, respectively, except that 3.75% by weight of real cyanamide is added to each solution. The solutions of the above pad baths are applied to 100% cotton broadcloth by padding to obtain wet pickups of 79.4% and 77.9%, respectively, based on the weight of the untreated fabric. The treated fabrics, A and B, respectively, are then dried for 3 minutes at 107° C., and cured for 3 minutes at 171° C. The treated fabric is then process washed with a 0.1% solution of soap and 1% soda ash, and dried.
The results obtained are shown below:
______________________________________ Wrinkle Recovery Tensile StrengthExample Fabric (degrees) (lbs)______________________________________3 A 220 344 B 202 35 Untreated 146 47______________________________________
Comparison of the above results with the results of Examples 1 and 2 shows that the process of the present invention gives superior wrinkle recovery than the corresponding process wherein the phosphoric acid, urea, and cyanamide are all applied in one bath.
EXAMPLE 5
A pad-bath solution is prepared, containing 3.75% by weight of cyanamide, and 6.7% by weight of orthophosphoric acid in water, and applied to 100% cotton broadcloth by padding to obtain a wet pickup of 75.4%, based on the weight of the untreated material. The treated fabric is then drid for 3 minutes at 107° C., and cured for one minute at 149° C. The treated fabric is then process washed with a 1% solution of soap and 1% soda ash, and dried.
The results obtained are shown below:
______________________________________ Wrinkle Recovery Tensile StrengthExample (degrees) (lbs)______________________________________5 222 29Untreated 146 47______________________________________
The above results, obtained by the conventional application of a mixture of cyanamid and phosphoric acid, show that the wrinkle recovery imparted by the application is inferior to that obtained by the process of the invention illustrated by Examples 1 and 2.
EXAMPLES 6 AND 7
Separate pad-bath solutions are prepared containing 21.5% by weight of urea and 6.0% by weight of othophosphoric acid in water to provide application solutions containing 5.85 moles of urea per mole of phosphoric acid.
The solutions of the above pad baths are applied to 100% cotton broadcloth by padding, two dips and two nips, to obtain wet pickups of 80.7 and 80.5%, respectively, based on the weight of the untreated fabric. The treated fabrics are dried for one and one-half minutes at 107° C. and cured for one minute at 171° C. The fabrics are then rinsed with water and dried at 107° C. for one and one-half minutes.
The fabric treated with the first pab-bath solution is labeled "Fabric A" and the one treated with the second pad-bath solution is labeled "Fabric B."
Pad-bath solutions, containing 1.0% and 0.5% by weight, respectively, of cyanamide in water, are applied to Fabrics A and B, respectively, by padding to obtain wet pickups of 77.3% and 79.1%, respectively, based on the weights of Fabrics A and B. The treated fabrics are then dried for one and one-half minutes at 107° C., and cured for one minute at 171° C.
The wrinkle recovery and tensile strength results obtained are shown below:
______________________________________ Wrinkle Recovery Tensile StrengthExample Fabric (degrees) (lbs)______________________________________6 A 268 197 B 236 20 Untreated 186 31______________________________________
The above results illustrate the process of the present invention wherein the amounts of cyanamide deposited on the fabric are 0.8% and 0.4%, respectively.
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The invention is a process whereby a fibrous cellulosic textile material is rendered wrinkle resistant by impregnating the material with an aqueous mixture of urea and at least one phosphoric acid, wherein the mole ratio of urea to phosphoric acid is about 4:1 to 8:1, to deposit thereon about 7.0-35% by weight of urea, and about 3.0-9.0% by weight of the phosphoric acid, based on the weight of the untreated material; heating the treated material to obtain a phosphorylated material; contacting the phosphorylated material with an aqueous solution of cyanamide to deposit thereon about 0.75-13.5% by weight of cyanamide, based on the weight of the phosphorylated material; and, heating the treated material to impart wrinkle resistance thereto.
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TECHNICAL FIELD
[0001] This invention relates to fabric systems and more particularly to a fabric of stitch bonded construction for covering the surface of office panel structures.
BACKGROUND OF THE INVENTION
[0002] In office environments it is common to find work space partitions in the form of modular wall panels. These panels are typically not designed to run from floor to ceiling but rather are free standing and are assembled as modules to enclose or partially enclose a work space. Wall panel systems may range in complexity from simple planar surfaces to complex arrangements incorporating integral work and storage surfaces such as cabinets, writing surfaces, shelves and the like. Wall panel systems provide a substantial benefit in a work place environment by affording the ability to reconfigure a work place with minimum disruption. Thus, they have gained wide acceptance in recent times.
[0003] Many forms of wall panel systems are known having various constructions and different aesthetic characteristics. By way of example only, one known form of office panel is constructed with steel frames surrounding cores of relatively lightweight material such as fiberboard or fiberglass having sound deadening capabilities. Often, these panels are covered with pieces of fabric supplied in colors which are meant to enhance the particular decor of the office environment. Illustrative wall panel constructions which incorporate outer fabric coverings are disclosed in U.S. Pat. No. 5,086,606 to Finses and U.S. Pat. No. 5,689,924 to Mason both of which are incorporated by reference as if fully set forth herein.
[0004] In the past, the fabric material which is used in covering relation to the panels has typically been formed in a woven or pile-forming fabric construction so as to provide both the desired aesthetic characteristics and the requisite physical strength and abrasion resistance to be suitable for use in the intended application. While such constructions have generally proven to be adequate, construction of such woven and pile-forming materials requires the use of a substantial quantity of preformed yarn which is then woven or tufted into a desired construction according to standard manufacturing techniques as are well known to those of skill in the art. However, such weaving and pile-forming techniques may be relatively expensive to carry out. This expense arises both from the relatively high cost of using preformed yarns as the primary construction constituent as well as from the limited speeds and output rates for traditional weaving and pile-forming equipment.
SUMMARY OF THE INVENTION
[0005] The present invention provides advantages and alternatives over the prior art by providing a fabric construction of potentially desirable aesthetic and performance character which makes use of highly efficient stitch bonding formation practices. The fabric utilizes a stitching yarn to form a surface covering across a support fabric of nonwoven fibrous material. The surface-forming stitching yarn provides a desirable aesthetic character across the selected surface which is visible during use. The stitch bonding arrangement also provides the fabric with suitable dimensional stability while nonetheless utilizing a relatively low cost nonwoven substrate.
[0006] Other advantages and aspects of the present invention will become apparent through reference to the following detailed description and/or through practice of the invention as described therein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The following drawings which are incorporated in and which constitute a part of this specification illustrate exemplary embodiments and constructions of the present invention and, together with the general description given above and the detailed description set forth below, serve to explain the principles of the invention wherein:
[0008] [0008]FIG. 1 is a plan view of the show surface face of panel covering textile fabric;
[0009] [0009]FIG. 2 is a plan view of the underside of the fabric illustrated in FIG. 1;
[0010] [0010]FIG. 3 is a magnified view of a segment of the face surface in the fabric illustrated in FIG. 1;
[0011] [0011]FIG. 4 is a magnified view of a segment of the underside of the fabric as illustrated in FIG. 2;
[0012] [0012]FIG. 5 is a cross-sectional view through a panel covering fabric taken along line 5 - 5 in FIG. 3; and
[0013] [0013]FIG. 6 illustrates a panel construction in which the panel covering fabric may be utilized.
[0014] While the invention has been illustrated and described above and will hereinafter be described in connection with certain potentially preferred embodiments and procedures, it is to be understood that in no event is the invention to be limited to such illustrated and described embodiments and procedures. On the contrary, it is intended that the present invention shall extend to all alternatives and modifications to the illustrated and described embodiments and procedures as may embrace the broad principles of this invention within the true spirit and scope thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Reference will now be made to the drawings wherein to the extent possible like reference numerals are utilized to designate corresponding elements throughout the various views. In FIG. 1, there is illustrated in plan view the face of fabric 10 defining a show surface for use in covering visible portions of an office panel structure or other extended surface. According to the illustrated embodiment, the fabric 10 is of a stitch bonded construction wherein a plurality of stitch yarns 12 are passed repeatedly in stitch forming relation through a textile substrate layer 14 of nonwoven construction. In the illustrated arrangement the show surface illustrated in FIG. 1 corresponds to the so called “technical face” of the fabric 10 .
[0016] In FIG. 2, the underside of the fabric 10 is illustrated showing the arrangement of stitch yarns 12 across the so called “technical back” of the fabric. As shown, while the stitch yarns are arranged in a configuration across the fabric face which results in substantial coverage, the stitch yarns 12 are preferably arranged across the underside in a substantially concentrated arrangement of stitch loops extending in the machine direction along the underside of the fabric 10 . Thus, the total quantity of preformed stitch yarns 12 is relatively low thereby enhancing the manufacturing efficiency and economic value of the formation process.
[0017] In the fabric 10 , the stitch yarns 12 serve the dual function of both establishing the aesthetic face covering illustrated in FIG. 1 as well as imparting stability to the overall structure. In practice, the substrate is preferably a spun laced hydroentangled nonwoven fabric formed from a multiplicity of individual staple fiber elements which have been entangled with one another so as to establish a substantially cohesive structure. Such fiber elements are preferably formed of polyester but may also be of any suitable natural or synthetic fiber type as may be desired. In the event that additional stability is desired, it is contemplated that the textile substrate layer 14 may be of a nonwoven spunbonded construction. As will be understood by those of skill in the art, such spunbonded nonwoven material is formed by the substantially random deposit of semi-molten strands of polymeric material across a support surface to build up a coordinated structure.
[0018] The stitch yarns 12 are preferably formed from polyester although any other suitable natural or synthetic fiber such as nylon and the like may likewise be used if desired. According to one potentially preferred embodiment, stitch yarns 12 are formed from a so called “bright” or lusterous polyester of relatively large denier so as to provide a substantially lustrous covering affect across the face of the fabric 10 . In such a construction the stitch yarns 12 preferably have a linear density in the range of about 300 to about 1,000 denier and most preferably have a linear density of about 450 denier. The substrate layer is preferably formed from solution dyed polyester fibers which are hydroentangled to form a fleece structure having a mass per unit area of about 30 to about 100 grams per square meter and most preferably about 50 grams per square meter. The use of a textile substrate layer 14 which is solution dyed to a dark color such as black or dark gray in combination with bright stitching yarns 12 has been found to provide a substantially metallic appearance across the face which may be desirable in some applications.
[0019] According to one exemplary formation practice, the stitch yarns 12 are inserted through the substrate layer 14 using a two bar Liba type stitch bonding machine although it is contemplated that other stitch bonding equipment such as a Malliwatt machine or the like as will be well known to those of skill in the art may also be utilized. According to the exemplary formation practice using the two bar Liba machine, both bars are preferably fully threaded at a 7 gauge spacing. Stitches are applied at about 12 stitches per inch according to a stitch pattern at the rear bar of 0-1/3-2// (or reverse) and a stitch pattern at the front bar of 1-2/1-0// (or reverse).
[0020] In some instances, it may be desirable to have the ability to mold the fabric 10 to a three-dimensional geometry so as to facilitate application across a contoured panel surface. It is contemplated that this moldability may be imparted by thermoforming a low melt constituent incorporated within the fiber arrangement forming the nonwover substrate layer 14 . According to one exemplary procedure, the nonwoven substrate layer 14 may include a percentage of low melting point polyester in combination with higher melting point polyester. In such a construction, the melting point of the higher melting point polyester is preferably in the range of about 250-400° F. and the melting point of the lower melting point polyester constituent is about 50° F. lower. It is contemplated that the lower melting point material may be present in the range of about 5% or greater and will most preferably be present in the range of about 5% to about 60% by weight of the overall textile substrate layer 14 . The lower melting point material may be present as a constituent of a bicomponent fiber such as a core/sheath fiber wherein the lower melting point material is disposed in surrounding relation to the higher melting point material. Of course, the lower melting point material may also be present in the form of discrete fiber elements. Combinations of multi-component fibers and discrete fibers may also be utilized if desired.
[0021] In a structure incorporating differential melting point fiber constituents the fabric 10 may be molded by raising the temperature following introduction of the stitch yarns 12 . In practice, the temperature is raised to a level greater than the melting point of the lower melting point constituent but below that of the higher melting point constituent. While the fabric is in the elevated temperature state, the fabric is molded to the desired configuration and thereafter allowed to cool. The resulting resolidification of the lower melting point constituent thereafter forms a bonding matrix between the higher melting point fibers resulting in a shape retaining structure which may be useful in three-dimensional covering applications such as covering raised or depressed portions of an office panel structure.
[0022] While the use of lower melting point and higher melting point polyester fibers may be preferred, it is also contemplated that other fiber blends of differential melting point may likewise be useful to impart moldability. Thus, by way of example only and not limitation, it is contemplated that the high melting point fiber constituent may be polypropylene and the lower melting point fiber constituent may be polyethylene. Likewise, the higher melting point constituent may be high density polypropylene intermixed with a low density polypropylene as the lower melting point constituent. Likewise, the higher melting point material may be nylon with the lower melting point material being either polyester or polypropylene or mixtures thereof. Of course, virtually any other combination of suitable fibers having differential melting points may likewise be utilized if desired.
[0023] Regardless of the composition of the fabric 10 , it is contemplated that the fabric 10 may have useful application as a covering material for an office panel or other high surface area structure. An exemplary office panel structure 20 is illustrated in FIG. 6. In the office panel structure 20 , two individual panel assemblies 22 , 24 are connected together at a supporting frame so as to form a free standing wall barrier. The fabric 10 is arranged across the panel assemblies 22 , 24 with the face of the fabric (FIGS. 1 and 3) facing away from the panel assemblies so as to establish the desired surface covering facing towards a user. Of course, the fabric 10 may also be applied across the exterior of the panel assemblies if desired. While the panel assemblies 22 , 24 are illustrated as being substantially planar, it is contemplated that such assemblies may also have raised and lowered surfaces across their expanse. In such arrangements, it is contemplated that the fabric 10 may be molded to a mating geometry so as to extend in matable relation over such raised and lowered surfaces.
[0024] While the present invention has been described in connection with certain potentially preferred embodiments and practices thereof, it will be apparent to those if skill in the art that many changes and modifications may be made without departing from the true spirit and scope of the invention. Accordingly, it is intended by the appended claims to cover all such changes and modifications as may fall within the full spirit and scope of the invention.
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An office panel assembly and fabric covering therefor. The panel assembly includes a supporting frame and a covering of textile fabric. The textile fabric is of a stitch bonded construction including a stitch yarns extending in a repeating stitch arrangement through a nonwoven fibrous substrate such that the stitch yarns cooperatively form a patterned show surface across one side of the said textile fabric.
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TECHNICAL FIELD
The subject of the present invention is a method for the production of images with high resolution in jacquard fabrics according to the preamble of claim 1 and to a plant for carrying out the method.
BACKGROUND
EP 0 692 562 describes a method for the optical illustration of a fabric consisting of warp and weft threads with a pattern. In this method, the patterns are recorded by a data processing system and displayed on a video screen, the patterns being scanned in from an original. Thereafter, by means of CAD, the warp and weft threads forming the fabric are assigned an intersection diagram, the weaves of which the fabric is to consist being defined. These are known regular weaves, such as linen weaves, satin weaves, twill weaves and basket weaves. Subsequently, the run of the warp and weft threads is determined, the thread-specific parameters and fabric parameters being taken into account. In light of the dynamic behavior and run of warp and weft, the predetermined run of the warp and weft threads is corrected. This corrected warp/weft thread run is illustrated by means of an output unit, for example by means of a video screen or printer. After the correction, various colors are assigned to the individual warp and weft threads.
It is considered a disadvantage that the colors are selected as a function of the colors capable of being illustrated in the output unit, for which purpose a person skilled in the art with experience of weaves is necessary. The output unit is a video screen or a printer which operate on the basis of the ground colors (RGB) and with additive color mixing. It is known, however, that an exact reproduction of an illustration cannot be achieved in the fabric in the ground colors by means of textile weft threads. Since the colors capable of being illustrated by the output unit also contain mixed colors, threads with such mixed colors have to be provided.
DE 44 38 535 discloses a method for the jacquard weaving of a colored cloth. In this method, an image copy to be woven is broken down by means of the screen method known from printing technology. In this method, an original is transferred into a computer by scanning and is displayed on the video screen, a very large number of color shades being present. Subsequently, the colors are reduced to an illustratable or a desired number of colors. Finally, this number of colors is broken down into screen dots having the colors red, yellow and blue and also black and white, the screen dot having the size of a weavable point. After the color breakdown, the weaving program is set up by means of computer technology, each screen dot corresponding to a weaving point. These weaving points are tied off according to the classic jacquard method, that is to say regular weaves with repeat repetitions are used.
The known method has substantial disadvantages. To carry out the method, it is absolutely necessary to have an experienced person skilled in the art with experience of weaves. To be precise, it has become clear that, in the case of woven colored image copies in the colors yellow, red and blue, the color mix is deficient, that is to say they do not have all the color shades of the original. As a rule, corrections are necessary in order to improve the woven image copy. However, corrections of this kind can be carried out only by an experienced person skilled in the art with experience of weaves. In the color breakdown for reprography, it is to be assumed that a color mix occurs in the region between the print colors during the printing operation. In other words, the printed color dots are not clearly delimited, but, instead, the print colors of the adjacent color dots flow partially one into the other in the edge region. In the known method, the illustration is broken down into screen dots which form a weaving point with clear delimitation. The mixing effects are to be generated as a result of the low resolution of the human eye.
It is therefore known that the introduction of jacquard weaving machines has made it possible to produce differently worked patterns, but the production times for more complex patterns are very long and the work to be carried out is extremely complicated. The introduction of the CAD systems in the area of jacquard weaving has led to a considerable simplification of the necessary work and at the same time has reduced the possibility of error during the planning and production of different thread interlacings for the purpose of obtaining various effects. The CAD systems nevertheless also force the workers to carry out special additional work on the images in order then to produce on the final fabric a structure which is as similar as possible to the initial image to be reproduced on the fabric.
In actual fact, the work for preparing the images and their respective treatment, quite apart from the weaving system which is used later, take place as set out below:
First, a color scanning of any desired initial image is carried out (the initial image may be of any desired type, without any restriction); scanning may take place with the aid of a scanner or by means of any other reading system.
The initial image read in this way is visualized by video by means of an appreciable number of colors. Said number of colors is closely related to the performance of the hardware system used and consequently to the configuration of the latter.
In professional configurations, an image with millions of image colors can be read and visualized by video. In actual fact, this is primarily a theoretical performance, since the possibility of visualization of this kind is very rare: normally, images coming from the scanner have thousands of image colors which are selected automatically, during the reading operation, from a spectrum consisting of millions of colors. It is necessary, however, to ensure that each image read by the scanner contains a specific color palette or, put better, a color palette which contains the colors of the image itself in a specific way.
At this point, said image undergoes a first operation for reducing the number of existing image colors, that is to say the initial colors of the initial image. The processes of color reduction may be carried out by means of different methods, such as by the use of special mathematic algorithms which, to be precise, vary on the basis of the way in which the colors are eliminated and/or are replaced by other colors within the image.
In any event, quite apart from the nature of the reduction used and, consequently, of the mathematic algorithm used, the initial image having a large number of initial colors is brought, for example, to 256 reduced colors. This is a step which takes place by virtue of the fact that the images which are subsequently processed by CAD for jacquard textiles do not require a large number of colors, and, as a rule, it is assumed that 256 colors are sufficient for the final objective and for the treatment of the image itself, specifically on the basis of the respective conversion to a pattern for jacquard textiles.
The image treated in this way (reduced in terms of the number of colors), is subsequently transferred into the jacquard CAD system in which all the operations are coordinated which make it possible to convert the image itself into a pattern for jacquard textiles. One of the first steps in this respect is a further reduction of the remaining, already reduced colors. In fact, the number of existing colors is reduced in the image on the basis of the type of fabric and on the basis of the effects to be achieved. Normally, in a fabric pattern, each individual color illustrates a specific type of interlacing and, consequently, a specific type of final effect on the fabric.
At this point, the following steps are linked to the additional work on the available image. On the other hand, the image then available has passed through a considerable series of steps in terms of the reduction, as regards the number of colors and consequently also as regards the information obtained from the image, and, consequently, as soon as the number of selected colors is reached, an image is available which necessarily has to undergo the additional work, so that it is as far as possible similar to the initial image.
The time necessary for the “additional work” on the images is in close interrelationship with the complexity of the pattern. This clearly and markedly implies that, even today, despite the use of highly developed systems, the complex patterns require long times for the complete and final additional work. At the present time, therefore, there is no mathematic algorithm available which makes it possible to convert automatically an image which is read by a scanner (and which is consequently rich in information in terms of the number of existing colors and the nuances, etc.) and at the same time to achieve the exact reproduction of the initial image, without the additional work having to be carried out.
In practice, the different steps described above, which are performed with the purpose of reducing the number of colors present in the read initial image, do not make it possible to maintain, unchanged, the nuances, color shades and different color variations which the image initially has. All this takes place to the disadvantage of the image processing times, but also to the disadvantage of the quality of the final fabric; by “quality” is meant in this case the difference existing between the initial image at the time of reading and the converted image reproduced on the jacquard fabric.
Of course, the number of colors which the image to be reproduced on the jacquard fabric possesses at most may be limited, specifically also by the maximum number of colors of the weft thread which are capable of being used in the weaving machine. Normally, what can be achieved, at least at the present time, in textile weaving machines is that these use up to a maximum of 12 weft thread colors, and therefore the number of reproducible colors is necessarily limited.
SUMMARY OF THE INVENTION
The main object of the present invention is to implement a method for the production of images in jacquard fabrics, which makes it possible to maintain the extremely high resolution of an image, without additional work on the image itself having to be carried out in this case.
Within the scope of this object, one aim of the present invention is to implement a method for the production of images in jacquard fabrics, which makes it possible to leave essentially unchanged the graphic resolution of the initial image, a particular operation to be precise, the reduction of the colors of the initial image, being carried out, and the additional work on the image being dispensed with.
A further aim of the present invention is to implement a method for the production of images in jacquard fabrics, which makes it possible to accelerate to an extreme extent the times for reproducing the image in the fabric.
A further aim of the present invention is to implement a method for the production of images in jacquard fabrics, which is capable of reproducing as exactly as possible the nuances and the whole of the image colors present in the initial image.
Last but not least, an aim of the present invention is to implement a method for production of images in jacquard fabrics, which is distinguished by high reliability, relatively simple implementation and low costs.
The subject and all the aims mentioned, which are set out more clearly below, are achieved by means of a method for the production of images with high resolution in jacquard fabrics.
Further advantageous refinements of the invention may be gathered, in particular, from the exemplary embodiments.
It is particularly advantageous if the breakdown of the reduced image colors takes place with the inclusion of a predetermined warp/weft thread ratio, and that the weaving program provides for the use of irregular weaves without weave repeat repetition. The weaving program provides for the use of irregular weaves without repeat repetition.
The electronic image processing by means of the system results in a high resolution of the illustration or image copy to be woven. By the warp/weft thread ratio being included in the splitting of the image colors into the basic colors, this resolution advantageously takes place largely free of loss and there is consequently a largely true-to-original reproduction of the illustration in the fabric. By the use of irregular weaves without repeat repetition, image dots which are mixed into the figure of a colored illustration are generated, as in printing. It is essential, in this case, that the image dots can be generated directly by the computer according to the original, without manual correction by a person skilled in the art with experience of weaves. After the color breakdown, including the warp/weft thread ratio, a weavable data format is prepared in a CAD system from the illustration to be woven and is delivered to a weaving machine.
It is advantageous if the warp/weft thread ratio is 2:1. With this ratio, the conditions during weaving, with twenty-eight weft threads and fifty-six warp threads per cm, can be adhered to exactly.
By use of thread groups of at least two basic colors, it becomes possible to generate an irregular weave without repeat repetition.
By the illustration of the initial image to be woven being reduced to a maximum of 256 colors, the image copy can be woven by means of weft threads in only four basic colors. This results in a simplification of the weaving machine.
The use of weft threads with the basic colors black and white has the advantage that, on the one hand, black/white illustrations with high resolution can be woven, and, on the other hand, the contrasts in colored image copies with the basic colors red, green, blue and yellow can be reproduced perfectly.
The free selection of the basic colors allows an unrestricted combination and, in particular, exact adaptation of the woven image copy to the illustration of the initial image.
The insertion of weft thread groups in a uniform order has the advantage that the weaving program to be prepared is simpler.
It is advantageous if the weaving program provides for the combination of regions having irregular weaves with regular weaves with repeat repetition, because the configuration of fabrics is thereby broadened substantially.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention are explained in more detail below with reference to the accompanying drawings in which:
FIG. 1 shows the diagrammatic run of a weft thread through warp threads of a jacquard fabric which are illustrated in section;
FIG. 2 shows the diagrammatic run of two weft threads through the warp threads of a jacquard fabric which are illustrated in section;
FIG. 3 shows a block diagram of one version of the programming system according to the invention for the production of a jacquard fabric,
FIG. 4 shows a copy of an initial imager serving as an original, of an image copy to be woven,
FIG. 5 shows an enlarged detail A of the original according to FIG. 4 on a larger scale after the color breakdown of the illustration into selected basic colors,
FIG. 6 shows an enlarged detail B in FIG. 5 ,
FIG. 7 shows an illustration of the weft sequence for the fabric,
FIG. 8 shows a sectional diagram of a fabric with an irregular weave,
FIG. 9 shows a top view of the fabric according to FIG. 8 ; and
FIG. 10 shows a weave point design paper for a regular weave.
DETAILED DESCRIPTION OF THE INVENTION
The method according to the invention comprises an initial phase of color scanning of any desired image which may be of any type, without any restriction in terms of typology and of dimensions.
The image read in this way is visualized by video by means of an appreciable number of colors: said number of colors is in close interrelationship with the performance of the hardware system used and, consequently, with the configuration of the latter.
At this point, the execution of a selection of the number of necessary colors is commenced, specifically directly from the video image or by a selection of the colors within the total spectrum of the visible field of colors, an infinite selection of color shades and variants consequently being offered.
In practice, the worker selects the number of basic colors of the weft and of the warp which he would like to use during weaving, that is to say the number of basic colors corresponding to the number of warp and weft threads which the weaving machine can use. According to the invention, the method provides for reducing the initial colors of the initial image within the maximum possible colors by means of the selected basic colors.
Essentially, a series of virtually infinite different color shades occurs in the initial image; all these color shades are obtained by means of the reproduction of the initial color by means of the combination of one or more threads of different colors, thus leading to the visualization of the desired color.
The result of the combination of one or more threads having basic colors selected by the worker is the reduced color of the reduced initial image which is prepared by means of a scanner.
A method for converting the pixels of the reduced image into the selected basic colors is called the “dithering” method. This method makes it possible to reproduce the extremely large number of image colors present in the initial image by means of a comparatively very small number of colors, without a reworking of the image having to be carried out. In fact, with this method, no details of the image are lost, which, by contrast, are lost in known techniques in which the reduction of the image colors to a highly accurate number of weft colors takes place, but without a reproduction of the unavoidably absent colors being carried out.
The interaction of the selected basic colors makes it possible to visualize all the other colors which are required for the image, so that it coincides with the initial image. The nuances of the image derive from the quantity of pixels of the color which is selected with greater or lesser intensity, the starting point being the basic colors which were initially selected by the worker.
The color shades are obtained by mixing the pixels of the basic colors which are selected with a greater or lesser intensity according to the color shades to be reproduced. If, for example, by virtue of the reduction in the number of colors, the following basic colors
black, white, red, yellow, green and blue
are selected, then a series of virtually infinite different color shades (red, gray, green, yellow shades, etc.) are achieved in the reduced initial image. All these color shades are obtained by the combination of threads of different basic colors (consequently, the color shades are simulated, since a weft or warp thread having this particular color shade is not necessarily inserted into the weaving machine) which (selected from the colors intended for carrying out the reduction) lead to the visualization of the desired color.
If, for example, the color straw yellow is to be simulated, the yellow and white threads are combined, thus resulting visually in the color straw yellow. Of course, the color shades of straw yellow which are to be achieved are diverse, and, consequently, processing must be carried out with regard to the quantity of the basic colors white and yellow which are combined so that all these color shades are obtained.
In light of the fact that the colors are always obtained by the interlacing of two types of threads which are arranged at right angles to one another, one type being the warp threads, the other type the weft threads, normally the weft thread having a specific color is interlaced with the warp threads, the final result being a particular color on the upper and the lower face of the fabric.
FIG. 1 illustrates the warp threads 1 , illustrated in section, and a weft thread 2 which executes the crossover through a warp thread. The final color of the fabric is consequently obtained from the respective color of the weft thread 2 , since this thread is worked over the warp thread (the weft thread portion is consequently yellow and the face of the fabric will be yellow). The situation illustrated is a standard situation in which an attempt is made to obtain a pure color on the fabric.
In the event that, by contrast, particular nuances of yellow are to be achieved, an attempt must be made to work the yellow weft thread 2 on the upper face of the fabric (consequently, above the warp threads 1 ), specifically together with a further weft thread 2 ′ or with a plurality of weft threads, in order to obtain the desired nuances.
FIG. 2 illustrates the situation where the yellow weft thread runs past, together with the white weft thread 2 ′, above the warp threads 1 ; a light medium yellow is thereby achieved. The quantity of the colors yellow and white can then be determined from the different nuances. By “quantity” it is meant in this case the number of warp threads 1 which are covered by the weft thread 2 , 2 ′. In FIG. 2 , it can be seen, for example, that the yellow weft thread 2 remains above the five warp threads 1 , while the white weft thread 2 ′ remains above the six warp threads. This means that, in this case, the yellow is very light (more white than yellow).
There is no limitation as regards the quantity of the colors to be used (the weft thread or the warp threads may also be interlaced to form a single warp thread) and as regards the number of weft threads which can be used in order to generate different color shades. In fact there are colors which can be created by combination of more than two threads of different basic colors.
The “dithering” method thus makes it possible to split each color into various dots of selected basic colors. It may therefore happen that, for some colors, it is necessary to use all the basic colors which were initially selected by the worker. This is due to the fact that the final colors of the fabric are not achieved by the direct presence of the weft thread having the specific color, but by the combination (in different quantities) of the selected basic colors: consequently, the colors are simulated and are not actually present. It therefore seems obvious that, in a situation of this kind, no reworking of the image is necessary, since the latter is converted into a fabric pattern, without initial information being lost at the same time.
Moreover, by means of the method according to the present invention, the initial image is treated as though it were already a pattern for jacquard textiles and not merely a graphic file. In fact, each initial image is composed of square pixels, whereas the equivalent textile images consist of right angles with dimensions which are different on the basis of the parameters to be used. The situation which arises as a result of the conversion of an image consisting of square pixels into a textile pattern is one where the image necessarily experiences changes in shape and consequently the final textile pattern no longer has a perfect graphic resolution. The method according to the invention makes it possible to change the dimensions of the initial pixels, so that the latter coincide with the rectangle on the drawing paper used for the textile pattern, or vice versa.
Consequently, does not experience any change in shape during the transition to the textile pattern and with the transition from pixel to drawing paper and therefore also does not require any reworking.
In practice, it was ascertained how the method according to the invention completely achieves the set object or fulfills the aims set in the introduction, since it makes it possible to reduce the number of colors of an image, without information on the image itself being lost at the same time, and without the need to carry out on the image itself reworking which unavoidably entails long processing times.
The method conceived in this way may undergo numerous and different modifications which are all within the scope of the concept of the invention. Thus, the method can be used, for example, for any type of warp thread, so that even micrometric particulars of the initial image are made possible. Moreover, all details may be replaced by other technically equivalent elements. In practice, the materials used, insofar as they are compatible with the respective application, and also the dimensions may be of any desired type according to the requirements and to the state of the art.
A more detailed description of various exemplary embodiments follows.
FIG. 3 shows a version of the invention in question here. The programming system starts from an original in the form of an initial image 3 and comprises the program steps of scanning 4 , color reduction 5 , color breakdown 6 and weaving program 7 which is worked through in a weaving machine 8 to produce the fabric 9 having the desired final image.
In the first step, an image having, for example, approximately 1.6 million colors is scanned and is illustrated on a video screen. Depending on the resolving capacity of the scanner and of the video screen, the illustration of the image which appears on the video screen usually has a few thousand colors or color shades.
In a second step, the colors of this image are reduced to an illustratable amount, for example, to 256 colors. In this color reduction, various colors are lost or are replaced by other colors within the color spectrum.
The third step comprises a plurality of substeps. First, a predetermined number of basic colors are selected for the warp and weft threads which are used during weaving. Advantageously, weft threads having the basic colors red, green, blue, yellow, black and white are selected.
Subsequently, the 256 reduced colors are broken down into the basic colors. This breakdown takes place automatically and generates a figure which shows the weaving pattern ( FIGS. 4 and 5 ).
During the electronic image processing, colors are illustrated by means of pixels. The image colors are illustrated as color cells, each color cell being represented by a representative color. Nuances of the image colors are obtained from the quantity of pixels of the color with a differing color depth which is selected. In the color reduction, the colors are replaced by representatives of the color cells into which the color falls. However, not every pixel is imaged onto the representative of the color cell, but, instead, is transferred on to one of the adjacent image colors.
Finally, a splitting of the image colors takes place, said transfer being carried out. By means of this transfer, there is a division, on the one hand, of the image colors into image dots of the basic colors and, on the other hand, of the color shades of the image colors in terms of their color depth into image dots of the basic colors, which are combined in order to generate the color shades, for example red and white for light red. The image dots are formed in each case by a weft thread which has a basic color and which crosses a weft thread above on the visible side of the fabric. During this splitting, a warp/weft thread ratio of 2:1 is included, so that the illustration to be woven is formed by the rectangular color dots, illustrated in FIG. 5 , forming the basis for the weaving program to be set up.
In the fourth step, the programming of the image copy to be woven is carried out on a computer. Reference is made to FIGS. 7 to 10 . By means of the weaving program, the insertion of the weft threads and the movement of the warp threads (upstroke and downstroke) are regulated. As shown in FIG. 7 , six weft threads having the basic colors red, green, blue, yellow, black and white are used. The weft threads are inserted in this order as a thread group in a weft line and form a color cell. The weft threads are tied off by means of the warp threads. For this purpose, the weaving program provides an irregular weave without repeat repetitions and regular weaves with repeat repetitions. The irregular weave takes place according to the color dots generated during the breakdown, in such a way that, for example, the red weft thread R of the thread group is visible as a red color dot on the visible side of the fabric and the remaining weft threads float on the back side. The same applies to the generation of a green color dot, the green weft thread G being visible. This is illustrated in FIGS. 8 and 9 .
As described above, during the color breakdown, color dots with color nuances and a different color depth are obtained. For color dots of this kind, the weaving program provides for a color mix which may take place, for example, by means of at least two weft threads having a different basic color. The weaving program provides further possibilities, for example with floating weft threads.
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The invention relates to a method for the production of images with high resolution jacquard fabric comprising the following steps: colour scanning of an output image to be reproduced on a fabric, video visualisation of said image with the largest number of colours possible with the means employed for said visualisation. The invention is characterised in that the method comprises further steps: selection of a number of base colours to be used for forming said image on said fabric, said number of base colours is related to the number of warp and weft threads which may be used in the loom and which are to be applied in the weaving of said fabric, reducing the original colours of the output image to a number of reduced colours which it is possible to produce by mixing the base colours of the warp and weft threads.
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BACKGROUND OF THE INVENTION
The present invention relates to an image processing method and an image processing apparatus.
With the popularization of digital printers producing prints on the basis of image information, opportunities of handling images incoming from various types of image inputting media and/or devices have proliferated. As an example, when the prints are produced by image information originating from various types of digital camera, a signal conversion technique in the predetermined color domain, which is standardized on the basis of subject intensity at the camera, is typically applied to the image information originating from the digital camera, in order to homogenize the image quality.
In reality, however, the accuracy of conversion into the predetermined color domain and an optical systems for capturing images have varied with various sorts of digital cameras. Owing to this fact, it has not been a simple task to homogenize the image quality, even if the predetermined color domain is standardized at the camera side.
In addition, with the increase of memory capacity for storing image information in digital cameras, the number of images, taken by the digital camera, have also increased. Therefore, in order to produce prints with the image information incoming from various types of digital cameras, it is required to rapidly determine the conditions necessary for image processings, corresponding to many image information. Development of such a method and an appropriate apparatus has been an urgent task in this field.
In addition to digital cameras, digital images incoming from various types of image inputting media have different image sizes (defined as vertical and lateral pixel number of image information). For example, in the case of print production based on an image information, an exclusive image processing system, which corresponds to the type of the image information, is required for adjusting the color/density. This fact has resulted in complexity of the processing system.
In a system called “Digital Mini-Lab.”, specifically comprising a film scanner, a print production process, wherein various kinds of image processings such as a color compensation, etc. are performed on the basis of the image information obtained from the film scanner, has been established. It has been an urgent goal for such a “Digital Mini-Lab.” to have a function of corresponding to various types of digital images without adding to the operator's work load.
In a printing system for producing prints from various kinds of photo documents, a system for automatically adjusting the print quality has been adopted to reduce the operator's work load for the additional quality manipulations. There have been drawbacks, however, such that finished print quality is not neccessary sufficiently good, e.g., a print of rear-lighting image being finished with too much dense tone, etc. Although it has been expected to introduce a system for automatically adjusting the print quality in the field of digital media such as digital cameras, etc. to reduce the operator's work load, such a system has not been realized so far. Further, in the system of “Digital Mini-Lab.” wherein simultaneous print processing of plural prints gathered from the media mentioned above is possible, it is desirable that the automatic adjusting system should have the capability of always finishing prints with constant image quality irrespectve of media type, as well as stable print quality of each medium. So far, however, such a system does not yet exist.
SUMMARY OF THE INVENTION
The primary objective of the present invention is to provide an image processing method and an apparatus for processing the image information incoming from various kinds of image inputting media, wherein a homogenization processing of image quality and a synthetic image processing are performed in a common system.
In order to minimize the aforesaid problems and to achieve the abovementioned objective, the present invention includes such an image processing method and image processing apparatus, described as follows:
1) an image processing method, comprising the steps of:
inputting the first image information;
converting the first image information into a predetermined image size to generate the second image information; and
applying image processing to the first image information or the second image information, on the basis of the second image information, to generate the third image information,
2) an image processing method, comprising the steps of:
inputting the first image information;
converting the first image information into a predetermined image size to generate the second image information; and
generating an image processing conditions for the image processings on the basis of the second image information,
3) an image processing apparatus, comprising:
means for inputting the first image information;
an image size converter to convert the first image information to the second image information having a predetermined image size; and
means for applying a image processing to the first image information or the second image information, on the basis of the second image information, to generate the third image information, and
4) an image processing apparatus, comprising:
means for inputting the first image information;
an image size converter to convert the first image information to the second image information having a predetermined image size;
means for generating image processing conditions for the image processing on the basis of the second image information.
In the present invention, the inputting means is defined as means for inputting image information which is equivalent to image signals representing images, which includes electric signals, optical signals, magnetic signals, etc. The inputting means includes CD-ROM, Floppy Disk Drive, Magnet-optics Disk Drive, means for reading data from media such as Hard Disk, etc., means for receiving image information via communication lines, a scanner for reading images recorded on documents, etc.
The term of “fixed size” defined in the present invention designates a size being in a range of ±35% of the predetermined image size.
It is desirable that the predetermined image size is set at a larger size than the fixed image size having a large number of pixels sufficient to discriminate a main subject (such as a human figure, a plant, a building, etc.) existing in an image. On the contrary, it is also desirable that the predetermined image size is set at a smaller size than the fixed image size having a small number of pixels sufficient to eliminate details of microstructure which are irrelevant to the main subject, e.g., granules existing in silver-halide photos.
Accordingly, in the image (color/density) processing described later, it is possible to obtain characteristic values pertaining to the main subject in the image and stable processing results with little influence of various visual noise which is irrelevant to the main structural element in the image.
In addition, when image printing is performed on the basis of the third image information, the larger the finished print size, the smaller the region which can be recognized as the main structural element. Although an appropriate image size of the second image information is apt to be getting large accordingly, it is not so much change as is the difference of the print size. Therefore, it may be appropriate that the image size of the second image information is predetermined in a range of 190-500 pixels in the longitudinal dimension of the image.
Now, the image processing methods and the image processing apparatus related to the present invention will be described in detail, item by item as follows. (1) After inputting image information from plural kinds of image inputting media, the first image information, which is input so as to have the same image size, irrespective of the kinds of image inputting media, is converted to the second image information by a resolution conversion method. Then, image processing is performed on the basis of the second image information.
According to the method described above, since the same image size is obtained by applying the resolution conversion to the image information with various image sizes, it becomes possible to commonly use the image processing process thereafter and to enlarge the applicable range of the image processing without increasing the complexity of the processing system. (2) After image processing conditions are determined on the basis of the second image information mentioned above, new image information is obtained by converting the first image information under the image processing conditions mentioned above.
According to the method described above, it becomes possible to use a common processing process such as an arithmetic image operation to derive the image processing conditions for homogenizing image quality of the image information incoming from various types of image inputting media. The image inputting media defined in the present invention are various kinds of recording media including CD-ROM, Floppy Disk, Magnet-optics Disk, Hard Disk, etc., and also including media which store image information in main body of the camera such as digital cameras, digital video cameras, etc. (3) A film scanner section for reading the image information from the photo film is provided, wherein the image information has the same image size as that of the second image information mentioned above.
According to the method described above, it becomes possible to apply image processings in the same processing system to image information read from a negative color transparent film or a positive color transparent film or a monochrome transparent film, or incoming from various kinds of digital cameras or media. Then, it also becomes possible to use a common system for such processings as an arithmetic operation to compensate for image information, image synthetic processing, image displaying processing, etc. (4) After determining the image processing conditions on the basis of the low resolution image information obtained from the film scanner, new image information is obtained by converting the image information at a higher resolution on the basis of the image processing conditions mentioned above, wherein the low resolution image information has the same image size as that of the second image information mentioned above.
According to the method described above, since the lower resolution image information is utilized for determining the image processing conditions, it becomes possible to increase the velocity of the arithmetic image processing, etc., and to perform image compensation for various kinds of image information in the same processing system. Thus, any desired image quality will be quite easier to obtain. (5) The image processing conditions mentioned above are compensating conditions for color and/or density.
According to the method described above, color and/or density compensating processing makes it possible to homogenize the color of various digital images incoming from different types of digital cameras, as well as other devices. (6) The image processing based on the second image information is an image synthesizing processing of a plurality of the second image information for a plurality of predetermined domains.
According to the method described above, since the image synthesizing processing systems for displaying plural image frames and for producing an index print can be utilized in common, it becomes possible to simplify the total image processing system. (7) In order to adjust the image size at the same, an additional portion of the image information can be attached in either the vertical or the horizontal direction to either the image information incoming from the film scanner or the second image information.
According to the method described above, since a common image synthesizing processing systems can be utilized for the image information with different aspect ratios without deformation or dropping of image portions when displaying images or producing index prints, it becomes possible to simplify the total image processing system. (8) The first image information mentioned above is image information obtained from digital cameras.
According to the method described above, it becomes possible to flexibly cope with the forthcoming popularization of high resolution images of digital cameras, and the effects of the present invention will become more marked. (9) The resolution of the second image information is lower than that of the first image information mentioned above.
According to the method described above, since the processing rate of image processing section common to various digital images can be increased, it becomes possible to improve the processing rate of the total image processing system. (10) After inputting image information from plural kinds of digital cameras, the new image information are obtained by applying the image processing to the inputted first image information under the image processing conditions for use of digital cameras, which are predetermined and stored beforehand.
According to the method described above, since the image processing conditions for digital camera use can also be applied for the inputted first image information, it becomes possible to shorten the processing time for the first image information and to improve the processing rate of the total image processing system. (11) Prints are produced by exposing photosensitive material on the basis of the image information obtained by using one of the methods described above.
According to the method described above, since the image processing processes from inputting various kinds of image information to printing can be communized and image quality can be homogenized, it becomes possible to produce prints with high image quality from various kinds of digital image information in a simplified processing system. (12) An image processing apparatus comprises means for converting the image resolution and means for image processing, wherein after inputting image information from plural kinds of image inputting media, the first image information, which is input so as to have the same image size, irrespective of the kinds of image inputting media, is converted to the second image information by the image resolution converting means, and then, image processing is performed by the image processing means on the basis of the second image information.
According to the apparatus described above, since the same image size is obtained by applying the resolution conversion to the image information with various image sizes, it becomes possible to use a common image processing process thereafter and to enlarge the applicable range of the image processing apparatus without increasing the complexity of the processing system. (13) The image processing apparatus further comprises means for determining image processing conditions on the basis of the second image information mentioned above, and means for obtaining a new image information by converting the first image information under the image processing conditions mentioned above.
According to the apparatus described above, it becomes possible to use common processing processes such as the arithmetic image operation to derive the image processing conditions for homogenizing image quality of the image information incoming from various types of image inputting media. The image inputting media defined in the present invention are various kinds of recording media including CD-ROM, Floppy Disk, Magnet-optics Disk, Hard Disk, etc., and also including media which store image information in the main body of cameras such as digital cameras, digital video cameras, etc. (14) The image processing apparatus further comprises a film scanner for reading the image information from the photo film, wherein the image resolution converting means converts the image information read by the film scanner into the same image size as that of the second image information mentioned above.
According to the apparatus described above, it becomes possible to apply image processings in the same processing system to image information read from a negative color transparent film or a positive color transparent film or a monochrome transparent film, or incoming from various kinds of digital cameras or media. Then, it also becomes possible to use a common system for such processing as an arithmetic operation to compensate the image information, image synthetic processing, image displaying processing, etc. (15) The image processing apparatus comprises means for generating new image information, wherein after determining the image processing conditions on the basis of the low resolution image information obtained from the film scanner, new image information is generated by converting the image information with higher resolution on the basis of the image processing conditions mentioned above, and the low resolution image information has the same image size as that of the second image information mentioned above.
According to the apparatus described above, since the lower resolution image information is utilized for determining the image processing conditions, it becomes possible to increase the velocity of the arithmetic image processing, etc., and to perform an image compensation for various kinds of image information in the same processing system. Thus, any desired image quality will be quite easier to obtain. (16) The image processing apparatus includes compensating conditions for color and/or density in regard to the image processing conditions mentioned above.
According to the apparatus described above, color and/or density compensating processing make it possible to homogenize the color of various digital images incoming from different types of digital cameras, as well as other devices. (17) The image processing apparatus comprises means for image synthesizing processing, wherein the image processing based on the second image information is an image synthesizing processing for a plurality of the second image information for a plurality of the predetermined domains.
According to the apparatus described above, since the image synthesizing processing systems for displaying plural image frames and for producing an index print can be utilized in common, it becomes possible to simplify the total image processing system. (18) The image processing apparatus comprises means for attaching an additional portion of the image information in either vertical or horizontal direction to either the image information incoming from the film scanner or the second image information, in order to adjust the image size at the same size.
According to the apparatus described above, since a common image synthesizing processing system can be utilized for the image information with different aspect ratios without deformation or dropping of image portions when displaying images or producing index prints, it becomes possible to simplify the total image processing system. (19) The image processing apparatus has a feature in which the first image information mentioned above is the image information obtained from digital cameras.
According to the apparatus described above, it becomes possible to flexibly cope with the forthcoming popularization of high resolution images of digital cameras, and the desirable effects of the present invention will become more marked. (20) The image processing apparatus has a feature such that the resolution of the second image information is lower than that of the first image information mentioned above.
According to the apparatus described above, since the processing rate of image processing section common with the various digital images can be increased, it becomes possible to improve the processing rate of the total image processing system. (21) The image processing apparatus comprises means for inputting image information from plural kinds of digital cameras and memory means for storing the image processing conditions for digital camera use, which are predetermined and stored beforehand, wherein after inputting the image information, the new image information are obtained by applying the image processing to the inputted first image information under the image processing conditions.
According to the apparatus described above, since the image processing conditions for digital camera can be applied for the inputted first image information, it becomes possible to shorten the processing time for the first image information and to improve the processing rate of the total image processing system. (22) The print producing apparatus has a function of producing prints by exposing a photosensitive material on the basis of the image information obtained by using one of the apparatus described above.
According to the apparatus described above, since the image processing processes from inputting various kinds of image information to printing can be communized and image quality can be homogenized, it becomes possible to produce prints with high image quality from various kinds of digital image information in a simplified processing system.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objectives and advantages of the present invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:
FIG. 1 shows a diagonal perspective view of the print producing apparatus utilizing apparatus and methods of the image processing, embodied in the present invention;
FIG. 2 shows a schematic diagram of the print producing apparatus;
FIG. 3 shows a schematic diagram of the film scanner section;
FIG. 4 shows a schematic diagram of the print producing apparatus;
FIG. 5 shows a schematic diagram of the another embodiment of the print producing apparatus;
FIG. 6 shows an explanetory illustration when an operator manually adjusting color/density of the image with displaying images of 6 frames on the CRT; and
FIG. 7 shows another explanatory illustration when an operator manually adjusting color/density of the image with displaying images of 6 frames on the CRT.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following, apparatus and methods of the image processing, embodied in the present invention, will be described, referring to the drawings.
FIG. 1 shows a perspective view of a print producing apparatus utilizing apparatus and methods of the image processing embodied in the present invention.
A print producing apparatus 1 incorporates a magazine loading section 3 mounted on the left side of a main body 2 , an exposure processing section provided in the main body 2 to expose images on photosensitive materials, and a development processing section 5 to produce the prints by developing the exposed photosensitive materials and drying them. The finished prints are delivered to a delivery tray 6 mounted on the right side of the main body 2 . In addition, a control section 7 is also incorporated in the main body 2 , and located at the upper portion of an exposure processing section 4 .
Further, a CRT 8 is mounted on the top of the main body 2 . A film scanner section 9 which reads image data of a transparent original film, and an inputting device 10 which reads image data of a reflective original sheet, are arranged at left and right sides of the CRT 8 , respectively.
FIG. 2 shows substantial schematic structural diagram of a print producing apparatus.
On the basis of instructions inputted by a key board 11 , the control section 7 of the print producing apparatus 1 carries out such processing as reading image data incoming from a film scanner section 9 or from a reflection type original image inputting device 10 (hereinafter, referred to as the inputting device 10 , for simplicity), reading image data incoming from a digital camera or a digital video camera through an external input interface 100 or a PC card slot 101 , reading image data incoming from various recording media by means of a floppy disk drive 102 or a CD-ROM drive 103 , storing the image data in an image information memory 71 , and displaying images on the CRT 8 , or producing prints.
The film scanner section 9 and the inputting device 10 , serving as image reading means, are provided for obtaining image data of the pictorial image developed on the silver-halide photosensitive material. Image data of an original 20 such as a negative color transparent film, a positive color transparent film, or a monochrome transparent original can be read by means of the film scanner section 9 . While image data of an original 20 such as a print P, which is produced through exposure and development processing of a film image, can be read by means of the inputting device 10 .
The PC card slot 101 , serving as a inputting means of image data incoming from various types of digital cameras, is provided for setting a recording media G in it to read the image data stored in the recording media G in which image data of various types of digital cameras are already stored. While, image data of various types of digital cameras also can be inputted through the external input interface 100 by means of the serial data transmission features.
In the image processor 70 , image data utilized for the exposing process are generated by processing the inputted image data, and are transmitted to the exposure processing section 4 wherein the images are exposed on photosensitive materials. The exposed photosensitive materials are sent to the development processing section 5 to produce the prints through the processes of developing and then drying them.
FIG. 3 shows the main configurations of the film scanning section.
In the film scanner section 9 , it is possible to read the image data of the original 20 such as a negative color transparent material, a positive color transparent material, or a monochrome transparent material. The film type original 20 is conveyed by paired rollers 21 which are driven by a motor 22 controlled by a motor control section 23 . When a light source 29 emits a light, the light penetrating through the original 20 is received by a CCD 24 , and the image signals converted by the CCD 24 are transmitted to a CPU 25 which controls the CCD 24 . The CPU 25 also carries out such processing as controlling a pre-scanning control section 27 to perform pre-scanning, storing the pre-scanning information into a memory section 28 , calculating processing based on the pre-scanning image data, and transmitting compensated values, utilized for image data compensation in the main scanning process, to the control section 7 .
FIG. 4 shows the essential configurations of the print producing apparatus.
In the print producing apparatus 1 , a photosensitive material 50 is fed by paired conveyance rollers 30 and is cut to predetermined length by means of a cutter 31 . This photosensitive material is conveyed to the exposure processing section 4 wherein the emulsion coated surface of the photosensitive material is exposed by means of an exposing head 40 under conditions of exposure compensation for the photosensitive material, and is then recorded. After exposing, the photosensitive material is further conveyed to the development processing section 5 by means of paired conveyance rollers 32 .
Alternatively, it is also possible to employ laser scanning exposure for the abovementioned image recording, instead of the exposing head 40 . For instance, three lasers, each of which corresponds to one of the three primary color layers (e.g. R, G and B) formed on the photosensitive material, are provided for two dimensional scanning by laser lights modulated in accordance with the image data. Specifically, image recording onto the photosensitive material is achieved by deflecting the modulated laser beams in the main scanning direction while conveying the photosensitive material in the sub-scanning direction, basically perpendicular to the main scanning direction.
In an image processing section 70 of the control section 7 , the compensated image data are generated by applying image processings to the image data incoming from various sections, such as, the film scanning section 9 , the inputting device 10 , means for reading the recording media, or digital camera etc. through the external interface 100 . In regard to the recording media, it is possible to employ such recording media, which are capable of storing image data and being read by computer, as, e.g., PC card, floppy disk and CD-ROM.
The image processing section 70 comprises means for applying a resolution converting processing, serving as an image size conversion processing, to the first image data incoming from the PC card slot 101 , the external interface 100 , the floppy disk drive 103 , or the CD-ROM drive to generate the second image data having the predetermined image size, and means for conducting image processing on the basis of image processing conditions, which are correlatively derived from the second image data, to generate new image data. In this case, the abovementioned image processing would be applied to the first image information, the second image information or an image information which is different in image size from the first and the second image information. For example, as a normal application, the abovementioned image processing is applied to the first image information, and the generated image data are transferred to the exposure processing section 4 to produce a print thereby. In addition, it is also possible to apply the abovementioned image processing to the second image information to produce an index print. Therefore, the image processing section 70 will make it possible to generate new image data with homogeneous image quality by converting the first image data incoming from various kinds of digital cameras into the second image data having a image size different from that of the first image data, and by conducting the image processings on the basis of image processing conditions in accordance with the second image data.
In order to generate the second image data by means of the resolution converting processing, serving as an image size conversion processing, the image expansion/reduction techniques, such as pixel supplement/thinning processing, etc., are available. In addition, if image information in file formatted image data, including images with a plurality of resolutions, selector means for selecting image data with a predetermined resolution is also available.
The image information from digital cameras, defined in the present invention, includes single frame image information from digital video cameras.
Further, the film scanning section 9 is provided for reading image data from transmission original materials such as negative films, positive films, etc., and those image data have the predetermined image size same as that of the second image data derived from various kinds of digital cameras. The image processing is carried out under image processing conditions corresponding to each kind of image data. While, in case of reflection type documents, the image data of which are read by the inputting device 10 , the image processing is carried out under image processing conditions which are correlatively derived from an image data having the predetermined image size same as that of the second image data or that of the pre-scanning image data.
As described above, it is possible to apply image processing in the same processing system to image data read from a negative color transparent film, a positive color transparent film, a monochrome transparent film or a reflection type document, or incoming from various kinds of digital cameras or media.
Provided that the image processing conditions are color and/or density compensating conditions, it is also possible to homogenize the color and/or density properties included in digital image information coming from various kinds of digital cameras or media by compensating the color and/or density of them.
As described above, it is possible to input various kinds of digital image information, to homogenize the image quality, and to make prints with high image quality from various kinds of digital image information.
In regard to the compensation method of color and/or density, it is possible to calculate the average value of image information as a basic value of the compensation. For instance, when an average pixel value of an image information group is predetermined at R=G=B=128 for each color and the average pixel values of the second image information are, e.g., R=108, G=118, B=138, the shift values are calculated out as +20 for R, +10 for G, −10 for B. The compensation of the first image information is accomplished by shifting the average pixel value of the first image information on the basis of the calculated shift values.
Another technique for color compensation is set forth in Tokkaihei 9-261505, wherein an original color image is divided into a plurality of blocks and the calculation of the first statistic is carried out by subtracting the influence of the high chroma blocks from the original color image, and then the calculation of the second statistic is carried out on the basis of the first statistic by subtracting the influence of the high chroma pixels, and, finally, the color compensation value for the original color image is obtained from the second statistic. Still another technique for color compensation is set forth in Tokkaihei 9-294215, wherein a plurality of statistics being different one another are derived from chroma data of pixels of an original color image, and conditions for extracting the neutral pixels are derived from an statistic obtained from each of the plural statistics to extract the neutral pixels, which satisfy all of the derived extracting conditions, from the original color image, and a color image reproduction method based on the extracted neutral pixels makes it possible to perform a color compensation with little influence of the color failure.
Further, a technique for density compensation is set forth in Tokkaihei 5-93973, wherein the image characteristics of an original image are derived from the obtained image data, and the value of the derived image characteristics and/or the first order linear sum of the image characteristic value functions are utilized for evaluating the image characteristics of an original image. The desirable density compensation with little influence of the density failure can be achieved by such the method that the group to which the original image should be belonged is discriminated from a plurality of the predetermined groups on the basis of the evaluating results mentioned above and then the exposing amount or the exposing compensation amount for the original image is calculated out by using the predetermined regression function corresponding to the discriminated group.
FIG. 5 shows another embodiment of the present invention, illustrating a simplified schematic diagram of the print producing apparatus.
An image processing conditions memory 73 (hereinafter referred to as the conditions memory 73 , for simplicity) for storing image processing conditions, which are predetermined for each type of digital camera, is included in the control section 7 of the print producing apparatus 1 . In the image processing section 70 , the image processing of the in coming first image information are carried out on the basis of image processing conditions stored in the conditions memory 73 to send the revised image data to the exposure processing section 4 . In the exposure processing section 4 , a photosensitive material is exposed to image data, then the photosensitive material is sent to the development processing section 5 where the exposed photosensitive material is developed, then, processed and dried, and thus a print is made. Accordingly, it becomes possible to homogenize the image quality of the image information incoming from various digital cameras, resulting in a production of prints with homogenized image quality.
The image processing conditions stored in the conditions memory 73 includes, e.g., the amount of color/density level shift, the amount of contrast conversion, color matrix coefficients for chromatic conversion, etc. Those values may be utilized for deriving the compensated image information from the original image information through a direct calculation process, or the image processing conditions may be utilized for setting the LUT by which the original image information is converted to the compensated image information. Other methods for correlating the image processing conditions with a sort of digital camera may include an automatic setting, wherein data pertaining to a sort of digital camera is attached to the original image data and is automatically read, as well as manual setting by the operator.
As mentioned above, it is possible to improve the processing speed of the first image information by employing the image processing conditions for each model of digital camera, which are already stored in the conditions memory 73 .
Even if an operator manually adjusts color/density of 6 images displayed on the CRT 8 by operating a touch panel 8 a and/or the keyboard 11 as shown FIG. 6 and FIG. 7, it is not neccessary for the operator to change the mode of the image display processing between the film data and the digital camera data, since the synthesized images displayed on the CRT 8 have the same frame size each other. This will simplify the processing system.
As shown in FIG. 7, when displaying the images of digital cameras, additional portions are vertically attached to each image displyed on the CRT 8 , in order to adjust the aspect ratio of them to that of the film images. This image synthesizing processing can be employed, as well, for the production of the index print on which a plurality of images are arranged. In this case, there is no need to prepare various kinds of printing formats in accordance with the sort of incoming image data.
Next, a method of inputting image information from a film scanning section 9 and applying an image processing for it is explained.
A transmission type original is read at the film scanning section 9 , whereby a preliminary-scanned image information (the second (the fourth) image information) is obtained. The image size of the preliminary-scanned image information is made as the expected image size as the same manner in the case that image information is read from the memory medium as stated above. Then, an image processing section 70 obtains an image processing condition such as a correcting condition for color and/or density on the basis of the preliminary-scanned image information. Also, the film scanning section 9 reads image information (main-scanned image information (the fifth image information)) having a different image size from that of the preliminary-scanned image information from a transmission type original. Here, it may be preferable that the above different image size is larger than that of the preliminary-scanned image information. Then, an image processing section 70 apples the image processing to the main-scanned image information in accordance with the obtained image processing condition.
In the above embodiment, the image processing is applied to the main-scanned image information. However, in the case that an index print is produced, it may be permissible that the image processing is applied to the preliminary-scanned image information.
Further, in the above embodiment, the example that the transmission type original is read again in order to obtain the main-scanned image information after the original is read in order to obtain the preliminary-scanned image information, is explained. However, it may be permissible that after the transmission type original is read in order to obtain the main-scanned image information, the processing to change the image size is applied to the main-scanned image information and the preliminary-scanned image information is obtained.
Now, a method of inputting image information from a reflection type original inputting device 10 and applying an image processing is explained.
A reflection type original is read by the reflection type original inputting device 10 , whereby the first image information is obtained. It may be preferable that the image size of the first image information is larger than the expected image size. The processing to change the image size is applied to the first image information, whereby the second (the fourth) image information having the expected image size smaller than that of the first image information. The expected image size is the same size as the image size in the case that the image information is read from the memory medium or in the case that the image information is read from the film scanning section 9 . Then, the image processing section 70 obtains an image processing condition such as a correcting condition for color and/or density on the basis of the second image information. Further, the reflection type original inputting device 10 reads the fifth image information having a different image size from those of the first image information and the second image information. Here, it may be preferable that the different image size of the fifth image information is larger than those of the first image information and the second image information. Then, the image processing section 70 apples the image processing to the fifth image information in accordance with the obtained image processing condition.
In the above embodiment, the image processing is applied to the fifth image information. However, in the case that an index print is produced, it may be permissible that the image processing is applied to the second image information or that the image processing is applied to the first image information.
Further, as same as the case that the transmission type original is read by the film scanning section 9 , that the image processing condition is obtained, and that the image processing is applied, it may be permissible that the second image information of the expected image size is read from the reflection type original inputting device 10 without obtaining the first image information, the image processing condition is obtained on the basis of the second image information, the fifth image information is read from the reflection type original inputting device 10 at the time different from the time at which the second image information is read, and the image processing is applied to the fifth image information.
According to the present invention, since the image information which is necessary for automatic adjustment of printing quality can be obtained appropriately, it is possible to produce images with high quality and stability, irrespective of the type of media. In addition, if the image size is predetermined to the same size, it is possible to use a common image processing process thereafter, and as a result, it is possible to enlarge the applicable scope of the image processings without further complicating the processing system.
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A method and apparatus for processing image information coming from various types of image inputting media yields an image processor for processing image information that consolidates image size irrespective of the type of image inputting medium. The apparatus is provided with a plurality of image inputting media, each of which inputs image information as a first image information having a fixed image size. An image size converter converts the fixed image size to a predetermined image size which is a constant image size independent of both the fixed image size and the type of image inputting medium that inputs the first image information. The conversion generates a second image information and a data generator generates conditional data for processing the second image information. An image processor processes the second image information using predetermined image processing procedures, based on the conditional data, to generate a third image information.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims domestic priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application serial No. 60/250,883, filed Dec. 4, 2000, incorporated herein by reference.
[0002] This application is related to U.S. patent applications Ser. Nos. 09/813,454, filed Mar. 20, 2001 and 09/813,362, filed Mar. 20, 2001, both incorporated herein by reference.
BACKGROUND
[0003] 1. Field
[0004] The present disclosure relates generally to optical filters. More particularly, the disclosure relates to tunable optical filters. Yet more particularly, the disclosure relates to tunable optical filters that are remotely actuated.
[0005] 2. Related Art
[0006] One common practice for transmitting multiple channels of information through an optical network is to use wavelength division multiplexing (WDM) to separate the channels by carrier wavelength. In order to separate the channels in WDM systems, the wavelength response of one or more components of the network must be tunable. WDM systems are expected to operate in a band of wavelengths spanning the range of 1,200-1,600 nm. Hundreds, or even thousands of channels can be accommodated in such a system having channels spaced apart by wavelength differences of 0.2 nm.
[0007] Components that should be tunable for optimum performance include, but are not limited to add/drop filters, lasers, detectors, cross-connect switches and others. Of these, the add/drop filter is representative, and will be discussed further in detail.
[0008] Many methods of tuning optical components, such as add/drop filters are known, but each has limitations affecting one or more applications for the method. For example, conventional methods of tuning optical components includes in three-dimensional structures, the physical rotation of optical thin film interference filters and the physical rotation of optical diffraction gratings; and in two-dimensional structures, thermo-optic effects, stretching of fibers, use of liquid crystals, use of micro-electro-mechanical systems (MEMS) such as tunable Fabry-Perot cavities or vertical cavity surface emitting lasers (VCSELs), etc. One technique used in distributed feedback (DFB) lasers to effect tunability is charge injection into semiconductor single crystal waveguide segments, thereby altering the index of the segments. In general, methods which alter the refractive index of a structure also usually tune the structure with respect to wavelength.
[0009] It is well known that single-crystal, pure and compound semiconductors including GaAs, InP, etc. alter their index in response to carrier density, generally controlled by current and charge injection. This is sometimes studied under the topic of electro-absorption. Physically, it is known that changes in the spectral absorption, i.e., the imaginary part of the complex refractive index, of a semiconductor are necessarily also accompanied by changes in the index, i.e., the real part of the complex refractive index, as well. The two are related through the Kramers-Kronig equation.
[0010] Related fundamental physical effects are present, although possibly in smaller magnitude due to the degree of defect density, in amorphous or nanocrystalline semiconductor films such as may be used to create photodetectors or solar cells on transparent glass substrates. In a reverse biased photodetector, charge carriers are deposited by photons absorbed in the band of spectral sensitivity. Thus, it is expected that finite changes in refractive index of such films can be induced optically Electroabsorption in amorphous semiconductors have been studied by Eric Schiff and others. For example, see “Electroabsorption Measurements and Built-In Potentials in Amorphous Silicon Solar Cells,” Lin Jiang, Qi Wang, E. A. Schiff, S. Guha, J. Yang, and X. Deng, Appl. Phys. Lett. 69, 3063 (1996), and others.
[0011] The methods noted above are nearly all electrically actuated. This is disadvantageous in some applications because the system is more complex and requires both electrical and optical signal generation, transmission and detection. For example, in transoceanic applications there may be no local supply of electric power, thus necessitating a high reliability, high power signaling system.
SUMMARY OF THE INVENTION
[0012] It is an object of the invention to provide a method and filter for controlling optical signals.
[0013] According to one aspect of an embodiment, there is a method of controlling an optical signal having a first wavelength, comprising: passing the optical signal through a device, the device substantially transparent to the first wavelength; and selectively illuminating the device with an optical signal at a second wavelength, illumination of the device by the second wavelength causing alteration of optical properties of the device relative to the first wavelength. The device may be a Mach-Zender modulator. The device may be a filter. The filter may further comprise a film having an index of refraction that varied in response to the second wavelength. The filter may yet further comprise a diffraction grating optically coupled to the side-polished fiber. In that case, the filter further comprises a side-polished fiber.
[0014] According to another aspect of an embodiment, an optically controlled optical filter comprises a semiconductor film whose transmission of a first optical wavelength varies with illumination at a second optical wavelength. The semiconductor film can have a refractive index at the first optical wavelength that varies with illumination as the second optical wavelength. The filter can alternatively include a diffraction grating incorporated into the semiconductor film; and a side-polished fiber coupled to the diffraction grating.
BRIEF DESCRIPTION OF THE DRAWING
[0015] In the Figures, in which like reference designations indicate like elements:
[0016] [0016]FIG. 1 is a perspective view of a structure incorporating aspects of an embodiment of the invention;
[0017] [0017]FIG. 2 is a schematic representation of aspects of an embodiment of the invention incorporating a Mach-Zender waveguide interferometer;
[0018] [0018]FIG. 3 is a schematic representation of aspects of another embodiment of the invention incorporating a Mach-Zender waveguide interferometer;
[0019] [0019]FIG. 4 is a perspective view of aspects of an embodiment of the invention incorporating a side-polished fiber structure;
[0020] [0020]FIG. 5 is a graph of the transmission spectrum produced by the structure of FIG. 4;
[0021] [0021]FIG. 6 is a perspective view of a structure incorporating aspects of an embodiment of the invention employing an optically variable diffraction grating; and
[0022] [0022]FIG. 7 is a perspective view of another structure employing a diffraction grating with a side-polished fiber structure.
DETAILED DESCRIPTION
[0023] The present invention will be better understood upon reading the following detailed description of various aspects of embodiments thereof in connection with the drawing.
[0024] One aspect of an embodiment of the invention is now described in connection with FIG. 1. Photodetectors fabricated from films of amorphous silicon in a PIN structure, or alternatively an open-circuit photovoltaic cell, as shown in FIG. 1 can be optically controlled. Exemplary embodiments of aspects of the invention are described with reference to specific wavelengths, but should not be considered so limited. Other materials and variations operate at other wavelengths. According to this aspect, the index at a wavelength where these films are largely transparent, such as the communications wavelength 1550 nm is altered by means of illumination at a shorter wavelength where the films are absorptive, for example 850 nm. Using this effect, it is possible to alter the index and thereby the speed or phase of propagation of light at 1550 nm in the film, indirectly, by means of optical illumination at 850 nm. This is an optically controlled optical effect, meaning that the 850 nm light indirectly alters the behavior of the 1550 nm light, and as such can be the basis for a remotely tuned filter, remotely operated switch, or other device.
[0025] The fundamental structure 100 shown in FIG. 1 is a planar optical waveguide 101 fabricated from semiconductor films made in a multilayered structure designed to enhance and preserve the charge carrier density. Methods of such enhancement are described in related U.S. patent applications Ser. Nos. 09/813,362 and 09/813,454. The film layers perform two functions simultaneously. First, they act as a photovoltaic generator of charge carriers with respect to relatively shorter wavelengths, for example 850 nm, where the films are opaque and absorptive. Second, the films act as a waveguide for relatively longer wavelengths, for example 1550 nm, where silicon and other semiconductors are predominantly transparent. The index of a-Si films at 1550 nm is approximately n=3, depending on film properties. Thus, a guiding film for 1550 nm light 102 injected longitudinally will be formed by a thin layer if the top is clad by air and the substrate 103 is glass or fused silica. The central signal of 850 nm light 104 impinges on a top surface of the waveguide 101 . For a PIN diode, the total thickness may be between 6.25 μm and 10 μm. This may be designed to be a multimode or single mode waveguide, depending on the exact index and thickness.
[0026] Several methods are proposed to produce a detectable alteration in 1550 propagation by means of illumination at 850 nm. FIGS. 2 and 3 show Mach-Zehnder arrangements whereby changes in the phase shift of the semiconductor waveguide are revealed, by means of interference with the parallel fiber or waveguide, by the changes in amplitude in the output fiber. Phase shifts of 0.1 waves are easily detectable by this method, corresponding to an index change of 3×10 −4 .
[0027] In FIG. 2, the structure 100 of FIG. 1 is placed in parallel with a strand of single-mode fiber 201 . An input signal is admitted to the parallel structure throng (a 3 dB splitter 202 and the resultant signal is produced by a second 3 dB splitter 203 employed as a joiner).
[0028] Alternatively, as shown in FIG. 3, the entire structure 300 can be integrated on a single substrate 301 . The tunable waveguide 101 and a parallel waveguide 302 are both formed on the substrate 301 , with a single input waveguide 303 and a single output waveguide 304 .
[0029] [0029]FIG. 4 shows an embodiment 400 which uses a side polished single mode fiber 401 , also known as a coupler-half or evanescent field access block. Here the fiber is mounted on a curved path, glued into a silica block 402 , and polished so that a surface 403 within about 1 μm of the core is exposed. Thus, the evanescent field of the fiber 401 is accessible and can couple to a thin film 404 placed on the block surface.
[0030] It is known that the transmission through such a fiber is strongly spectrally dependent. For example, FIG. 5 shows data on the fiber transmission of such a device, with an overlay oil film index n=1.65, over the band 1510-1570 nm. Note the strong periodicity of the fiber transmission, alternating with absorption into the modal resonances of the film. This periodicity would be even more dense for a film index n=3. If the film index is now altered by a small amount, for example dn/n≈0.005, then the spectral transmission of the coupler half will shift to the blue or red by approximately 0.005×1500 nm=7.5 nm. Thus 7.5 nm of tuning is caused in the fiber transmission.
[0031] Thus, optically induced index changes in the range of 3×10 −4 to 5×10 −3 , or more can be used for practical devices.
[0032] Another class of devices, shown in FIGS. 6 and 7, have gratings 601 impressed into the semiconductor waveguides 602 by lithography, forming a Bragg reflector with center wavelength for reflection=2 n D, where D is the period of said grating. This reflects light of this wavelength back into the waveguide 603 . By optically tuning the value of n by external illumination 604 , the reflective wavelength is varied. This is shown schematically in FIG. 6. Such a scheme could also be implemented in the side-polished fiber structure; in this case the grating 601 could act to drop a given wavelength=(n fiber +N film )D from the fiber 701 by reflecting it backwards into the film 602 , or a given wavelength=2 n fiber D backwards into the fiber, as shown in FIG. 7.
[0033] In these embodiments, the structure of FIG. 6 is analogous to that of FIG. 1, while the structure of FIG. 7 is analogous to that of FIG. 4.
[0034] Related U.S. patent applications Ser. Nos. 09/813,365 and 09/813,454 describe methods for thin film deposition and for engineering the properties of such films.
[0035] The films used are amorphous or polycrystalline or microcrystalline semiconductors, or combinations of these, which may include Si or Ge or other species or alloys, in multiple layers, doped or intrinsic. These films, whose materials, composition and deposition and processing methods are described in the referenced related applications, have properties optimized for various applications and wavelengths. These layered film structures may comprise photoconductors, photodiodes, or phototransistors, in various embodiments, any of which shall be referenced as “optical sensors” for the purpose of this disclosure.
[0036] The films described in the noted related applications possess several useful properties, listed below.
[0037] Controlled absorption/transmission. Optical responses are provided at selected wavelength bands, with a controlled balance between partial absorption and partial transparency in order to respond to the light passing through the film while transmitting a portion, typically a larger portion, for example 80-90%, for use in the system. The bands of sensitivity and degree of transparency may be controlled over a broad range. For example, films of various different compositions may be responsive to selected bands within the 800-1600 nm range, which includes the principal datacom and telecom wavelengths.
[0038] Low temperature processing. The semiconductor films disclosed elsewhere are deposited by relatively low temperature processes, typically below 300° C. and in many cases, below 250° C., enabling deposition without damage onto fibers made of optical glass, fused silica, and in some cases onto polymer or plastic fibers.
[0039] Deposition onto nonplanar surfaces. The deposition processes are based primarily on plasma enhanced chemical vapor deposition (PECVD) methods supplemented by sputtering for certain layers and are suitable for producing spatially uniform coatings onto complex, nonplanar surfaces, such as the cylindrical surface near the end of an optical fiber. Methods of photolithography for the patterning of connecting traces and circuits will also be described for application to nonplanar surfaces.
[0040] The process of deposition of a photodiode, as a typical but not restrictive example of sensor fabrication, involves application of a transparent conducting layer, three or more semiconductor layers with various dopings, and a top transparent conducting layer. Passivation layers may also be required. In addition, photolithographic patterning is used to add metallic or other conductive electrodes in contact with key layers of the stack for bias and photocurrent access. In addition, for high optical transmission, there may be one or more anti-reflection layers deposited between the sensor films and the substrate before sensor deposition, and one or more anti-reflection layers after sensor deposition, between the sensor layers and air, as is known in the art. Thus, the total structure of films comprising the “smart surface” of the optical fiber may contain a substantial number of individual depositions and the use of different processes in sequence, possibly including thermal evaporation, electron beam evaporation, sputtering and PECVD, among others, and also photolithographic patterning steps to provide electrical contact to the front and back conducting films.
[0041] The present invention has now been described in connection with a number of specific embodiments of aspects thereof. However, numerous modifications, which are contemplated as falling within the scope of the present invention, some of which have been described above, should now be apparent to those skilled in the art. Therefore, it is intended that the scope of the present invention be limited only by the scope of the claims appended hereto.
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A method of controlling an optical signal having a first wavelength, includes passing the optical signal through a device, the device substantially transparent to the first wavelength; and selectively illuminating the device with an optical signal at a second wavelength, illumination of the device by the second wavelength causing alteration of optical properties of the device relative to the first wavelength. An optically controlled optical filter, includes a semiconductor film whose transmission of a first optical wavelength varies with illumination at a second optical wavelength.
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This application is a continuation of Ser. No. 06/425,335 filed Sept. 28, 1982, now U.S. Pat. No. 4,815,520 issued Mar. 28, 1989 and which application is a continuation of Ser. No. 06/200,936 filed Oct. 27, 1980, now abandoned.
BACKGROUND OF INVENTION
Continuous metal casting is conventionally practiced utilizing a furnace, ladle or tundish to continuously charge molten metal to a water jacketed mold. A thin layer of the molten metal which contacts the chilled surface of the mold solidifies and forms a thin walled casting with a molten core which continuously issues from the bottom of the mold onto a supporting apron set with rollers to bend and direct the casting along a curved path through cooling water sprays. At the point of horizontal tangency to the curved arc of the casting, a second set of bending rolls straightens the casting for travel along a run-out table where the casting is further cooled and is flame cut to desired lengths. In passing through the bending and straightening rolls, the casting is tensilely stressed and the skin is stretched, and to minimize the danger of rupturing the skin of the casting and to avoid spills of molten metal, the radius of curvature of the arc through which the casting is bent is made relatively large and the elevation of the mold above the work floor relatively great compared to that which would otherwise be employed if the casting were not stretched by being bent.
PRIOR ART
U.S. Pat. Nos. 3,447,591, 3,837,391, and 3,780,552 show continuous casting apparatus equipped with roller pairs contacting, respectively, only the inner and outer peripheral faces of a curved casting; only the radial faces of such a casting; and only non-parallel faces of a casting with a trapezoidally configured cross-section. Nothing in the prior art shows means which alter the cross-sectional configuration of a casting to effect change in axial linearity nor does any prior art show means for bending a casting without tensilely stressing and stretching it.
SUMMARY OF THE DISCLOSURE
A continuous casting mold is configured with a curvilinear cavity of trapezoidal cross-section which is radiused to a pivot axis about which the mold is oscillated. At the point of horizontal tangency to the arc of the casting, a pair of pinch rollers set on vertical axes squeeze the non-parallel side faces of the casting causing the inner, broader peripheral face to be narrowed and simultaneously elongated to conform in dimension to the outer peripheral face and thereby straighten the casting without tensilely stressing it. The continuous casting is pinched-off to desired lengths while the core is molten thereby obviating the need to flame cut the casting. A relatively short radius of casting curvature may be provided and low elevation of the mold is possible because of the absence of bending stresses being imposed on the casting which tend to tensilely stress it and risk rupture of the solidified skin on the casting.
An inventive embodiment which is suitable for use with existing continuous casting molds provides pinch rolls for shaping a casting into one having a trapezoidal cross-section, the rolls being disposed adjacent the mold discharge. In a manner analogous to straightening an arced casting by passing it between parallel vertical rolls, non-parallel horizontally set rolls may be placed below a mold to simultaneously narrow and elongate by compressing one face of the casting to provide an outer peripheral face of narrower and longer dimension than the undisturbed opposite face which consitutes the inner peripheral face.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view in partial section of one embodiment of the invention taken along line 1--1 of FIG. 2;
FIG. 2 is a side elevation in cross-section taken along line 2--2 in FIG. 1;
FIG. 3 is an end elevation in cross-section taken along line 3--3 in FIG. 2;
FIG. 4 is a plan view of the top of a straight cavity oscillating mold taken along line 4--4 of FIG. 6;
FIG. 5 is a sectional plan view of the embodiment of FIG. 4
FIG. 6 is an elevation in partial section of the embodiment of FIGS. 4 and 5 taken along line 6--6 of FIG. 5;
FIG. 7 is a cross-sectional plan view of the embodiment of FIG. 2 taken along line 7--7 of FIG. 8;
FIG. 8 is a cross-sectional elevation of the embodiment of FIG. 2 taken along lines 8--8 of FIGS. 2 and 7.
DESCRIPTION OF THE INVENTION
The embodiment of the invention depicted in FIGS. 1, 2, 7 and 8 show the casting of a billet in a curved mold with the inner peripheral face of the billet being wider than the outer peripheral face to provide the billet with a trapezoidal cross-sectional configuration as cast whereas the embodiment of invention shown in FIGS. 4, 5, and 6 is suitable for being retro-fitted to existing casting molds of rectilinear cross-section and vertically linear alignment. Referring to FIGS. 1, 2, and 3, casting machine 11 comprises curved water jacketed mold 40, cavity 12, pouring spout 13, cam 14, and follower 15 mounted and powered to oscillate the mold, and guide rollers 16 as conventional components for which no invention is claimed. Cylindrically configured squeeze roller 17 and 18 compress the inner arcuate face 8 of cast billet 9 to a width substantially equal to that of the outer arcuate face 7 thereby simultaneously elongating face 8 and compressively sealing the two faces of the casting. The relationship of the configuration of billet 9 is such that the width of the billet cross-section is greater on the inside of the arc than it is on the outside in an amount that relates to the radius of curvature of the billet such as to render the two faces of substantially equal area for a given angular sector, so that correspondingly when the two faces are equalized in width by passing billet 9 between rollers 17 and 18, the faces become equal in length also with the result that the billet is straightened. Shaping and straightening of a billet is accomplished, using the method and means of this invention, entirely by compressive force and without tensilely stressing the solidified skin portion of the billet, thereby firming, strengthening and sealing the facings of the billet rather than stretching and fissuring them in the manner of conventional bending rolls. In the absence of stretching forces being imposed on billet 9 during straightening, the radius of curvature of the billet may be substantially less than is required when bending rolls are used to shape or straighten a billet and the elevation of the casting machine above the floor may be lower than is required in conventional practice. The shorter travel path for billet 9 than for conventional castings which issue from conventional horizontal discharge molds results in less cooling of the casting before it is straightened and a thinner solidified outer layer or "skin" on the casting when it is straightened than conventionally is the case, and requires less energy utilization to straighten the billet than is required when a greater portion of the billet cross-section is solidified. Rollers 19 and 20 are provided as flattening rollers to prevent bulging of the side faces of billet 9 as it is straightened and insure that the billet is of true rectilinear section.
Molten metal flowing from discharge spout 13 falls by gravity through an evacuated space into mold cavity 12, being de-gassed by the passage. Bellows 32 flexibly connects skirt 36 depending from tundish 37 to the upper surface of mold 40. Vacuum line 35 communicates the environment between the pouring spout and the mold with a vacuum pump or ejector, not shown, to provide sub-atmospheric pressure within the bellows and to remove gases and vapors which escape from the molten metal. A pair of cylindrical sleeves 33 and 34 are annularly spaced to enable gas to readily flow to vacuum line 35, but prevent spatter from the molten metal from reaching and damaging the bellows.
Mold 40 is pivotally mounted by shaft 38 for being oscillated by means of cam 14 driven by motor means, not shown, cam follower 15 and connecting arm 39, to move arcuately downward substantially at the speed at which billet 9 is fed through rollers 17, 18, 19, and 20, the billet being supported along the arc of travel by apron rollers 16 and being cooled during its travel by water sprays 10. On the upswing of mold 40, billet 9 continues at uniform speed in its downward course and is withdrawn from the mold exposing the chilled mold surface at the upper portion of the mold cavity to molten metal to cause the creation of a continuation in the formation of a solidified "skin" on the casting in the mold. Cooling water 53 is circulated through mold 40 by means of pumps and flexible connecting hoses, not shown.
Electric motor 31 through means of shaft 54 and bevel gear sets 55' and 56' drive rollers 18 and 17, respectively, at constant speed to establish the speed of travel of billet 9. The straightened billet passes between rollers 60 which guide it for being laterally squeezed and narrowed by hydraulic powered side rams 72 and 73 (FIG. 7) which are mounted by carriage 26 together with pinch-off rams 21, and 22 for traveling with billet 9 in a horizontal path while a length of the billet such as section 30 is being severed by the rams pinching the billet to part it and seal the severed ends against loss of molten core metal. The pinched-off end of the billet thus produced, is somewhat pointed, facilitating entering of the billet section into the mill rolls during further processing to finished shape. Cooling water is supplied to pinch-off rams 21 and 22 by means of flexible coolant water hoses 59, 61 and 62, 63, respectively, and the rams are actuated to open and close against one another by hydraulic cylinder 64 and piston rod 23 being provided in operable connection in ram 21, and by hydraulic cylinder 65 and piston rod 24 being similarly coupled to ram 22. Hydraulic pump means and prime movers are not shown in connection with rams 21 and 22, nor is motive means shown for driving carriage 26, nor is connection with cylinders 70, 71 for actuating rams 72, 73, respectively, shown, such means being conventional. Carriage 26 is provided with flanged wheels 27, 28 for operably traversing track 29 either by being operably driven by motor means or by moving under urging of billet 9 when pinch rams 21 and 22 are in contact therewith. Return movement after the billet is severed may either be by means of moter reversal to the drive means or by return spring or counterweight biasing, or other operble means. The entire assembly of rams and actuating means is mounted by frame 25 which is supported on carriage 26. As shown in FIG. 2, the two pinch-off rams 21 and 22 are configured one with a protruding ridge and the other with a groove at the contact line between the two for the purpose of enabling the stretched billet to be totally severed by tearing of the stretched skin of the billet at the contact line between the rams, while the generally blunt nose configurations of the rams press the skin facings of the billet together into a pressure weld.
In FIG. 4 water cooled mold 20' is shown with cavity 12' of square cross-section and is axially linear as shown in FIG. 6. Forming rollers 43, 44 (FIG. 5) of substantially conical configuration are disposed immediately below mold 40' for reshaping billet 9' into trapezoidal cross-sectional configuration similar to that of billet 9 of FIG. 1. Electric motor and integral gear box 50 power shaft 47 on which bevel gears 48 and 49 are mounted and operably meshed with gears 48' and 49', respectively. Shafts 42 and 42' operably mount both gear roller 43 and gear 49' on one shaft and gear 48' and roller 44 on the other. Rollers 45 and 46 are operably mounted to bear against adjacent opposite faces of billet 9' from those which are contacted by rollers 43 and 44 and are so placed to enable the billet to be bent into curvilinear configuration immediately below the elevation where rollers 45 and 46 contact the billet. The apparatus forstraightening and shearing the billed befow frame 41 on which the rollers and drive mechanism are mounted is similar to that shown in FIGS. 2 and 3.
In FIGS. 7 and 8 are shown cross-sectional views of rams 72, 73 which are biased laterally to compress and narrow billet 9 and form a vertical channel in which pinch-off rams 21, 22 are biased to section the billet and seal the sectioned ends against leakage of the molten core by compressing the walls of the billet together to effect a fused, pointed end.
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Continuously cast steel billet is sectioned to length while the core of the casting is molten by being pinched-off to seal the ends of the casting sections and contain molten core metal, effecting thereby energy conservation and economic savings in the production of steel products. The inventive method and means avoids tensilely stressing the casting lessening the risk that the skin of the casting will be caused to rupture from being stretched and that molten metal from the core of the casting will spill to ruin the casting and endanger personnel and equipment.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a non-provisional application which claims benefit under 35 USC §119(e) to U.S. Provisional Application Ser. No. 61/165,304 filed Mar. 31, 2009, entitled “Compaction Tolerant Basepipe for Hydrocarbon Production,” which is incorporated herein in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] None.
FIELD OF THE INVENTION
[0003] This invention relates to base pipe which is used in a production tubing/liner string in a fluid production well and especially a hydrocarbon production well where the base pipe is positioned in the proximity of the fluid production formation and has holes and typically a screen around the base pipe to allow the fluid into the production string while substantially excluding sand and other solid particles.
BACKGROUND OF THE INVENTION
[0004] Prior to extracting fluids from a downhole formation, the fluids occupy space within the formation. In the process of producing fluids from a formation, the fluid pressure will generally decline. Reduced pore pressure in the reservoir rock will increase the effective stress and thereby cause the rock itself to shrink, and thus the reservoir will compact. Reservoir compaction may then cause subsidence at the surface. Subsidence is a substantial concern in the production of hydrocarbons, especially where the formation is comprised of unconsolidated sands or does not have significant structural integrity. Offshore platforms mounted to the seafloor and arranged to stand well above sea level and above any wave action at the sea surface have settled toward the sea because of subsidence. Actually, the amount of subsidence could be alarming if a substantial safety zone wasn't established in the design phase of the well development plan and such subsidence has been measured in as much as tens of feet.
[0005] The thickness of the producing zone typically diminishes to some extent during production of well fluids, but in poorly consolidated sands and high porosity rocks may diminish by a substantial amount such as about 10% over the life of the production operation. Compaction of the producing zones exerts powerful forces on equipment and pipe in the well. Conventional base pipe is subject to buckling when the compaction of the production string is less than 2 to 3% with relatively good lateral confinement supports and it is likely that the well will have to be abandoned or recompleted if the production string has buckled.
SUMMARY OF THE INVENTION
[0006] The invention more particularly includes a base pipe for use in a wellbore to tolerate compaction of the production zone where the base pipe includes an elongated generally cylindrical hollow body with an upper end, a lower end, a peripheral exterior wall and in interior space and at least one connector at the upper end for connecting to production tubing or liner. The base pipe further includes holes in the peripheral wall through which production fluid may pass from the outside of the base pipe into the interior space and screen mesh mounted around the peripheral wall to prevent sand and other particles from being carried by production fluids through the holes in the peripheral wall and into the interior space. Additionally, the base pipe includes compaction absorber segments spaced along the generally cylindrical hollow body to absorb longitudinal stresses and reduce the length of the elongated generally cylindrical hollow body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The invention, together with further advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
[0008] FIG. 1 is a fragmentary cross sectional view of a wellbore undergoing the stresses and illustrating a failure of a drillstring with conventional base pipe;
[0009] FIG. 2 is a fragmentary perspective view of the base pipe of the present invention;
[0010] FIG. 3 is a cross sectional end view of the base pipe of the present invention; and
[0011] FIG. 4 is an enlarged, fragmentary side view of the base pipe particularly illustrating a compaction absorber segment.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Turning now to the preferred arrangement for the present invention, reference is made to the drawings to enable a more clear understanding of the invention. However, it is to be understood that the inventive features and concept may be manifested in other arrangements and that the scope of the invention is not limited to the embodiments described or illustrated. The scope of the invention is intended only to be limited by the scope of the claims that follow.
[0013] Turning now to FIG. 1 , a wellbore is generally indicated by the arrow 10 and extends deep into the ground G and into hydrocarbon bearing formation F. A drill string comprising pipe 15 extends down into wellbore 10 with base pipe 20 attached at the lower end. The screens and screen base pipes can be run as a part of production liner separately from the tubing string. Base pipe 20 includes holes that are not shown and a wire wrapped screen surrounding the base pipe 20 to keep sand and other solids out of the production string. Within the production string is a pump may be arranged to pump liquids to the surface for transporting to a refinery.
[0014] As fluid from formation F is withdrawn to the surface 12 , the thickness of formation F may shrink over time as shown by the reduced vertical dimension of formation F in the proximity of base pipe 20 . The upper portion of the formation F has subsided along with the layers of earth over top of the formation so that the surface actually sinks or subsides. The subsidence exerts a substantial amount of compression on the length of the production string and can force a buckle as shown at 17 in the pipe 15 effectively closing off the production string and stopping or severely limiting further production.
[0015] Turning now to FIG. 2 , a section of compaction tolerant base pipe 30 is shown with compaction absorber segments 32 . The compaction absorption segments are comprised of cross cut slots 34 that extend for a substantial portion of a circumferential arc of the pipe 30 . Preferably, each cross cut slot 34 extends for about 120 degrees or about ⅓ of the circumference of the pipe 30 and are perpendicular to the axis of the pipe 30 . However, the compaction absorber segments 32 include a number of overlapping cross cut slots 34 that will work together to preferential collapse the length of the base pipe 30 without buckling or conveying excessive compressive forces up the production string to a weak point where a buckling failure or other failure may occur.
[0016] The overlaps of slots 34 are preferably at least 50% the circumferential length of the tangential cuts and spaced apart by two to three times the width of the cross cuts. While the compaction absorber segments 32 are intended to accommodate the reduction in length of the base pipe 30 , they are also intended to maintain necessary strength parameters in other respects. The base pipe 30 of the present invention must retain sufficient compressive and tensile strength to be put into and withdrawn from wellbore 10 in the event the production string must be withdrawn and re-installed. Also, the base pipe 30 must have sufficient radial strength to resist forces that would tend to collapse the base pipe and close the hollow space through which fluids are produced to the surface.
[0017] It should be understood that base pipe 30 includes conventional holes 36 and a screen such as wire wrap screen 38 . Wire wrap screen 38 is removed from the end of the base pipe 30 to reveal the holes 36 and slots 34 , but in practice would cover the portions of base pipe 30 that would include any openings Base pipe 30 would preferably include screw threads at each end or at the top end to connect to other lengths of base pipe in a large producing formation and to the conventional production tubing to form the production string. The bottom end of the base pipe 30 is typically closed, but may be open with screen or other mesh to prevent sand and other solids from entering the hollow interior of the base pipe 30 .
[0018] FIG. 3 shows the wire wrapped screen 38 surrounding base pipe 30 with spacers 39 attached to the outside of the peripheral wall of base pipe 30 to create a space for fluids to pass fully through the screen 38 and then move toward holes 36 . It should be understood that the wire wrapped screen 38 may also be closely attached to base pipe 30 without spacers, if desired.
[0019] In FIG. 4 , the compaction absorber segments 32 are more clearly illustrated where it can be seen that each of the slots 34 have a dimension called slot width 44 . Also, the slots 34 are spaced by a dimension called slot spacing 42 and overlap one another by a dimension called slot overlap 40 . With the slot overlap 40 , slot spacing 42 and slot width 40 , some relative ratios can be identified. For example, it is preferred for the slot spacing to be at least two times the slot width and preferably at most four times the slot width.
[0020] The segments 32 are illustrated with four perfectly transverse slots, but three, four, five or six or more substantially transverse slots that overlap with suitable slot width and slot overlap to slot spacing ratios may perform adequately. In this example, the slots are cut slightly offline from the circumference of the base pipe 30 such that each slot overlaps one adjacent slot closer to the bottom end of the base pipe while the other end overlaps the other adjacent slot closer to the top end of the base pipe. Also, it should be understood that six or eight nearly transverse overlapping slots may be used for reservoirs that are highly likely to compact during fluid production.
[0021] It is preferred that each slot is at least three millimeters in width and up to about ten millimeters in width.
[0022] Another parameter of the base pipe of the present invention is segment spacing which is the distance one compaction absorber segment 32 is from the next adjacent compaction absorber segment 32 . While the spacing may be irregular, it is preferred that the segment spacing would be less than four times the diameter of the base pipe 30 and more preferably less than three times the diameter. At the same time, it is preferred that the segment spacing is at least the diameter of the base pipe 30 and more preferably at least twice the diameter of the base pipe 30 .
[0023] Finally, the scope of protection for this invention is not limited by the description set out above, but is only limited by the claims which follow. That scope of the invention is intended to include all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as an embodiment of the present invention. Thus, the claims are part of the description and are a further description and are in addition to the preferred embodiments of the present invention. The discussion of any reference is not an admission that it is prior art to the present invention, especially any reference that may have a publication date after the priority date of this application.
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The invention relates to base pipe with slots cut into the peripheral wall to form compaction absorber segments that are arranged to permit the base pipe to be compacted in length without buckling or transferring excessive compressive forces to other pipe sections when a poorly consolidated formation shrinks due to production from the formation. Over time, the slots close as the base pipe shrinks in length and production continues through conventional holes in the base pipe.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. National Phase Application of PCT International Application PCT/JP2013/085163, filed Dec. 27, 2013 which claims priority to Japanese Application No. 2012-289043, filed Dec. 28, 2012, the contents of which are incorporated herein by reference in their entireties for all purposes.
TECHNICAL FIELD
[0002] The present invention relates to a bacterial cellulose and a bacterium producing it, and particularly to a bacterial cellulose excellent in dispersibility in liquids and a bacterium producing it.
BACKGROUND OF THE INVENTION
[0003] A bacterial cellulose typically consists of a nanofiber having a width of about 50 nm, and has received attention as a material capable of being utilized in various industrial fields since it has characteristics, such as high mechanical strength and biocompatibility and biodegradability. The bacterial cellulose is typically obtained in the form of a film consisting of a gelled substance (hereinafter, referred to as “gelled film”) on the culture medium surface by subjecting a bacterium, such as an acetic acid bacterium, to stationary culture; however, the gelled film has a problem, such as being poorly applicable as an actual material since it is poor in moldability and miscibility with other substances when applied to materials and high in cost because of being low in production efficiency.
[0004] To address such a problem, there is a need for a bacterial cellulose not in the form of a gelled film but dispersible in liquids and therefore excellent in applicability. For example, Non Patent Literature 1 discloses a bacterial cellulose obtained by subjecting Acetobacter xylinum subsp. sucrofermentans to aerated and agitated culture, and Non Patent Literature 2 also discloses a bacterial cellulose obtained by subjecting Gluconacetobacter xylinum strain JCM10150 to rotary shaking culture in a culture medium containing carboxymethyl cellulose (CMC).
CITATION LIST
Non Patent Literature
[0000]
Non Patent Literature 1: Yoshinaga, et al., Kagaku To Seibutsu (Chemistry and Biology), vol. 35, no. 11, p. 7-14, 1997
Non Patent Literature 2: S. Warashina, et al., 2010 Cellulose R&D Abstracts at the 17th Annual Meeting of the Cellulose Society, p. 98, 2010
SUMMARY OF THE INVENTION
Technical Problem
[0007] However, the bacterial cellulose described in Non Patent Literature 1 is not high in dispersibility in water as is evident from the description that it is not one produced using a culture medium containing CMC having the effect of improving the dispersibility of a bacterial cellulose and that it is dispersed “in the form of tiny grains or fibers” in water (ibid; page 9, right column). Consequently, the bacterial cellulose is insufficient in terms of moldability and miscibility with other substances for practical use. The bacterial cellulose described in Non Patent Literature 2 is also not high in dispersibility in water since water containing the bacterial cellulose is higher in white turbidity at the bottom than at the top and has sedimentation observed and cellulose grains are visibly large (ibid; FIG. 1 ) in any of the cases where the amount of addition of CMC to the culture medium is 0.5%, 1%, and 2%. Consequently, this bacterial cellulose is insufficient in terms of moldability and miscibility with other substances, necessary for practical use.
[0008] Thus, the bacterial celluloses described in both of Non Patent Literatures 1 and 2 are insufficient in moldability as a material and miscibility with other substances, and also poor in practicability in terms of efficiency of material production.
[0009] The present invention has been made to solve such problems and an object thereof is to provide a bacterial cellulose high in dispersibility in liquids, favorable in moldability and miscibility with other materials in being put to practical use, and excellent in applicability as an actual material, and a bacterium producing the bacterial cellulose.
Solution to Problem
[0010] As a result of intensive studies, the present inventors have found that the bacterial cellulose is highly water-dispersible, which is obtained by subjecting the strain SIID9587 as a new strain of Gluconacetobacter intermedius (accession number NITE BP-01495) (hereinafter, sometimes referred to as “strain NEDO-01 ( G. intermedius strain SIID9587)”) to agitated culture in a CMC-containing culture medium using a glycerol-containing by-product generated in producing a biodiesel fuel from vegetable oil (Bio Diesel Fuel By-product; BDF-B, waste glycerin), reagent glycerol, or molasses as a carbon source, thereby accomplishing the following inventions.
[0011] (1) The bacterial cellulose according to the present invention has the physical characteristic of a transmittance of light at a wavelength of 500 nm of water containing the bacterial cellulose at a final concentration of 0.1±0.006% (w/w) of 35% or more.
[0012] (2) The bacterial cellulose according to the present invention further has the physical characteristic of a retention volume of the peak top of the chromatogram in the gel permeation chromatography performed under the following conditions i) to vi) of from 2.5 mL inclusive to 3.0 mL exclusive:
[0013] i) column: a column 6.0 mm in inside diameter and 15 cm in length, packed with a methacrylate polymer having a particle diameter of 9 μm; ii) guard column: 4.6 mm in inside diameter and 3.5 cm in length; iii) column temperature: 35° C.; iv) feed flow rate: 0.07 mL/minute; v) eluent: a 40 to 42% (w/w) tetrabutylphosphonium hydroxide aqueous solution; and vi) final concentration of the bacterial cellulose in the eluent: 0.2% (w/w).
[0014] (3) The bacterial cellulose according to the present invention is preferably produced by the assimilation of BDF-B.
[0015] (4) The bacterial cellulose according to the present invention is preferably produced by the assimilation of 1 or 2 or more selected from the group consisting of sugar, a sucrose-containing by-product generated in producing sugar, and hydrolysates thereof, and isomerized sugar.
[0016] (5) The by-product is preferably molasses when the bacterial cellulose according to the present invention is produced by the assimilation of the sucrose-containing by-product generated in producing sugar.
(6) The bacterial cellulose according to the present invention may be one produced by Gluconacetobacter intermedius.
[0018] (7) The bacterial cellulose according to the present invention may be one produced by Gluconacetobacter intermedius strain SIID9587 (strain NEDO-01) (accession number NITE BP-01495).
[0019] (8) The bacterium according to the present invention is characterized by producing the bacterial cellulose according to any one of (1) to (5) above.
[0020] (9) The bacterium according to the present invention may be Gluconacetobacter intermedius strain SIID9587 (strain NEDO-01) (accession number NITE BP-01495) producing the bacterial cellulose according to any one of (1) to (5) above.
Advantageous Effects of Invention
[0021] The bacterial cellulose according to the present invention can provide a bacterial cellulose almost uniformly dispersible in liquids such as water, and can contribute to an improvement in the quality of the final product and production efficiency or a reduction in production cost since this bacterial cellulose is excellent in moldability and miscibility with other substances. The present invention can provide a bacterial cellulose almost uniformly dispersible in liquids by purification under mild conditions without requiring steps of refining with a mixer and the like, and can provide a bacterial cellulose having a relatively large average molecular weight. In addition, the present invention can contribute to effective resource utilization by using a sucrose-containing by-product generated in producing sugar, such as BDF-B or molasses, as a carbon source, and enables the achievement of the reduction of bacterial cellulose price. Further, the present invention can efficiently provide a large amount of a bacterial cellulose by production using Gluconacetobacter intermedius or Gluconacetobacter intermedius strain SIID9587 (strain NEDO-01).
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a flow diagram showing a protocol for isolating a bacterium producing a bacterial cellulose by assimilating BDF-B. In the figure, the bacterial cellulose is abbreviated as BC. FIG. 2-1 is a diagram showing points of identity and difference between the 16S rDNA nucleotide sequences of the strain SIID9587 and G. intermedius strain TF2. In the figure, the points of identity in the nucleotide sequences are represented by *marks and the points of difference are represented by quadrangular boxes. In the figure, G. intermedius indicates G. intermedius strain TF2.
[0023] FIG. 2-2 is a diagram showing points of identity and difference between the 16S rDNA nucleotide sequences of the strain SIID9587 and G. intermedius strain TF2. In the figure, the points of identity in the nucleotide sequences are represented by *marks and the points of difference are represented by quadrangular boxes. In the figure, G. intermedius indicates G. intermedius strain TF2.
[0024] FIG. 3 is a pair of tables showing bacteriological properties of the strain SIID9587.
[0025] FIG. 4 is a series of charts showing IR spectra of a bacterial cellulose obtained by subjecting the strain NEDO-01 ( G. intermedius strain SIID9587) to stationary culture (top chart) and products obtained by aerated and agitated culture using BDF-B and reagent glycerol as carbon sources (middle and bottom charts).
[0026] FIG. 5 is a series of photographs showing the appearance of waters each containing bacterial celluloses obtained by subjecting the strain NEDO-01 ( G. intermedius strain SIID9587) to aerated and agitated culture and stationary culture (left and middle) and a pulp-derived bacterial cellulose nanofiber (right).
[0027] FIG. 6 is a series of drawings showing the light transmittance at a wavelength of 500 nm of waters containing bacterial celluloses obtained by subjecting strain NEDO-01 ( G. intermedius strain SIID9587) to aerated and agitated culture using molasses and reagent glycerol as carbon sources, respectively, and the amount of the bacterial cellulose produced (amount of the BC produced) and the rate of production thereof (BC production rate).
[0028] FIG. 7 is a series of drawings showing the light transmittance at a wavelength of 500 nm of waters containing bacterial celluloses obtained by subjecting strain NEDO-01 ( G. intermedius strain SIID9587) and the known bacterial cellulose-producing bacteria G. hansenii strain ATCC23769 , G. xylinus strain ATCC53582 , G. xylinus strain ATCC700178 (BPR2001), G. xylinus strain JCM10150 , G. intermedius strain DSM11804, and G. xylinus strain KCCM40274 to aerated and agitated culture, and the amount of the BC produced, the BC production rate, and the BC production rate ratio.
[0029] FIG. 8 is a chart showing chromatograms of the gel permeation chromatography of a bacterial cellulose obtained by subjecting strain NEDO-01 ( G. intermedius strain SIID9587) to rotation culture using BDF-B as a carbon source (sample B), a pulp-derived cellulose nanofiber (pulp-derived CNF solution), and pullulan.
[0030] FIG. 9 is a pair of photographs showing the fiber widths and the transmission electron microscope-observed images of bacterial celluloses obtained by subjecting strain NEDO-01 ( G. intermedius strain SIID9587) to aerated and agitated culture (agitated-culture BC solution) and stationary culture (mixer-treated stationary-culture BC solution).
[0031] FIG. 10 is a pair of photographs showing the transmission electron microscope-observed images of a bacterial cellulose obtained by subjecting strain NEDO-01 ( G. intermedius strain SIID9587) to aerated and agitated culture (agitated-culture BC solution) and a pulp-derived cellulose nanofiber (pulp-derived CNF solution).
[0032] FIG. 11 is a pair of photographs showing the polarization microscope-observed images of a bacterial cellulose obtained by subjecting strain NEDO-01 ( G. intermedius strain SIID9587) to aerated and agitated culture (agitated-culture BC solution) and a pulp-derived cellulose nanofiber (pulp-derived CNF solution).
[0033] FIG. 12 is a graph showing the weight of bacterial celluloses obtained by subjecting strain NEDO-01 ( G. intermedius strain SIID9587) and the known bacterial cellulose-producing bacteria G. hansenii strain ATCC23769 , G. xylinus strain ATCC53582, and G. xylinus strain ATCC700178 (BPR2001) to stationary culture using reagent glycerol or BDF-B as a carbon source.
[0034] FIG. 13 is a graph showing the weight of bacterial celluloses obtained by subjecting strain NEDO-01 ( G. intermedius strain SIID9587) and the known bacterial cellulose-producing bacteria, the strain ATCC53582 and the strain ATCC23769, to shake culture using reagent glycerol or BDF-B as a carbon source.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The bacterial cellulose according to the present invention and a bacterium producing it will be described below in detail. The bacterial cellulose according to the present invention refers to a cellulose produced by a bacterium.
[0036] For the purpose of the present invention, bacterial cellulose “being dispersed” in a liquid such as water refers to bacterial cellulose being floated or suspended in the liquid. The high dispersibility refers to, for example, the particle diameter or fiber width of a bacterial cellulose as a dispersoid being relatively small in a liquid, or the bacterial cellulose as a dispersoid being relatively uniformly floated or suspended in the liquid.
[0037] The bacterial cellulose according to the present invention has a high dispersibility in such an extent that it is almost uniformly dispersed in a liquid. Here, the liquid in which the bacterial cellulose is dispersed may be any of an organic solvent and an aqueous solvent; however, an aqueous solvent is preferable.
[0038] How high or low the dispersibility of a bacterial cellulose is can be measured, for example, using the light transmittance as an index; the relationship holds true that higher dispersibility results in a larger light transmittance and lower dispersibility results in a smaller light transmittance. The light transmittance can be determined by providing water containing the bacterial cellulose at a predetermined concentration to a spectrophotometer, irradiating the water with light at a predetermined wavelength, and measuring the amount of the transmitted light.
[0039] The bacterial cellulose according to the present invention has the physical characteristic of a transmittance of light at a wavelength of 500 nm of water containing the bacterial cellulose at a final concentration of 0.1±0.006% (w/w) of 35% or more. Here, examples of the transmittance of light at a wavelength of 500 nm of water containing the bacterial cellulose at a final concentration of 0.1±0.006% (w/w) according to the present invention can include 35% or more as well as 36% or more, 37% or more, 38% or more, 39% or more, 40% or more, 35% to 99% (both inclusive), 36% to 99% (both inclusive), 37% to 99% (both inclusive), 38% to 99% (both inclusive), 40% to 99% (both inclusive), 35% to 95% (both inclusive), 36% to 95% (both inclusive), 37% to 95% (both inclusive), 38% to 95% (both inclusive), 40% to 95% (both inclusive), 35% to 90% (both inclusive), 36% to 90% (both inclusive), 37% to 90% (both inclusive), 38% to 90% (both inclusive), 40% to 90% (both inclusive), 35% to 85% (both inclusive), 36% to 85% (both inclusive), 37% to 85% (both inclusive), 38% to 85% (both inclusive), 40% to 85% (both inclusive), 35% to 80% (both inclusive), 36% to 80% (both inclusive), 37% to 80% (both inclusive), 38% to 80% (both inclusive), and 40% to 80% (both inclusive).
[0040] The bacterial cellulose according to the present invention may also have a large average molecular weight compared to that of a plant-derived cellulose, such as a pulp-derived cellulose nanofiber. The average molecular weight of a cellulose can be measured using, for example, a chromatogram in the gel permeation chromatography as an index; the relationship holds true that a smaller molecular weight results in a larger retention volume of the peak top of such a chromatogram and a larger molecular weight results in a smaller retention volume. Specifically, the bacterial cellulose according to the present invention may have the physical characteristic of a retention volume of the peak top of the chromatogram in the gel permeation chromatography performed under the following conditions i) to vi) of from 2.5 mL inclusive to 3.0 mL exclusive: i) the column is a column 6.0 mm in inside diameter and 15 cm in length, packed with a methacrylate polymer having a particle diameter of 9 μm; ii) the guard column is 4.6 mm in inside diameter and 3.5 cm in length; iii) the column temperature is 35° C.; iv) the feed flow rate is 0.07 mL/minute; v) the eluent is a 40 to 42% (w/w) tetrabutylphosphonium hydroxide aqueous solution; and vi) the final concentration of the bacterial cellulose in the eluent is 0.2% (w/w).
[0041] The bacterial cellulose according to the present invention can be produced, for example, by causing a bacterium to produce a bacterial cellulose by culture in a culture medium containing a suitable carbon source.
[0042] Here, examples of the carbon source can include monosaccharides, such as glucose and fructose; disaccharides, such as sucrose, maltose, and lactose; oligosaccharides; sugar; sucrose-containing by-products generated in producing sugar, hydrolysates thereof, and isomerized sugar; saccharides, such as starch hydrolysates; mannitol; ethanol; acetic acid; citric acid; glycerol; and BDF-B. The carbon source can be properly set depending on the type of a bacterium, the culture conditions, the cost of production, and the like. BDF-B consists of 41.5% of glycerol, 21.4% of fatty acid, 12.4% of methanol, 6.3% of ignition residue, and 18.4% of others (Japan Food Research Laboratories) as a typical composition, and is a composition containing a large amount of glycerol available as a carbon source for a bacterium.
[0043] Here, sugar refers to a sweetener consisting essentially of sucrose (Kohjien, 6th Ed.), and, for the purpose of the present invention, may be a chemically synthesized one, or one produced using a natural product, such as sugar cane, sugar beet (white beet), sugar maple, gomuti ( Borassus flabellifer ), or sweet sorghum ( Sorghum bicolor dulciusculum ), as a raw material. Examples of the sugar according to the present invention can include non-centrifugal sugar, such as muscovado, shiroshita-to, casonade (brown sugar), wasanbon, or maple sugar, and centrifugal sugar, such as raw sugar or refined sugar. Examples of the refined sugar can include hard sugar, such as shirozara-to, coarse crystal medium soft sugar, or granulated sugar; soft sugar, such as white superior soft sugar or yellow soft sugar; processed sugar, such as cube sugar, crystal sugar, powdered sugar, or frost sugar; and liquid sugar.
[0044] The sucrose-containing by-product generated in producing sugar refers to one containing sucrose among by-products generated in a step of producing sugar, and specific examples thereof can include the pomace of natural raw materials, such as sugar cane and sugar beet as above described; molasses; and the residue generated in a purification step using filtration or ion-exchange resin.
[0045] The hydrolysate of a disaccharide, an oligosaccharide, sugar, or a sucrose-containing by-product generated in producing sugar refers to one obtained by subjecting the disaccharide, oligosaccharide, sugar, or sucrose-containing by-product generated in producing sugar to hydrolysis treatment, such as heating in an acidic solution.
[0046] The components in the culture medium other than the carbon source may be the same ones as those in well-known culture media used for the culture of bacteria, and preferably contain CMC. Specific examples of such a culture medium can include common nutrient culture media containing CMC, nitrogen sources, inorganic salts, and, as needed, organic trace nutrients, such as amino acids and vitamins. Examples of the nitrogen source can include organic or inorganic nitrogen sources, such as ammonium salts (e.g., ammonium sulfate, ammonium chloride, and ammonium phosphate), nitrates, urea, or peptone. Examples of the inorganic salt can also include phosphates, magnesium salts, calcium salts, iron salts, and manganese salts. Examples of the organic trace nutrient can include amino acids, vitamins, fatty acids, nucleic acids, and further peptone, casamino acids, yeast extracts, and soybean protein hydrolysates containing the nutrients. When an auxotrophic mutant requiring amino acids for growth is used, the required nutrients may further be supplemented.
[0047] The bacterium is not particularly limited provided that it can produce a bacterial cellulose; however, preferred is a bacterium capable of producing the bacterial cellulose under agitated culture or aerated culture, more preferably a bacterium assimilating BDF-B. Specific examples thereof can include bacteria of the genus Acetobacter , the genus Gluconacetobacter , the genus Pseudomonas , the genus Agrobacterium , the genus Rhizobium , and the genus Enterobacter . More specific examples thereof can include Gluconacetobacter intermedius, Gluconacetobacter hansenii, Gluconacetobacter swingsii, Acetobacter pasteurianus, Acetobacter aceti, Acetobacter xylinum, Acetobacter xylinum subsp. sucrofermentans, Acetobacter xylinum subsp. nonacetoxidans, Acetobacter ransens, Sarcina ventriculi, Bacterium xyloides , and Enterobacter sp.; however, among these, Gluconacetobacter intermedius is preferable. Still more specific examples thereof can include Gluconacetobacter intermedius strain SIID9587 (strain NEDO-01) (accession number NITE BP-01495), Gluconacetobacter xylinus strain ATCC53582 , Gluconacetobacter hansenii strain ATCC23769 , Gluconacetobacter xylinus strain ATCC700178 (BPR2001), Gluconacetobacter swingsii strain BPR3001E, Acetobacter xylinum strain JCM10150, and Enterobacter sp. strain CJF-002; among these, Gluconacetobacter intermedius strain SIID9587 (strain NEDO-01) (accession number NITE BP-01495) is preferable.
[0048] Culture methods can include, for example, agitated culture and aerated culture. Specific examples of the agitated culture can include culture using a fermenter, not involving aeration (non-aerated and agitated culture), culture using a fermenter, involving aeration (aerated and agitated culture), culture under swaying from side to side using a baffled flask (shake culture), and rotary culture using a baffled flask (rotation culture). The culture conditions may be well-known culture conditions used for the culture of the above bacteria; examples thereof can include culture conditions of an aeration volume of 1 to 10 L/minute, a rotation number of 100 to 800 rpm, a temperature of 20 to 40° C., and a culture period of 1 day to 7 days.
[0049] In the production of the bacterial cellulose according to the present invention, a step of pretreating a carbon source, a pre-preculture step, a preculture step, a step of purifying, drying, and suspending the bacterial cellulose, and the like may be carried out, as needed.
[0050] The bacterial cellulose according to the present invention can be used, for example, as an additive for paper strong agents, thickeners for food products, suspension stabilizers, and the like.
[0051] Then, the bacterium according to the present invention produces the above-described bacterial cellulose. For bacteria producing the bacterial cellulose according to the present invention, the same or equivalent components to those of the bacterial cellulose according to the present invention will not be described again.
[0052] The bacterial cellulose according to the present invention and a bacterium producing it will be described below based on Examples. However, the technical scope of the present invention is not intended to be limited to the features exhibited by these Examples.
EXAMPLES
Example 1
Isolation and Identification of Bacteria
[0053] (1) Isolation of Bacteria
[0054] Bacteria producing a bacterial cellulose by assimilating BDF-B were isolated. Specifically, using the protocol shown in FIG. 1 , enrichment culture was first carried out employing a culture medium containing 2% (w/v) of reagent glycerol (a guaranteed reagent from Wako Pure Chemical Industries Ltd.) in place of glucose in Hestrin-Schramm standard culture medium (composition; bacto pepton 0.5% (w/v), yeast extract 0.5% (w/v), Na 2 HPO 4 0.27% (w/v), citric acid 0.115% (w/v), glucose 2% (w/v); HS culture medium) (HS/glycerol culture medium) using apple and prune as separation sources. The resultant bacteria were inoculated on an HS/glycerol culture medium containing a cellulose staining reagent and cultured on plates at 30° C., and 15 bacterial strains producing bacterial celluloses were selected. Subsequently, these strains were inoculated on an LB culture medium (composition; trypsin 1% (w/v), yeast extract 0.5% (w/v), and sodium chloride 0.5% (w/v)) containing 2% (w/v) of reagent glycerol (a guaranteed reagent from Wako Pure Chemical Industries Ltd.) and subjected to stationary culture at 30° C. to form gelled films. The dry weight of the gelled films (hereinafter, referred to as “dry film weight”) was measured, and 8 strains for which the dry film weight was large were selected as bacteria assimilating glycerol and having a high bacterial cellulose-producing ability. Then, these strains were inoculated on an LB culture medium containing BDF-B and cultured on plates at 30° C., and further inoculated on the HS culture medium and subjected to stationary culture at 30° C. to form gelled films. The operation of selecting a bacterial strain for which the dry film weight was large among these bacteria, culturing on plates with the glycerol-containing LB culture medium or the HS/glycerol culture medium, and then subjecting the resultant to stationary culture on the HS culture medium was repeated to select one bacterial strain having a BDF-B-assimilating property and having a high bacterial cellulose-producing ability, which was called strain SIID9587.
[0055] (2) Identification of Bacteria
[0056] Sequencing was carried out according to an ordinary method for the strain SIID9587 of 1 (1) of this Example to determine the nucleotide sequence of the full-length 16S rDNA (1367 bp; SEQ ID NO: 1). Subsequently, 16S rDNA nucleotide sequence analysis and bacteriological property test were performed in TechnoSuruga Laboratory Co., Ltd.
[0057] [2-1] 16S rDNA Nucleotide Sequence Analysis
[0058] The 16S rDNA nucleotide sequence analysis was carried out using Aporon 2.0 (TechnoSuruga Laboratory Co., Ltd.) as software and Aporon DB-BA 6.0 (TechnoSuruga Laboratory Co., Ltd.) and the International Nucleotide Sequence Databases (GenBank/DDBJ/EMBL) as databases. As a result of homology search with Aporon DB-BA 6.0, the 16S rDNA nucleotide sequence for the strain SIID9587 (SEQ ID NO: 1) was found to have high homology to the 16S rDNA nucleotide sequence for the genus Gluconacetobacter and have the highest homology to the 16S rDNA nucleotide sequence for G. intermedius strain TF2 (accession number Y14694) (homology rate: 99.8%). As a result of homology search with GenBank/DDBJ/EMBL, the 16S rDNA nucleotide sequence for the strain SIID9587 (SEQ ID NO: 1) was also found to have high homology to the 16S rDNA nucleotide sequence for the genus Gluconacetobacter , and that for the type strain was found to have high homology to the 16S rDNA nucleotide sequence for G. intermedius strain TF2 (accession number NR — 026435) (homology rate: 99.8%). The sequence of the accession number Y14694 is identical to the sequence of the accession number NR — 026435. The results of the comparison between the 16S rDNA nucleotide sequences for the strain SIID9587 and G. intermedius strain TF2 (accession number Y14694 or NR — 026435) are shown in FIGS. 2-1 and 2 - 2 . As shown in FIGS. 2-1 and 2 - 2 , 4 nucleotides were different between both sequences. In homology search with Aporon DB-BA 6.0, as a result of simplified molecular phylogenetic analysis based on the 16S rDNA nucleotide sequences for the top 15 strains having high homology, the strain SIID9587 was found to be included in the cluster formed by the species of the genus Gluconacetobacter.
[0059] [2-2] Bacteriological Property Test
[0060] The results of bacteriological property test are shown in FIG. 3 . As shown in FIG. 3 , the strain SIID9587 was different in property in terms of not growing on a 5% acetic acid-containing culture medium from known G. intermedius and not different in other properties therefrom (BRENNER et al., Bergey's manual of Systematic Bacteriology. Vol. 2. The Proteobacteria, Part C The Alpha-, Beta-, Delta-, and Epsilonproteobacteria. 2005. Springer. p72-77).
[0061] The above results of (2) [2-1] and [2-2] of this Example 1 showed that the strain SIID9587 belonged to Gluconacetobacter intermedius . On the other hand, it was shown that the strain SIID9587 was a new strain of G. intermedius since differences exist in the 16S rDNA nucleotide sequence and the bacteriological property between the strain SIID9587 and Gluconacetobacter intermedius strain TF2 as the type strain for G. intermedius as described above. Accordingly, this bacterial strain was deposited in the National Institute of Technology and Evaluation, Patent Microorganisms Depositary (NITE-IPOD; #122, 2-5-8 Kazusakamatari, Kisarazu-shi, Chiba 292-0818, Japan) under the accession number NITE BP-01495, Dec. 21, 2012. Hereinafter, the Gluconacetobacter intermedius strain SIID9587 (accession number NITE BP-01495) is called strain NEDO-01 ( G. intermedius strain SIID9587).
[0062] (3) Determination of Product
[0063] The strain NEDO-01 ( G. intermedius strain SIID9587) was precultured to proliferate bacterial cells. Subsequently, the culture solution obtained by the preculture (preculture solution) was added to the HS culture medium (carbon source; glucose), which was then subjected to stationary culture at 30° C. for about 8 days to perform the main culture to form a gelled film on the culture medium surface. The infrared spectroscopy (IR) spectrum and x-ray diffraction profile of the gelled film were obtained and analyzed according to an ordinary method. As a result, the gelled film was shown to be a cellulose having a I-type crystal structure. As a result of obtaining and analyzing a scanning electron microscope image according to an ordinary method, cellulose fibers having a width of the nano order (cellulose nanofibers) were shown to form a network structure in the gelled film. From these results, the strain NEDO-01 ( G. intermedius strain SIID9587) was determined to produce a cellulose.
Example 2
Evaluation of Product Obtained by Aerated and Agitated Culture
[0064] (1) Preparation of Product by Aerated and Agitated Culture
[0065] BDF-B was subjected to neutralization treatment and further subjected to autoclave treatment to provide pretreated BDF-B.
[0066] Culture media were prepared in which reagent glycerol (a guaranteed reagent from Wako Pure Chemical Industries Ltd.) was added in place of glucose as a carbon source in an HS culture medium containing 2% (w/v) CMC (chemical grade, from Wako Pure Chemical Industries Ltd.) and in which the pretreated BDF-B was added to a concentration of 2% (w/v) in place of glucose in the CMC-containing HS culture medium, and called a main-culture medium with glycerol and a main-culture medium with BDF-B, respectively. The strain NEDO-01 ( G. intermedius strain SIID9587) was first precultured to proliferate bacterial cells. Then, the preculture solution was inoculated on 5 L each of the main-culture medium with glycerol and the main culture medium with BDF-B and using the fermenter, subjected to aerated and agitated culture for 4 days under conditions of an aeration volume of 7 to 10 L/minute, a rotation number of 200 to 800 rpm, and a temperature of 30° C. to perform main culture. A 1% (w/v) NaOH aqueous solution was added to the culture solution obtained by the main culture (main-culture solution), which was then shaken at 60° C. and 80 rpm for 4 to 5 hours to lyse bacterial cells. After subjecting the resultant to centrifugation, the supernatant was removed to recover the precipitate to remove water-soluble bacterial cell components. The operation of adding ultrapure water thereto, performing centrifugation, and then removing the supernatant was repeated until the pH of the precipitate in a wet state reaches 7 or less to purify the product, and the resultant was called an agitated-culture BC solution.
[0067] (2) Preparation of Bacterial Cellulose by Stationary Culture
[0068] A gelled film was obtained by the method described in (3) of Example 1 and cut to a size of about 1 cm×1 cm. Subsequently, a 1% (w/v) NaOH aqueous solution was added thereto, which was then shaken at 60° C. and 80 strokes/minute for 4 to 5 hours and then shaken overnight at 20° C. The liquid was removed by filtration using a metal gauze to recover a gelled film. The operation of adding ultrapure water thereto and shaking the resultant overnight at 20° C. was repeated until pH reaches 7 or less for purification, followed by suspension treatment using a mixer for several minutes, and the resultant was called a mixer-treated stationary-culture BC solution.
[0069] (3) Analysis
[0070] The agitated-culture BC solution of (1) of this Example 2 and the mixer-treated stationary-culture BC solution of (2) of this Example 2 were each added dropwise onto a silicon plate, dried, and then provided to an infrared spectrophotometer (FT/IR-4200; JASCO Corporation), and measured at a cumulative number of 32 and a resolution of 2 cm −1 or 4 cm −1 to provide an IR spectrum. The results are shown in FIG. 4 . As shown in FIG. 4 , the IR spectra of the agitated-culture BC solutions obtained using the main-culture medium with BDF-B and the main-culture medium with glycerol had similar shapes to the IR spectrum of the mixer-treated stationary-culture BC solution. From these results, the product obtained by subjecting the strain NEDO-01 ( G. intermedius strain SIID9587) to agitated culture using BDF-B or reagent glycerol as a carbon source was determined to be a cellulose.
Example 3
Dispersibility of Bacterial Cellulose in Water
[0071] (1) Appearance of Water Containing Bacterial Cellulose
[0072] The agitated-culture BC solution using the main-culture solution with BDF-B of (1) of Example 2 and the mixer-treated stationary-culture BC solution of (2) of Example 2 were provided. Commercial pulp-derived cellulose nanofibers were added to water for dispersion, and the resultant was called a pulp-derived CNF solution. The agitated-culture BC solution, the mixer-treated stationary-culture BC solution, and the pulp-derived CNF solution were allowed to stand for 1 day, followed by observing their appearance. The results are shown in FIG. 5 .
[0073] As shown in FIG. 5 , the cellulose precipitation was observed in the pulp-derived CNF solution. Massive bacterial cellulose was observed in the mixer-treated stationary-culture BC solution, showing that the dispersion state of the bacterial cellulose was non-uniform. In contrast, in the agitated-culture BC solution, no precipitation or massive bacterial cellulose was observed and the bacterial cellulose was observed to be in the state of being uniformly dispersed. These results showed that the bacterial cellulose obtained by subjecting the strain NEDO-01 ( G. intermedius strain SIID9587) to agitated culture had high dispersibility and was uniformly dispersed in a liquid, such as water, compared to the bacterial cellulose obtained by subjecting the pulp-derived cellulose nanofibers or the strain NEDO-01 ( G. intermedius strain SIID9587) to stationary culture.
[0074] (2) Light Transmittance of Water Containing Bacterial Cellulose
[0075] [2-1] Comparison Between Bacterial Cellulose Obtained by Stationary Culture and Pulp-Derived Cellulose
[0076] In the method described in (1) of Example 2, rotation culture was performed under conditions of 150 rpm and a temperature of 30° C. for 3 days using a baffled flask in place of the fermenter as main culture to prepare agitated-culture BC solutions, which were called sample A (obtained using the main-culture medium with glycerol) and sample B (obtained using the main-culture medium with BDF-B). The agitated-culture BC solution obtained using the Main-culture medium with BDF-B of (1) of Example 2 was called sample C, and the agitated-culture BC solution obtained using the main-culture medium with glycerol was called sample D. The mixer-treated stationary-culture BC solution of (2) of Example 2 and the pulp-derived CNF solution of (1) of Example 3 were provided. These solutions were adjusted to a final cellulose concentration of 0.1±0.006% (w/w) and 1 mL each thereof were added to cells and subjected to a spectrophotometer (U-2001 double-beam spectrophotometer; Hitachi, Ltd.) to measure the transmittance of light at a wavelength of 500 nm. A polyethylene disposable cuvette (semi-micro, having a light path length of 10 mm and a light path width of 4 mm) was used as each cell, and ultrapure water was used as a reference. The results are shown in Table 1.
[0000]
TABLE 1
Final Concentration
of Cellulose
Culture Method
Carbon Source
(% (w/w))
Transmittance (%)
Sample A
Agitated culture (Baffled Flask)
Reagent Glycerol
0.10505
74.75
Sample B
Agitated culture (Baffled Flask)
BDF-B
0.10309
70.53
Sample C
Agitated culture (Fermenter)
BDF-B
0.09570
63.82
Sample D
Agitated culture (Fermenter)
Reagent Glycerol
0.10375
49.66
Mixer-Treated Stationary-
Stationary culture
Glucose
0.09964
19.19
culture BC Solution
Pulp-Derived CNF Solution
0.10514
12.72
[0077] As shown in Table 1, the transmittance of the samples A, B, C, and D was 74.75%, 70.53%, 63.82%, and 49.66%, respectively, prominently high compared to 19.19% for the mixer-treated stationary-culture BC solution and 12.72% for the pulp-derived CNF solution, and roughly in the range of from 40% to 80% (both inclusive).
[0078] [2-2] Comparison Between Presence and Absence of CMC in Culture Medium
[0079] In the method described in (1) of Example 2, the HS culture medium containing 2% (w/v) CMC and the HS culture medium containing no CMC were each used to provide agitated-culture BC solutions. However, molasses was used in place of glucose as a carbon source. When molasses was used as a carbon source, the number of days in the main culture was set to 3 days in place of 4 days since the carbon source in the culture medium virtually disappeared at day 3 of the main culture. Subsequently, the light transmittance of bacterial cellulose-containing waters was measured by the method described in (2) [2-1] of Example 3. The results are shown in the following Table 2.
[0000]
TABLE 2
CMC in
Carbon
Transmittance
Culture Medium
Culture Method
Source
(%)
Contain
Agitated culture
Molasses
57
Not Contain
Agitated culture
Molasses
18
[0080] As shown in Table 2, the transmittance when the HS culture medium containing CMC was used was 57%, whereas the transmittance when the HS culture medium containing no CMC was used was 18%.
[0081] The above results of (2) [2-1] and [2-2] of this Example 3 showed that the water containing the bacterial cellulose obtained by subjecting the strain NEDO-01 ( G. intermedius strain SIID9587) to agitated culture in the CMC-containing culture medium at a final concentration of 0.1±0.006% (w/w) had a transmittance of light at a wavelength of 500 nm of 40% to 80% (both inclusive). In other words, the agitated culture of the strain NEDO-01 ( G. intermedius strain SIID9587) in the CMC-containing culture medium was shown to provide a bacterial cellulose having a prominently high dispersibility in a liquid and uniformly dispersible in the liquid.
Example 4
Comparison in Transmittance and Bacterial Cellulose Production Rate Between Different Carbon Sources
[0082] Agitated-culture BC solutions were each obtained by the method described in (1) of Example 2. However, molasses and reagent glycerol were used as carbon sources in place of glucose. When molasses was used as a carbon source, the number of days in the main culture was set to 3 days in place of 4 days. Subsequently, the light transmittance of each bacterial cellulose-containing water was measured by the method described in (2) [2-1] of Example 3. The agitated-culture BC solution was dried to measure the absolute dry weight of the bacterial cellulose, and the concentration of the bacterial cellulose per 1 L of the culture medium was calculated based on the measurement results and defined as the amount of the bacterial cellulose produced (amount of BC produced; g/L). A value provided by dividing the amount of BC produced by the number of days in the main culture is calculated, and the value was defined as the bacterial cellulose production rate (BC production rate; g/L/day). The results are shown in FIG. 6 .
[0083] As shown in the table and left bar graph of FIG. 6 , the transmittance when molasses was used as a carbon source was 57% and was the same (57%) as that when reagent glycerol was used as a carbon source. These results showed that the culture of the strain NEDO-01 ( G. intermedius strain SIID9587) using molasses as a carbon source provided a bacterial cellulose having a high light transmittance at a wavelength of 500 nm of water containing the bacterial cellulose at a final concentration of 0.1±0.006% (w/w) and was the same as when reagent glycerol was used as a carbon source. In other words, the culture of the strain NEDO-01 ( G. intermedius strain SIID9587) using molasses as a carbon source was shown to provide a bacterial cellulose having high dispersibility and uniformly dispersible in a liquid.
[0084] As shown in the table and right bar graph of FIG. 6 , the BC production rate when molasses was used as a carbon source was 1.48 g/L/day and was about 1.5 times higher than that (0.95 g/L/day) when reagent glycerol was used as a carbon source. These results showed that the culture of the strain NEDO-01 ( G. intermedius strain SIID9587) using molasses as a carbon source provided a bacterial cellulose having high dispersibility in high amounts in a short period of time.
Example 5
Comparison in Transmittance and Bacterial Cellulose Production Rate Between Different Bacteria
[0085] An agitated-culture BC solution was obtained by the method described in (1) of Example 2. However, molasses was used as a carbon source in place of glucose. The strain NEDO-01 ( G. intermedius strain SIID9587) and Gluconacetobacter hansenii strain ATCC23769 , Gluconacetobacter xylinus strain ATCC53582 , Gluconacetobacter xylinus strain ATCC700178 (BPR2001), Gluconacetobacter xylinus strain JCM10150 , Gluconacetobacter intermedius strain DSM11804, and Gluconacetobacter xylinus strain KCCM40274 as known bacterial cellulose-producing bacteria were used as bacteria, respectively. When the strain NEDO-01 ( G. intermedius strain SIID9587) was used, the number of days in the main culture was set to 3 days in place of 4 days since the carbon source in the culture medium virtually disappeared at day 3 of the main culture. On the other hand, when the strain DSM11804 was used, the number of days in the main culture was set to 5 days in place of 4 days since the decrease in the carbon source in the culture medium was small in magnitude even at day 4 of the main culture. Subsequently, the light transmittance of each bacterial cellulose-containing water was measured by the method described in (2) [2-1] of Example 3. The amount of BC produced (g/L) and the BC production rate (g/L/day) were calculated by the method described in Example 4, and the transmittance and the BC production rate were quantified in bar graphs. The results are shown in FIG. 7 .
[0086] As shown in the table and left bar graph of FIG. 7 , the transmittance when the strain NEDO-01 ( G. intermedius strain SIID9587) was used was 57%, whereas the transmittance when G. hansenii strain ATCC23769 , G. xylinus strain ATCC53582 , G. xylinus strain ATCC700178 (BPR2001), G. xylinus strain JCM10150, G. intermedius strain DSM11804, and G. xylinus strain KCCM40274 were used was 20%, 33%, 29%, 27%, 9%, and 13%, respectively. These results showed that the transmittance of light at a wavelength of 500 nm of the water containing the bacterial cellulose obtained by culturing the strain NEDO-01 ( G. intermedius strain SIID9587) at a final concentration of 0.1±0.006% (w/w) was prominently high (35% or more) compared to the light transmittance of the water containing the bacterial cellulose obtained by culturing each of the strains other than NEDO-Ol ( G. intermedius strain SIID9587). In other words, the culture of the strain NEDO-01 ( G. intermedius strain SIID9587) was shown to be capable of providing a bacterial cellulose having high dispersibility and uniformly dispersible in a liquid.
[0087] As shown in the table and right bar graph of FIG. 6 , the BC production rate when the strain NEDO-01 ( G. intermedius strain SIID9587) was used was 1.48 g/L/day, whereas the BC production rate when G. hansenii strain ATCC23769 , G. xylinus strain ATCC53582 , G. xylinus strain ATCC700178 (BPR2001), G. xylinus strain JCM10150 , G. intermedius strain DSM11804, and G. xylinus strain KCCM40274 were used was 1.05 g/L/day, 1.03 g/L/day, 1.11 g/L/day, 1.10 g/L/day, 0.42 g/L/day, and 0.43 g/L/day, respectively. In other words, the BC production rate when the strain NEDO-01 ( G. intermedius strain SIID9587) was used was prominently high compared to the BC production rate when the strains other than NEDO-01 ( G. intermedius strain SIID9587) were used. These results showed that the culture of the strain NEDO-01 ( G. intermedius strain SIID9587) could provide a bacterial cellulose having high dispersibility in high amounts in a short period of time.
Example 6
Molecular Weight of Bacterial Cellulose
[0088] The samples A, B, C, and D and pulp-derived CNF solution of (2) of Example 3 were provided as samples. These samples were each freeze-dried, added to a 57 to 59% tetrabutylphosphonium hydroxide aqueous solution, and dissolved by standing at 35° C., followed by adding water to a tetrabutylphosphonium hydroxide concentration of 40 to 42% (w/w) and a sample concentration of 0.2% (w/w). Subsequently, centrifugation was carried out to precipitate impurities to recover the supernatant. The supernatant was subjected to the gel permeation chromatography under the following conditions to measure the retention volume of the peak top of the chromatogram. The supernatant was measured 3 times under the same conditions. The results are shown in Table 3, and a randomly selected chromatogram is shown in FIG. 8 .
Condition for Gel Permeation Chromatography
[0089] Instrument; high-performance liquid chromatograph (Shimadzu Corporation)
[0090] Column; a column 6.0 mm in inside diameter and 15 cm in length, packed with a methacrylate polymer having a particle diameter of 9 μm (TSKgel super AWM-H; Tosoh Corporation) Guard column; 4.6 mm in inside diameter and 3.5 cm in length (TSK guardcolum super AW-H; Tosoh Corporation)
[0091] Column temperature; 35° C.
[0092] Feed flow rate; 0.07 mL/minute
[0093] Sample injection volume; 10 μL
[0094] Eluent; a 40 to 42% (w/w) tetrabutylphosphonium hydroxide aqueous solution
[0095] Final concentration of bacterial cellulose in the eluent; 0.2% (w/w)
[0096] Control sample; pullulan having a molecular weight of 85.3×10 4 (Shodex standard P-82)
[0000]
TABLE 3
Standard
Retention
Retention
Average/
Deviation/
Time/Minute
Volume/mL
mL
mL
Sample A (1st)
40.4
2.828
2.79
0.05
Sample A (2nd)
39.1
2.737
Sample A (3rd)
40
2.8
Sample B (1st)
39.8
2.786
2.81
0.03
Sample B (2nd)
39.9
2.793
sample B (3rd)
40.7
2.849
Sample C (1st)
40.1
2.807
2.82
0.02
Sample C (2nd)
40.5
2.835
Sample C (3rd)
40.1
2.807
Sample D (1st)
39.2
2.744
2.76
0.02
Sample D (2nd)
39.4
2.758
Sample D (3rd)
39.8
2.786
Pulp-derived
42.9
3.003
3.04
0.04
CNF Solution (1st)
Pulp-derived
43.4
3.038
CNF Solution (2nd)
Pulp-derived
43.9
3.073
CNF Solution (3rd)
Pullulan (1st)
45.7
3.199
3.24
0.04
Pullulan (2nd)
46.8
3.276
Pullulan (3rd)
46.4
3.248
[0097] As shown in Table 3 and FIG. 8 , the retention volume of the peak top of each of the samples A, B, C, and D was on average 2.79 mL, 2.81 mL, 2.82 mL, and 2.76 mL, respectively and small compared to 3.04 mL for the pulp-derived CNF solution and 3.24 mL for pullulan. These results showed that the average molecular weight of the bacterial cellulose obtained by subjecting the strain NEDO-01 ( G. intermedius strain SIID9587) to agitated culture was larger than that of the pulp-derived cellulose and more than 85.3×10 4 in terms of pullulan. Table 3 also showed that when the bacterial cellulose obtained by subjecting the strain NEDO-01 ( G. intermedius strain SIID9587) to agitated culture was subjected to the gel permeation chromatography under the above conditions, the retention volume of the peak top of the chromatogram reached 2.5 mL (inclusive) to 3.0 mL (exclusive) since the retention volume of the peak top of each of the samples A, B, C, and D was in the range of 2.737 to 2.849 mL.
Example 7
Morphology of Bacterial Cellulose
[0098] (1) Measurement of Fiber Width
[0099] The agitated-culture BC solution using the main-culture medium with glycerol of (1) of Example 2 and the mixer-treated stationary-culture BC solution of (2) of Example 2 were provided. These cellulose solutions were each adjusted to a concentration of about 0.001% (w/w), and then, 10 μL of each solution was added dropwise onto a Formvar-coated copper grid and air-dried. Subsequently, 5 μL of a 5% (w/v) gadolinium acetate aqueous solution was added dropwise thereto, and the excess solution was removed with a paper filter 10 seconds later for negative staining. The resultant was observed under a transmission electron microscope at an acceleration voltage of 80 kV and an observation magnification of 30,000 times to measure the width of cellulose fibers based on the observed image. The results are shown in FIG. 9 .
[0100] As shown in FIG. 9 , the width of the cellulose fibers was 17±8 nm for the agitated-culture BC solution, was prominently small compared to 55±22 nm for the mixer-treated stationary-culture BC solution, and had a small standard deviation. These results showed that the bacterial cellulose obtained by subjecting the strain NEDO-01 ( G. intermedius strain SIID9587) to agitated culture formed fine and uniform fibers showing small variations in width between the fibers.
[0101] (2) Determination of Uniformity of Fiber Width and Aggregation State
[0102] The agitated-culture BC solution using the main-culture medium with BDF-B of (1) of Example 2 and the pulp-derived CNF solution of (1) of Example 3 were provided. These cellulose solutions were each adjusted to a concentration of about 0.01% (w/w), and then, the operation of spraying the solution on a Formvar-coated copper grid and drying it using a dryer was repeated 10 times. Subsequently, 5 μL of a 5% (w/v) gadolinium acetate aqueous solution was added dropwise thereto, and the excess solution was removed with a paper filter. In addition, the sequence of dropwise adding 5 μL of ultrapure water and then removing the excess solution with a paper filter was repeated 2 times, followed by negative staining by air-drying. The resultant was observed under a transmission electron microscope at an acceleration voltage of 80 kV and an observation magnification of 10,000 times. The results are shown in FIG. 10 . It was also observed with crossed nicols using a polarizing microscope. The results are shown in FIG. 11 .
[0103] As shown in FIG. 10 , many cellulose fibers having comparable widths of the nano-scale were observed in the agitated-culture BC solution, whereas cellulose fibers having various widths, including widths as large as about 500 nm or more, were observed in the pulp-derived CNF solution. From these results, it was again determined that the bacterial cellulose obtained by subjecting the strain NEDO-01 ( G. intermedius strain SIID9587) to agitated culture formed fibers having a uniform width of the nano-scale.
[0104] As shown in FIG. 11 , relatively thick fibers as shown by arrows were definitely observed in the pulp-derived CNF solution, whereas dim images were observed in the portion enclosed by a dotted line in the agitated-culture BC solution. These results showed that relatively thick fibers, such as submicrofibers and microfibers, were present for the pulp-derived cellulose, whereas thin fibers of the nano-scale were uniformly dispersed for the bacterial cellulose obtained by subjecting the strain NEDO-01 ( G. intermedius strain SIID9587) to agitated culture.
Example 8
Evaluation of Bacterial Cellulose-Producing Ability
[0105] (1) Production Ability in Stationary Culture
[0106] Culture media were prepared in which pretreated BDF-B and reagent glycerol, respectively, were added in place of glucose as a carbon source in the LB culture medium, and called LB/BDF-B culture medium and LB/glycerol culture medium, respectively. The strain NEDO-01 ( G. intermedius strain SIID9587), Gluconacetobacter xylinus strain ATCC53582 , Gluconacetobacter hansenii strain ATCC23769, and Gluconacetobacter xylinus strain ATCC700178 (BPR2001) were each inoculated on each of the LB/glycerol culture medium and the LB/BDF-B culture medium and subjected to stationary culture at 30° C. for 7 days to form a gelled film. The operation of adding a 1% (w/v) NaOH aqueous solution thereto and performing autoclave treatment was repeated until the gelled film became white. Thereafter, the operation of adding water and performing autoclave treatment was repeated until pH reached 7 or less for purification. The bacterial cellulose obtained by drying after purification was measured for the absolute dry weight. The results are shown in FIG. 12 .
[0107] As shown in FIG. 12 , G. hansenii strain ATCC23769 produced small weights of bacterial celluloses in both of the LB/glycerol culture medium and the LB/BDF-B culture medium. G. xylinus strain ATCC53582 and G. xylinus strain ATCC700178 (BPR2001) produced relatively large weights of bacterial celluloses in the LB/glycerol culture medium, whereas no bacterial cellulose production was observed in LB/BDF-B culture medium. In contrast, the strain NEDO-01 ( G. intermedius strain SIID9587) produced comparably large weights of bacterial celluloses in both of the LB/glycerol culture medium and the LB/BDF-B culture medium. These results showed that the strain NEDO-01 ( G. intermedius strain SIID9587) could efficiently produce a bacterial cellulose by being subjected to stationary culture using either reagent glycerol or BDF-B as a carbon source. Its feature of being capable of producing a bacterial cellulose using BDF-B as a carbon source is a feature which other compared strains do not have, also advantageous on the practical side in which the by-product can be utilized, and greatly contributes to a reduction in production cost.
[0108] (2) Production Ability in Agitated Culture
[0109] The strains NEDO-01 ( G. intermedius strain SIID9587), strain ATCC53582, and strain ATCC23769 were each inoculated on 10 mL of the HS culture medium and subjected to stationary culture at 30° C. for 3 days for pre-preculture. Subsequently, the culture solution obtained by the pre-preculture was inoculated on 10 mL of the HS culture medium and subjected to stationary culture at 30° C. for 3 days for preculture. Then, 100 mL of each of the main-culture medium with glycerol and the main culture medium with BDF-B of (1) of Example 2 was placed in a bladed Erlenmeyer flask, and the preculture solution was inoculated in an amount corresponding to the same number of bacterial cells for each bacterial strain thereon and subjected to shake culture for 3 days under conditions of 150 rpm and 30° C. for the main culture. Subsequently, a bacterial cellulose in the main-culture solution was purified by the method described in (1) of Example 2. However, shake was performed at 60° C. and 80 rpm for 4 to 5 hours, followed by further shaking at 20° C. overnight. The purified bacterial cellulose was dried and measured for the absolute dry weight. The results are shown in FIG. 13 .
[0110] As shown in FIG. 13 , G. xylinus strain ATCC53582 was not observed to produce a bacterial cellulose in each of the main-culture medium with glycerol and the main culture medium with BDF-B. For G. hansenii strain ATCC23769, the absolute dry weight of the bacterial cellulose was relatively large when the main-culture medium with glycerol was used, but no bacterial cellulose production was observed when the main culture medium with BDF-B was used. In contrast, for the strain NEDO-01 ( G. intermedius strain SIID9587), the absolute dry weight of the bacterial cellulose was large when each of the main-culture medium with glycerol and the main culture medium with BDF-B was used. These results showed that the strain NEDO-01 ( G. intermedius strain SIID9587) could efficiently produce the bacterial cellulose by either stationary culture or agitated culture using either reagent glycerol or BDF-B as a carbon source.
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[Problem]
To provide a bacterial cellulose which is highly dispersible in a liquid, shows excellent molding properties and high miscibility with other materials when applied to materials, and, therefore, has a high applicability as a practical material, and a bacterium which produces the bacterial cellulose.
[Solution]
A bacterial cellulose, water that contains said bacterial cellulose at a final concentration of 0.1±0.006 (w/w) showing a light transmittance at a wavelength of 500 nm of 35% or greater, and a bacterium producing the bacterial cellulose. According to the present invention, the bacterial cellulose that is uniformly dispersible in a liquid such as water can be obtained. The bacterial cellulose shows excellent molding properties and high miscibility with other materials and, therefore, can contribute to the improvement in the qualities of a final product or production efficiency thereof or to the reduction of production cost.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a system for stabilizing the output wavelength of a laser oscillator that generates light for transmission in an optical communication network, a system for monitoring the wavelength of a light signal received from an optical communication network, and more generally a method of monitoring the wavelength of a modulated light signal.
[0002] As optical communication networks carry increasing amounts of information, there is a trend toward the use of increasingly narrow optical wavelength bands, to avoid running out of wavelength resources. This trend has made it essential to study techniques for stabilizing the output wavelengths of optical signal transmitters.
[0003] In particular, growing communication traffic has led to the use of wavelength-division multiplexing systems with increasing numbers of wavelengths, therefore with increasingly narrow wavelength spacing. If the stability of the individual wavelengths deteriorates, crosstalk occurs between adjacent wavelengths, and communication quality is degraded. Communication systems in which wavelength-division multiplexing is employed therefore have stringent requirements for wavelength stability.
[0004] The transmitters used in optical communication systems, however, generally employ semiconductor lasers having a temperature-dependent wavelength characteristic; the emitted wavelength varies with the temperature of the laser. In conventional transmitters, this temperature-dependency problem is dealt with by measuring the temperature of the semiconductor laser, and using a heat-pumping device such as a Peltier device to hold the semiconductor laser at a substantially constant temperature. Conventional optical communication networks rely on this scheme to maintain wavelength stability, and do not attempt to monitor the wavelength of the received optical signals.
[0005] [0005]FIG. 7 shows a conventional optical transmitting apparatus that transmits a signal on, for example, an optical fiber in an optical communication network. The optical transmitting apparatus 7 includes a transmitting light source 41 that generates coherent output light OL with a fixed frequency, a transmitting modulator 42 that modulates the fixed-frequency output light OL to obtain a transmit light signal SL, and a control unit 96 that receives temperature information from the transmitting light source 41 , supplies the transmitting light source 41 with control signals for adjusting the power and wavelength of the laser output light OL, receives information to be transmitted (send data, SD) from an external source (not visible), and sends a corresponding modulating signal MD to the transmitting modulator 42 .
[0006] The transmitting light source 41 includes a laser oscillator 51 such as a semiconductor laser, a wavelength adjustment unit 52 including a heat-pumping device such as a Peltier device, and a temperature-measuring unit 53 including a device such as a thermistor that detects ambient temperature changes as changes in electrical resistance.
[0007] The conventional optical transmitting apparatus 7 operates as follows.
[0008] When information SD to be transmitted is input, the control unit 96 controls the transmitting light source 41 so that the laser oscillator 51 outputs light OL of a fixed wavelength, and supplies the transmitting modulator 42 with a modulating signal MD. The transmitting modulator 42 modulates the output light OL according to the modulating signal MD to obtain the transmit light signal SL.
[0009] If information SD to be transmitted is input continuously, the laser oscillator 51 operates continuously, and its temperature begins to rise. The temperature of the laser oscillator 51 may also rise because of heat generated from another device (not visible) in the equipment, or because of a rise in the ambient temperature. Similarly, a drop in the ambient temperature may lower the temperature of the laser oscillator 51 . If the temperature of the laser oscillator 51 varies, so does the wavelength of the output light OL.
[0010] To limit these wavelength variations, the temperature-measuring unit 53 detects the temperature in the vicinity of the laser oscillator 51 , and the control unit 96 responds by controlling the wavelength adjustment unit 52 so as to keep the temperature around the laser oscillator 51 within a fixed range. For example, the control unit 96 may operate according to two thresholds, controlling the wavelength adjustment unit 52 so as to lower the temperature around the laser oscillator 51 if the temperature indicated by the temperature-measuring unit 53 exceeds the upper threshold, and to raise the temperature around the laser oscillator 51 if the temperature indicated by the temperature-measuring unit 53 falls below the lower threshold. A feedback loop is thereby established, involving the wavelength adjustment unit 52 , the temperature-measuring unit 53 , and the control unit 96 .
[0011] A problem with this feedback loop is that it is not always possible to mount the thermistor or other temperature-sensing element of the temperature-measuring unit 53 close enough to the laser oscillator 51 to detect its temperature accurately. There may be a considerable difference between the temperature measured by the temperature-measuring unit 53 and the actual temperature of the laser oscillator 51 , preventing the control unit 96 from keeping the temperature of the laser oscillator 51 within the desired range. Since the feedback loop does not include any measurement of the wavelength of the output light OL or light signal SL, there is no guarantee that feedback control will actually produce the desired wavelength.
SUMMARY OF THE INVENTION
[0012] An object of the present invention is to provide a method of monitoring the wavelength of a modulated light signal.
[0013] Another object of the invention is to stabilize the wavelength of light generated by a laser oscillator and modulated for transmission in an optical communication system.
[0014] Another object is to monitor the wavelength of a modulated light signal received in an optical communication system.
[0015] The invented method of monitoring the wavelength of a modulated light signal includes the steps of generating criterion light having a stable wavelength, splitting the modulated light signal into at least two parts, and combining one part of the modulated light signal with the criterion light, thereby obtaining a combined light signal. The combined light signal is compared with the modulating signal, and an error rate indicating how often the combined light signal disagrees with the modulating signal is calculated. A high error rate indicates wavelength agreement between the modulated light signal and the criterion signal, since wavelength agreement leads to interference when the modulated light signal and criterion light are combined.
[0016] The comparison step may include conversion of the combined light signal to an electrical signal.
[0017] The criterion light may also be modulated according to the modulating signal, to make the error rate a more sensitive indicator of wavelength agreement.
[0018] The polarization planes of the modulated light signal and the criterion light are preferably controlled so that the modulated light signal and criterion light are polarized in the same plane when combined, leading to greater interference when their wavelengths match.
[0019] In an optical transmitting apparatus, the invented method can be used to control the wavelength of light output by a laser oscillator. For example, the wavelength can be controlled by controlling the temperature of the laser oscillator according to the error rate. In this case, the modulating signal is a signal by which the output light of the laser oscillator is modulated.
[0020] The invention may also be used to monitor the wavelength of a modulated light signal received by an optical receiving apparatus. In this case, the modulating signal is determined from the output of the optical receiving apparatus.
[0021] When the optical transmitting apparatus or the optical receiving apparatus is located at a node in an optical communication network, the reference light source may be external to the node, and may supply the criterion light to a plurality of nodes in the network.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In the attached drawings:
[0023] [0023]FIG. 1 is a block diagram of an optical transmitting apparatus illustrating a first embodiment of the invention;
[0024] [0024]FIG. 2 is a block diagram of an optical transmitting apparatus illustrating a second embodiment of the invention;
[0025] [0025]FIG. 3 is a block diagram of an optical transmitting apparatus illustrating a third embodiment of the invention;
[0026] [0026]FIG. 4 is a block diagram of an optical ring network in which the invention is applied;
[0027] [0027]FIG. 5 is a block diagram of a node in the network in FIG. 4, illustrating a fourth embodiment of the invention;
[0028] [0028]FIG. 6 is another block diagram of a node in the network in FIG. 4, illustrating a fifth embodiment of the invention; and
[0029] [0029]FIG. 7 is a block diagram of a conventional optical transmitting apparatus.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Embodiments of the invention will be described with reference to the attached drawings, in which like parts are indicated by like reference characters. Repeated descriptions of conventional elements also appearing in FIG. 7 will be omitted.
[0031] The optical transmitting apparatus 1 in FIG. 1 includes a wavelength stabilization system 11 embodying the present invention. The optical transmitting apparatus 1 also includes a conventional transmitting modulator 42 , and a transmitting light source 44 comprising a conventional laser oscillator 51 and a conventional wavelength adjustment unit 52 . The transmitting light source 44 does not include a temperature-measuring unit.
[0032] The wavelength stabilization system 11 includes an optical splitter 62 , a reference light source 71 , an optical combiner 81 , an optical-electrical (O/E) converter 82 , a data comparator 83 , and a control unit 91 .
[0033] The control unit 91 receives information SD to be transmitted and generates a corresponding modulating signal MD, which is supplied to both the transmitting modulator 42 and the data comparator 83 . The information SD is received from, for example, a telephone set or facsimile machine (not visible). The control unit 91 also receives comparison result data CD from the data comparator 83 , and generates signals that control the laser oscillator 51 and wavelength adjustment unit 52 . To control the wavelength adjustment unit 52 , the control unit 91 calculates an error rate from the comparison result data CD, and varies the control signal sent to the wavelength adjustment unit 52 until a maximum error rate is obtained.
[0034] The optical splitter 62 uses an optical element such as a semitransparent mirror or prism to split the transmit light signal SL received from the transmitting modulator 42 into two parts SLa, SLb. Light signal SLa forms the output of the optical transmitting apparatus 1 . Light signal SLb is sent to the optical combiner 81 .
[0035] The reference light source 71 is a light-emitting device such as a semiconductor laser or light-emitting diode that operates with relatively little temperature dependence and emits criterion light CL with a highly stable wavelength.
[0036] The optical combiner 81 combines the criterion light signal CL from the reference light source 71 with the split-off light signal SLb from the optical splitter 62 to generate a combined light signal XL.
[0037] The optical-electrical converter 82 converts the combined light signal XL to an electrical signal XD, which is supplied to the data comparator 83 .
[0038] The data comparator 83 compares the electrical signal XD with the modulating signal MD, and supplies the comparison result data CD to the control unit 91 .
[0039] Furthermore, when the combined light signal XL is compared with the modulating signal MD, an output power of the criterion light signal CL has been adjusted in order to prevent deviation of synchronization.
[0040] The elements described above form a type of feedback loop. A difference between this feedback loop and most conventional feedback loops is that the control unit 91 attempts to maximize the error, instead of minimizing the error. Further explanation will be given in the following description of the operation of the optical transmitting apparatus 1 .
[0041] When the control unit 91 receives information SD to be transmitted, it sends control signals to the laser oscillator 51 and reference light source 71 , causing them to generate output light OL and criterion light CL at nominally equal wavelengths. The control unit 91 also converts the information SD to a modulating signal MD. The transmitting modulator 42 modulates the output light OL according to the modulating signal MD. The optical splitter 62 splits the resulting light signal SL into two parts SLa and SLb, of which SLa is transmitted to the outside and SLb is supplied to the optical combiner 81 . Light signal SL and its two parts SLa, SLb have the same wavelength as the output light OL.
[0042] When the split-off light signal SLb is combined with the criterion light CL in the optical combiner 81 , if the split-off light signal SLb and the criterion light CL have the same wavelength, they will interfere strongly, and the information carried in the light signal will be difficult to detect in the combined light signal XL or the electrical signal XD. Thus, when the data comparator 83 compares the electrical signal XD with the modulating signal MD, it will find comparatively little correlation between the two, and the control unit 91 will calculate a high error rate from the comparison result data CD.
[0043] If the light signal SLb and criterion light CL have slightly different wavelengths, they will interfere less. The information carried in the light signal SLb will then be more easily detectable in the combined light signal XL, the data comparator 83 will detect a stronger correlation between the electrical signal XD and the modulating signal MD, and the control unit 91 will calculate a lower error rate. In general, the more difference there is between the wavelengths of the light signal SLb and the criterion light CL, the less they will interfere and the lower the error rate will be.
[0044] The error rate accordingly provides feedback information that the control unit 91 uses to determine how to control the wavelength adjustment unit 52 in order to reach the maximum error rate. At this error rate, the split-off light SLb, and thus the output light OL, the light signal SL, and the transmit light signal SLa, have substantially the same wavelength as the criterion light CL. Since the criterion light CL has high wavelength stability, not varying with temperature, the transmit light signal SLa has similar wavelength stability.
[0045] Compared with the conventional optical transmitting apparatus 7 shown in FIG. 7, the optical transmitting apparatus 1 in FIG. 1 can achieve a higher degree of wavelength stability, because the wavelength of the modulated light signal is compared directly with the wavelength of the highly stable reference light source 71 , by measuring the error rate produced by interference between the two light signals. A further advantage is that no temperature measurement is necessary. The first embodiment is therefore particularly useful in situations in which it would be impractical to mount a thermistor or other temperature-sensing device close to the laser oscillator 51 .
[0046] [0046]FIG. 2 illustrates a second embodiment of the invention, which adds a criterion modulator 72 to the structure of the first embodiment, and modifies the control unit 92 . The other elements in the wavelength stabilization system 12 in the optical transmitting apparatus 2 in FIG. 2 are similar to the corresponding elements in FIG. 1.
[0047] The principal modification to the control unit 92 is that it supplies the modulating signal MD not only to the transmitting modulator 42 and data comparator 83 , but also to the criterion modulator 72 .
[0048] The criterion modulator 72 modulates the criterion light CL according to the modulating signal MD, and supplies the modulated criterion light ML to the optical combiner 81 to be combined with light signal SLb. The modulated criterion light ML has the same wavelength as the criterion light CL.
[0049] The combined light signal XLa is converted to an electrical signal XDa by the optical-electrical converter 82 and compared with the modulating signal MD by the data comparator 83 . Since both components SLb and ML of the combined signal XLa have been modulated according to the same modulating signal MD, when the two components SLb, ML differ in wavelength and interference is relatively slight, the electrical signal XDa will closely match the modulating signal MD, and the control unit 92 will measure a lower error rate than in the first embodiment from the comparison result data CDa. When the two components SLb, ML have the same wavelength or nearly the same wavelength, however, they will still interfere strongly and a high error rate will be measured, as in the first embodiment.
[0050] Compared with the first embodiment, accordingly, the second embodiment produces a sharper decline in the error rate as the wavelength of the light signal SLb moves away from the wavelength of the criterion light CL. This enables the control unit 92 to adjust the wavelength of the laser oscillator 51 more closely to the wavelength of the reference light source 71 than in the first embodiment.
[0051] Depending on the modulation system used, modulation of the criterion light may also have the effect of increasing the amount of interference when the wavelength of the laser oscillator 51 matches the wavelength of the reference light source 71 . Once again, the result is a steeper decline in the error rate as the wavelength of the laser oscillator 51 moves away from the wavelength of the reference light source 71 .
[0052] [0052]FIG. 3 illustrates a third embodiment of the invention, which adds a pair of polarization controllers (POL CON) 61 , 73 to the structure of the second embodiment, and modifies the control unit 92 . The other elements in the wavelength stabilization system 13 in the optical transmitting apparatus 3 in FIG. 3 are similar to the corresponding elements in FIG. 2.
[0053] The polarization controllers 61 , 73 are, for example, optical polarizers or polarizing prisms. The first polarization controller 61 is inserted between the transmitting modulator 42 and optical splitter 62 to control the polarization plane of the light signal SL. The polarization-controlled light signal output from the polarization controller 61 to the optical splitter 62 is denoted SDL. The second polarization controller 73 is inserted between the criterion modulator 72 and optical combiner 81 to control the polarization plane of the modulated criterion light ML. The polarization-controlled light output from the polarization controller 73 to the optical combiner 81 is denoted DL.
[0054] Aside from controlling the polarization planes of the light signal and criterion light, the optical transmitting apparatus 3 operates as described in the second embodiment. The split-off polarization-controlled light signal SDLb is combined with the polarization-controlled modulated criterion light DL. The polarization controllers 61 , 73 are arranged so that the split-off polarization-controlled light signal SDLb and the polarization-controlled modulated criterion light DL are both polarized in the same plane. The combined light XLb is converted to an electrical signal XDb, and the control unit 94 controls the wavelength adjustment unit 52 so as to maximize the error rate calculated from the comparison result data CDb.
[0055] In general, the degree of interference between two light waves depends on the angle between their polarization planes. If the two polarization planes are mutually orthogonal, for example, no interference occurs. Maximum interference occurs when the two polarization planes are identical.
[0056] Because of the matched polarization of the two components SDLb, DL of the combined light signal XLb, accordingly, when the wavelength of the laser oscillator 51 matches the wavelength of the reference light source 71 , the split-off polarization-controlled light signal SDLb and modulated polarization-controlled criterion light DL tend to interfere more strongly than in the preceding embodiments, and the control unit 93 measures a higher error rate. Thus as the wavelength of the laser oscillator 51 moves away from the wavelength of the reference light source 71 , there is an even sharper decline in the error rate than in the second embodiment. This enables the control unit 93 to adjust the wavelength of the laser oscillator 51 more closely to the wavelength of the reference light source 71 than in the second embodiment, so that the transmit light signal SDLa has even higher wavelength stability than in the second embodiment.
[0057] [0057]FIG. 4 shows a reference light source 100 , which constitutes part of a fourth embodiment of the invention, transmitting criterion light CL to four nodes 101 , 102 , 103 , 104 linked by an optical ring network 110 . FIG. 5 shows how the reference light source 100 is connected to an arbitrary node 24 , which may be any one of the four nodes 101 , 102 , 103 , 104 in FIG. 1. The reference light source 100 supplies the same criterion light CL to all of these nodes.
[0058] The node 24 in FIG. 5 includes an optical receiving apparatus 34 , which receives a light signal RL from the optical ring network 110 , and an optical transmitting apparatus 4 , which transmits a light signal SLa to the optical ring network 110 .
[0059] The optical transmitting apparatus 4 is generally similar to the optical transmitting apparatus in the first embodiment, except that criterion light CL is supplied to the optical combiner 81 by the reference light source 100 , which is external to the node 24 , and the control unit 94 does not control the reference light source 100 .
[0060] Aside from obtaining criterion light CL from the external reference light source 100 , the optical transmitting apparatus 4 operates as described in the first embodiment. The criterion light CL is combined with light signal SLb, the combined light XLc is converted to an electrical signal XDc, and the control unit 94 controls the wavelength adjustment unit 52 so as to maximize the error rate calculated from the comparison result data CDc.
[0061] The information SD to be transmitted may be obtained from terminal equipment such as a facsimile machine or telephone (not visible) connected to the node 24 , as mentioned in the first embodiment. However, the control unit 94 may also receive this information SD from the optical receiving apparatus 34 , as shown. The optical receiving apparatus 34 generates the information SD by converting the received light RL to an electrical signal. The optical receiving apparatus 34 may also amplify or reshape the electrical signal to optimize the waveform of the information signal SD.
[0062] When several nodes are linked in a network of the type shown in FIG. 4, it is necessary to stabilize the wavelengths of the optical transmitting apparatus at all of the nodes in the same way. By supplying criterion light from a common reference light source 100 , the fourth embodiment assures that all nodes are stabilized at the same wavelength.
[0063] The fourth embodiment can be modified by using the optical transmitting apparatus of the second or third embodiment instead of the optical transmitting apparatus of the first embodiment as a basis for the optical transmitting apparatus 4 .
[0064] Illustrating a fifth embodiment of the invention, FIG. 6 shows another node 25 in an optical ring network. The node 25 may be any one of the four nodes 101 , 102 , 103 , 104 in FIG. 4, for example.
[0065] The node 25 in FIG. 6 includes an optical transmitting apparatus 5 similar to, for example, the optical transmitting apparatus 4 in FIG. 5, an optical receiving apparatus 35 similar to the optical receiving apparatus 34 in FIG. 5, and a wavelength monitoring apparatus 6 . The wavelength monitoring apparatus 6 receives criterion light CL from a reference light source 100 , which may be external to the node 25 , as shown in FIG. 4. The wavelength monitoring apparatus 6 uses the criterion light CL and the method of the preceding embodiments to monitor the wavelength of the received light RL before the received light is supplied to the optical receiving apparatus 35 .
[0066] The wavelength monitoring apparatus 6 comprises an optical splitter 62 , an optical combiner 81 , an optical-electrical converter 82 , a data comparator 83 , and a control unit 95 . The optical splitter 62 splits the received light RL into two parts RLa and RLb, supplies RLa to the optical receiving apparatus 35 , and supplies RLb to the optical combiner 81 . The optical combiner 81 combines RLb with the criterion light from the reference light source 100 . The optical-electrical converter 82 converts the combined light XLd to an electrical signal XDd.
[0067] The received light RL and its parts RLa, RLb are modulated signals similar to the light signals SL, SLa, SLb in the preceding embodiments. The optical receiving apparatus 35 converts the received light RLa to information SD to be transmitted, which is supplied to the optical transmitting apparatus 5 and the control unit 95 . The control unit 95 uses this information SD to generate a modulating signal MD which may be, for example, substantially identical to SD. The modulating signal MD represents the information carried in the received light RL. The control unit 95 sends the modulating signal MD to the data comparator 83 , where it is compared with the electrical signal XDd, and determines an error rate from the comparison results CDd.
[0068] As explained in the preceding embodiments, if the wavelength of the received light RL substantially matches the wavelength of the criterion light CL, the light signals RLb and CL combined in the optical combiner 81 interfere strongly, so the electrical signal XDd will frequently disagree with the modulating signal MD and a high error rate will be measured. If the wavelength of the received light RL moves away from the wavelength of the criterion light CL, the error rate decreases. If the error rate falls below a predetermined alarm threshold value, the control unit 95 sends an alarm signal AL to system supervisory equipment (not visible) to notify an administrator of the network in FIG. 4, for example, that the wavelength of the received light RL is varying excessively. The system administrator can then take corrective action, such as repairing or replacing the optical transmitting apparatus that transmitted the received light RL.
[0069] Although this is not shown in FIG. 6, the reference light source 100 may also supply criterion light CL to the optical transmitting apparatus 5 .
[0070] The fifth embodiment enables the received light signals at all network nodes to be monitored with reference to the same criterion light CL.
[0071] The fifth embodiment can be modified by modulating the criterion light CL as in the second embodiment, and by adding polarization controllers as in the third embodiment, to achieve more accurate wavelength monitoring. In an optical ring network in which the same light signal circulates around all nodes, the criterion modulator and polarization controller that modulate and control the polarization of the criterion light CL can be installed together with the reference light source 100 at a central location, instead of at each node, thereby reducing the cost of the system.
[0072] In the foregoing embodiments, the invention has been used to stabilize the wavelength of a transmitted light signal, and to monitor the wavelength of a light signal received at a node in an optical communication network, but the invention can also be used to monitor the wavelength of the optical signal at an arbitrary point in the network.
[0073] Those skilled in the art will recognize that further variations are possible within the scope claimed below.
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The wavelength of light modulated according to a modulating signal is monitored by generating criterion light having a stable wavelength, combining part of the modulated light with the criterion light, comparing the combined light with the modulating signal, and calculating an error rate indicating how frequently the combined light disagrees with the modulating signal. A high error rate indicates that the modulated light has the same wavelength as the criterion light, leading to interference when the two are combined. In a monitoring system, an alarm signal is output if the error rate is too low. In a wavelength stabilizing system, the wavelength of the modulated light is controlled so as to maximize the error rate.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part application which claims the benefit of priority under 35 USC §120 of U.S. Ser. No. 09/861,966, filed May 21, 2001, which is a divisional application of U.S. Pat. No. 6,268,165, which claims the benefit of priority under 35 USC §120 of U.S. Ser. No. 09/039,211, filed Mar. 14, 1998, which claims benefit of provisional patent application U.S. Ser. No. 60/041,404, filed Mar. 19, 1997, now abandoned.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Generally, the present invention relates to the fields of molecular biology and medicine. More specifically, the present invention invention is in the field of cancer research, especially ovarian cancer diagnosis.
BACKGROUND OF THE INVENTION
[0004] In order for malignant cells to grow, spread or metastasize, they must have the capacity to invade local host tissue, dissociate or shed from the primary tumor, enter and survive in the bloodstream, implant by invasion into the surface of the target organ and establish an environment conducive for new colony growth (including the induction of angiogenic and growth factors). During this progression, natural tissue barriers such as basement membranes and connective tissue have to be degraded. These barriers include collagen, laminin, fibronectin, proteoglycans and extracellular matrix glycoproteins. Degradation of these natural barriers, both those surrounding the primary tumor and at the sites of metastatic invasion, is believed to be brought about by the action of a matrix of extracellular proteases.
[0005] Proteases have been classified into four families: serine proteases, metallo-proteases, aspartic proteases and cysteine proteases. Many proteases have been shown to be involved in human disease processes and these enzymes are targets for the development of inhibitors as new therapeutic agents. Certain individual proteases are induced and overexpressed in a diverse group of cancers, and as such, are potential candidates for markers of early diagnosis and targets for possible therapeutic intervention. A group of examples are shown in Table 1.
TABLE 1 Known proteases expressed in various cancers Gastric Brain Breast Ovarian Serine uPA uPA NES-1 NES-1 Proteases: PAI-1 PAI-1 uPA uPA tPA PAI-2 Cysteine Cathepsin B Cathepsin L Cathepsin B Cathepsin B Proteases: Cathepsin L Cathepsin L Cathepsin L Metallo- Matrilysin* Matrilysin Stromelysin-3 MMP-2 proteases: Collagenase* Stromelysin MMP-8 Stromelysin-1* Gelatinase B MMP-9 Gelatinase A
[0006] There is a good body of evidence supporting the downregulation or inhibition of individual proteases and the reduction in invasive capacity or malignancy. In work by Clark et al., inhibition of in vitro growth of human small cell lung cancer was demonstrated using a general serine protease inhibitor. More recently, Torres-Rosedo et al., [ Proc. Natl. Acad. Sci. USA. 90, 7181-7185 (1993)] demonstrated an inhibition of hepatoma tumor cell growth using specific antisense inhibitors for the serine protease hepsin gene. Metastatic potential of melanoma cells has also been shown to be reduced in a mouse model using a synthetic inhibitor (batimastat) of metallo-proteases. Powell et al. [ Cancer Research, 53, 417-422 (1993)] presented evidence to confirm that the expression of extracellular proteases in a non-metastatic prostate cancer cell line enhances their malignant progression. Specifically, enhanced metastasis was demonstrated after introducing and expressing the PUMP-1 metallo-protease gene. There is also a body of data to support the notion that expression of cell surface proteases on relatively non-metastatic cell types increases the invasive potential of such cells.
[0007] To date, ovarian cancer remains the number one killer of women with gynecologic malignant hyperplasia. Approximately 75% of women diagnosed with such cancers are already at an advanced stage (III and IV) of the disease at their initial diagnosis. During the past 20 years, neither diagnosis nor five-year survival rates have greatly improved for these patients. This is substantially due to the high percentage of high-stage initial detection of the disease. Therefore, the challenge remains to develop new markers that improve early diagnosis and thereby reduce the percentage of high-stage initial diagnoses. The ability to disengage from one tissue and re-engage the surface of another tissue is what provides for the morbidity and mortality associated with this disease. Therefore, extracellular proteases may be good candidates for markers of malignant ovarian hyperplasia.
[0008] Thus, the prior art is deficient in a tumor marker useful as an indicator of early disease, particularly for ovarian cancers. The present invention fulfills this long-standing need and desire in the art.
SUMMARY OF THE INVENTION
[0009] This invention allows for the detection of cancer, especially ovarian cancer, by screening for hepsin mRNA in tissue, which is indicative of the hepsin protease, which is shown herein to be specifically associated with the surface of 80 percent of ovarian and other tumors. Proteases are considered to be an integral part of tumor growth and metastasis, and therefore, markers indicative of their presence or absence are useful for the diagnosis of cancer. Furthermore, the present invention is useful for treatment (i.e., by inhibiting hepsin or expression of hepsin), for targeted therapy, for vaccination, etc.
[0010] In one embodiment of the present invention, there is provided a method for detecting malignant hyperplasia in a biological sample by detecting hepsin mRNA in the sample. The presence of the hepsin mRNA in the sample is indicative of the presence of malignant hyperplasia, and the absense of the hepsin mRNA in the sample is indicative of the absence of malignant hyperplasia.
[0011] In another embodiment of the present invention, there are provided methods of inhibiting expression of hepsin in a cell by introducing into a cell a vector encoding an antisense hepsin mRNA or an antibody that binds the hepsin protein.
[0012] In yet another embodiment of the present invention, there is provided a method of targeted therapy to an individual, comprising the step of administering a compound to an individual, wherein the compound has a targeting moiety and a therapeutic moiety, wherein the targeting moiety is specific for hepsin.
[0013] In still yet another embodiment of the present invention, there are provided methods of vaccinating an individual against hepsin or produce immune-activated cells directed toward hepsin by inoculating an individual with a hepsin protein or fragment thereof, wherein the hepsin protein or fragment thereof lack hepsin protease activity.
[0014] In still another embodiment of the present invention, there are provided compositions comprising immunogenic fragments of hepsin protein or an oligonucleotide having a sequence complementary to SEQ ID No. 188. Also embodied is a method of treating a neoplastic state in an individual in need of such treatment with an effective dose of the above-described oligonucleotide.
[0015] In another embodiment of the present invention, there is provided a method of screening for compounds that inhibit hepsin activity, comprising the steps of contacting a sample with a compound, wherein the sample comprises hepsin protein; and assaying for hepsin protease activity. A decrease in the hepsin protease activity in the presence of the compound relative to hepsin protease activity in the absence of the compound is indicative of a compound that inhibits hepsin activity.
[0016] Other and further aspects, features, and advantages of the present invention will be apparent from the following description of the presently preferred embodiments of the invention. These embodiments are given for the purpose of disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The appended drawings have been included herein so that the above-recited features, advantages and objects of the invention will become clear and can be understood in detail. These drawings form a part of the specification. It is to be noted, however, that the appended drawings illustrate preferred embodiments of the invention and should not be considered to limit the scope of the invention.
[0018] [0018]FIG. 1 shows agarose gel comparison of PCR products derived from normal and carcinoma cDNA.
[0019] [0019]FIG. 2 shows Northern blot analysis of ovarian tumors using hepsin, SCCE, PUMP-1, TADG-14 and β-tubulin probes.
[0020] [0020]FIG. 3 shows amplification with serine protease redundant primers: histidine sense (S1) with aspartic acid antisense (AS1), using normal cDNA (Lane 1) and tumor cDNA (Lane 2); and histidine sense (S1) with serine antisense (AS2), using normal cDNA (Lane 3) and tumor cDNA (Lane 4).
[0021] [0021]FIG. 4 shows amplification with cysteine protease redundant primers. Normal (Lane 1), low malignant potential (Lane 2), serious carcinoma (Lane 3), mucinous carcinoma (Lane 4), and clear cell carcinoma (Lane 5).
[0022] [0022]FIG. 5 shows amplification with metallo-protease redundant primers. Normal (Lane 1), low malignant potential (Lane 2), serious carcinoma (Lane 3), mucinous carcinoma (Lane 4), and clear cell carcinoma (Lane 5).
[0023] [0023]FIG. 6 shows amplification with specific primers directed towards the serine protease, hepsin. Expression in normal (Lanes 1-3), low malignant potential tumors (Lanes 4-8), and ovarian carcinomas (Lanes 9-12).
[0024] [0024]FIG. 7 shows hepsin expression levels in normal, low malignant potential tumors, and ovarian carcinomas. S=serious, M=mucinous, LMP=low malignant potential.
[0025] [0025]FIG. 8 shows serine protease stratum corneum chymotrypsin enzyme (SCCE) expression in normal, low malignant potential tumors, and ovarian carcinomas.
[0026] [0026]FIG. 9 shows metallo-protease PUMP-1 (MMP-7) gene expression in normal (lanes 1-2) and ovarian carcinomas tissue (Lanes 3-10).
[0027] [0027]FIG. 10A shows Northern blot analysis of hepsin expression in normal ovary and ovarian carcinomas. Lane 1, normal ovary (case 10); lane 2, serous carcinoma (case 35); lane 3, mucinous carcinoma (case 48); lane 4, endometrioid carcinoma (case 51); and lane 5, clear cell carcinoma (case 54). In cases 35, 51 and 54, more than a 10-fold increase in the hepsin 1.8 kb transcript abundance was observed. FIG. 10B shows Northern blot analysis of hepsin in normal human fetal. FIG. 10C shows Northern blot analysis of hepsin in adult tissues. Significant overexpression of the hepsin transcript is noted in both fetal liver and fetal kidney. Notably, hepsin overexpression is not observed in normal adult tissue. Slight expression above the background level is observed in the adult prostate.
[0028] [0028]FIG. 11 A shows hepsin expression in normal (N), mucinous (M) and serous (S) low malignant potential (LMP) tumors and carcinomas (CA). β-tubulin was used as an internal control. FIG. 11B shows the ratio of hepsin:β-tubulin expression in normal ovary, LMP tumor, and ovarian carcinoma. Hepsin mRNA expression levels were significantly elevated in LMP tumors, (p<0.005) and carcinomas (p<0.0001) compared to levels in normal ovary. All 10 cases of normal ovaries showed a relatively low level of hepsin mRNA expression.
[0029] [0029]FIG. 12A shows northern blot analysis of mRNA expression of the SCCE gene in fetal tissue. FIG. 12B shows northern blot analysis of mRNA expression of the SCCE gene in ovarian tissue.
[0030] [0030]FIG. 13 A shows a comparison of quantitative PCR of SCCE cDNA from normal ovary and ovarian carcinomas. FIG. 13B shows a bar graph comparing the ratio of SCCE to -tubulin in 10 normal and 44 ovarian carcinoma tissues.
[0031] [0031]FIG. 14 shows a comparison by quantitative PCR of normal and ovarian carcinoma expression of mRNA for protease M.
[0032] [0032]FIG. 15 shows the TADG-12 catalytic domain including an insert near the His 5′-end.
[0033] [0033]FIG. 16A shows northern blot analysis comparing TADG-14 expression in normal and ovarian carcinoma tissues.
[0034] [0034]FIG. 16B shows preliminary quantitative PCR amplification of normal and carcinoma cDNAs using specific primers for TADG-14.
[0035] [0035]FIG. 17A shows northern blot analysis of the PUMP-1 gene in human fetal tissue. FIG. 17B shows northern blot analysis of the PUMP-1 gene in normal ovary and ovarian carcinomas.
[0036] [0036]FIG. 18A shows a comparison of PUMP-1 expression in normal and carcinoma tissues using quantitative PCR with an internal β-tubulin control. FIG. 18B shows the ratio of mRNA expression of PUMP-1 compared to the internal control β-tubulin in 10 normal and 44 ovarian carcinomas.
[0037] [0037]FIG. 19 shows a comparison of PCR amplified products for the hepsin, SCCE, protease M, PUMP-1 and Cathepsin L genes.
[0038] [0038]FIG. 20 shows CD8 + CTL recognition of hepsin 170-178 peptide in a 5 hour 51 Cr release assay. Targets were LCL loaded with hepsin 170-178 (closed circles) and control LCL (open circles).
[0039] [0039]FIG. 21 shows CD8 + CTL recognition of hepsin 172-180 peptide in a 5 hr 51 Cr release assay. Targets were LCL loaded with hepsin 172-180 (closed circles) and control LCL (open circles).
DETAILED DESCRIPTION OF THE INVENTION
[0040] This invention identifies hepsin protease as a marker for ovarian tumor cells. In various combinations with other proteases, hepsin expression is characteristic of individual tumor types. Such information can provide the basis for diagnostic tests (assays or immunohistochemistry) and prognostic evaluation (depending on the display pattern). Long-term treatment of tumor growth, invasion and metastasis has not succeeded with existing chemotherapeutic agents. Most tumors become resistant to drugs after multiple cycles of chemotherapy. The present invention identifies hepsin as a new therapeutic intervention target utilizing either antibodies directed at the protease, antisense vehicles for downregulation or protease inhibitors both from established inhibition data and/or for the design of new drugs.
[0041] A primary object of the present invention is a method for detecting the presence of malignant hyperplasia in a tissue sample. The cancer is detected by analyzing a biological sample for the presence of markers to proteases that are specific indicators of certain types of cancer cells. This object may be accomplished by isolating mRNA from a sample or by detection of proteins by polyclonal or preferably monoclonal antibodies. When using mRNA detection, the method may be carried out by converting the isolated mRNA to cDNA according to standard methods; treating the converted cDNA with amplification reaction reagents (such as cDNA PCR reaction reagents) in a container along with an appropriate mixture of nucleic acid primers selected from the list in Table 2; reacting the contents of the container to produce amplification products; and analyzing the amplification products to detect the presence of malignant hyperplasia markers in the sample. The analyzing step may be accomplished using Northern Blot analysis to detect the presence of malignant hyperplasia markers in the amplification product. Northern Blot analysis is known in the art. The analysis step may be further accomplished by quantitatively detecting the presence of malignant hyperplasia marker in the amplification products, and comparing the quantity of marker detected against a panel of expected values for known presence or absence in normal and malignant tissue derived using similar primers.
[0042] The present invention also provides various nucleic acid sequences that are useful in the methods disclosed herein. These nucleic acid sequences are listed in Table 2. It is anticipated that these nucleic acid sequences be used in mixtures to accomplish the utility of this invention. Features of such mixtures include: SEQ ID No. 1 with SEQ ID No. 2; SEQ ID No. 1 with SEQ ID No. 3; SEQ ID No. 4 with SEQ ID No. 5; SEQ ID No. 6 with SEQ ID No. 7; SEQ ID No. 8 with SEQ ID No. 9; and SEQ ID No. 10 with SEQ ID No. 11. The skilled artisan may be able to develop other nucleic acid sequences and mixtures thereof to accomplish the benefit of this invention, but it is advantageous to have the sequences listed in Table 2 available without undue experimentation.
[0043] The present invention provides a method for detecting malignant hyperplasia in a biological sample, comprising the steps of isolating mRNA from the sample; and detecting hepsin mRNA in the sample. The presence of the hepsin mRNA in the sample is indicative of the presence of malignant hyperplasia, wherein the absense of the hepsin mRNA in the sample is indicative of the absence of malignant hyperplasia. This method may further comprise the step of comparing the hepsin mRNA to reference information, wherein the comparison provides a diagnosis and/or determines a treatment of the malignant hyperplasia. A typical means of detection of hepsin mRNA is by PCR amplification, which, preferably, uses primers shown in SEQ ID No. 8 and SEQ ID No. 9. Representative biological samples are blood, urine, saliva, tears, interstitial fluid, ascites fluid, tumor tissue biopsy and circulating tumor cells.
[0044] The present invention is further directed toward a method of inhibiting expression of hepsin in a cell, comprising the step of introducing into a cell a vector comprises a hepsin gene operably linked in opposite orientation to elements necessary for expression, wherein expression of the vector produces hepsin antisense mRNA in the cell. The hepsin antisense mRNA hybridizes to endogenous hepsin mRNA, thereby inhibiting expression of hepsin in the cell.
[0045] The present invention is still further directed toward a method of inhibiting a hepsin protein in a cell, comprising the step of introducing an antibody into a cell, wherein the antibody is specific for a hepsin protein or a fragment thereof. Binding of the antibody to hepsin inhibits the hepsin protein. Preferably, the hepsin fragment is a 9-residue fragment up to a 20-residue fragment, and more preferably, the 9-residue fragment is SEQ ID Nos. 28, 29, 30, 31, 88, 89, 108, 109, 128, 129, 148, 149, 150, 151, 152, 153 and 154.
[0046] The present invention is also directed toward a method of targeted therapy to an individual, comprising the step of administering a compound to an individual, wherein the compound has a targeting moiety and a therapeutic moiety, and wherein the targeting moiety is specific for hepsin. Preferably, the targeting moiety is an antibody specific for hepsin or a ligand or ligand binding domain that binds hepsin. Likewise, the therapeutic moiety is preferably a radioisotope, a toxin, a chemotherapeutic agent, an immune stimulant or cytotoxic agent. Generally, the individual suffers from a disease such as ovarian cancer, lung cancer, prostate cancer, colon cancer or another cancer in which hepsin is overexpressed.
[0047] The present invention is additionally directed toward a method of vaccinating an individual against hepsin, comprising the steps of inoculating an individual with a hepsin protein or fragment thereof, wherein the hepsin protein or fragment thereof lack hepsin protease activity. Inoculation with the hepsin protein, or fragment thereof, elicits an immune response in the individual, thereby vaccinating the individual against hepsin. Generally, this method is applicable when the individual has cancer, is suspected of having cancer or is at risk of getting cancer. Sequences of preferred hepsin proteins or fragment thereof are shown in SEQ ID Nos. 28, 29, 30, 31, 88, 89, 108, 109, 128, 129, 148, 149, 150, 151, 152, 153 and 154.
[0048] The present invention is yet directed toward a method of producing immune-activated cells directed toward hepsin, comprising the steps of exposing immune cells to hepsin protein or fragment thereof that lacks hepsin protease activity. Typically, exposure to hepsin protein or fragment thereof activates the immune cells, thereby producing immune-activated cells directed toward hepsin. Generally, the immune-activated cells are B-cells, T-cells and/or dendritic cells. Preferably, the hepsin fragment is a 9-residue fragment up to a 20-residue fragment, and more preferably, the 9-residue fragment is SEQ ID Nos. 28, 29, 30, 31, 88, 89, 108, 109, 128, 129, 148, 149, 150, 151, 152, 153 or 154. Oftentimes, the dendritic cells are isolated from an individual prior to exposure and then reintroduced into the individual subsequent to the exposure. Typically, the individual has cancer, is suspected of having cancer or is at risk of getting cancer.
[0049] The present invention is further directed toward a n immunogenic composition, comprising an immunogenic fragment of hepsin protein and an appropriate adjuvant. Preferably, the fragment is a 9-residue fragment up to a 20-residue fragment, and more preferably, the 9-residue fragment is SEQ ID Nos. 28, 29, 30, 31, 88, 89, 108, 109, 128, 129, 148, 149, 150, 151, 152, 153 or 154.
[0050] The present invention is further directed toward a n oligonucleotide having a sequence complementary to SEQ ID No. 188 or a frgament thereof. The present invention further provides a composition comprising the above-described oligonucleotide and a physiologically acceptable carrier, and a method of treating a neoplastic state in an individual in need of such treatment, comprising the step of administering to the individual an effective dose of the above-described oligonucleotide. Typically, the neoplastic state may be ovarian cancer, breast cancer, lung cancer, colon cancer, prostate cancer or another cancer in which hepsin is overexpressed.
[0051] The present invention is still further directed toward a method of screening for compounds that inhibit hepsin activity, comprising the steps of contacting a sample with a compound, wherein the sample comprises hepsin protein; and assaying for hepsin protease activity. A decrease in the hepsin protease activity in the presence of the compound relative to hepsin protease activity in the absence of the compound is indicative of a compound that inhibits hepsin activity.
[0052] It will be apparent to one skilled in the art that various substitutions and modifications may be made to the invention disclosed herein without departing from the scope and spirit of the invention.
[0053] In accordance with the present invention there may be employed conventional molecular biology, microbiology, and recombinant DNA techniques within the skill of the art. Such techniques are explained fully in the literature. See, e.g., Maniatis, Fritsch & Sambrook, “Molecular Cloning: A Laboratory Manual (1982); “DNA Cloning: A Practical Approach,” Volumes I and II (D. N. Glover ed. 1985); “Oligonucleotide Synthesis” (M. J. Gait ed. 1984); “Nucleic Acid Hybridization” (B. D. Hames & S. J. Higgins eds. 1985); “Transcription and Translation” (B. D. Hames & S. J. Higgins eds. 1984); “Animal Cell Culture” (R. I. Freshney, ed. 1986); “Immobilized Cells And Enzymes” (IRL Press, 1986); B. Perbal, “A Practical Guide To Molecular Cloning” (1984). Therefore, if appearing herein, the following terms shall have the definitions set out below.
[0054] As used herein, the term “cDNA” shall refer to the DNA copy of the mRNA transcript of a gene.
[0055] As used herein, the term “PCR” refers to the polymerase chain reaction that is the subject of U.S. Pat. Nos. 4,683,195 and 4,683,202 to Mullis, as well as other improvements now known in the art.
[0056] The present invention comprises a vector comprising a DNA sequence which encodes a hepsin protein, wherein said vector is capable of replication in a host, and comprises, in operable linkage: a) an origin of replication; b) a promoter; and c) a DNA sequence coding for said hepsin protein. Preferably, the vector of the present invention contains a portion of the DNA sequence shown in SEQ ID No. 188. Vectors may be used to amplify and/or express nucleic acid encoding a hepsin protein, a fragment of hepsin protein, or an antisense hepsin mRNA.
[0057] An expression vector is a replicable construct in which a nucleic acid sequence encoding a polypeptide is operably linked to suitable control sequences capable of effecting expression of the polypeptide in a cell. The need for such control sequences will vary depending upon the cell selected and the transformation method chosen. Generally, control sequences include a transcriptional promoter and/or enhancer, suitable mRNA ribosomal binding sites and sequences which control the termination of transcription and translation. Methods which are well known to those skilled in the art can be used to construct expression vectors containing appropriate transcriptional and translational control signals. See, for example, techniques described in Sambrook et al., 1989 , Molecular Cloning: A Laboratory Manual (2nd Ed.), Cold Spring Harbor Press, N.Y. A gene and its transcription control sequences are defined as being “operably linked” if the transcription control sequences effectively control transcription of the gene. Vectors of the invention include, but are not limited to, plasmid vectors and viral vectors. Preferred viral vectors of the invention are those derived from retroviruses, adenovirus, adeno-associated virus, SV40 virus, or herpes viruses.
[0058] As used herein, the term “host” is meant to include not only prokaryotes but also eukaryotes such as yeast, plant and animal cells. A recombinant DNA molecule or gene which encodes a human hepsin protein of the present invention can be used to transform a host using any of the techniques commonly known to those of ordinary skill in the art. Especially preferred is the use of a vector containing coding sequences for the gene which encodes a human hepsin protein of the present invention for purposes of prokaryote transformation. Prokaryotic hosts may include E. coli, S. tymphimurium, Serratia marcescens and Bacillus subtilis . Eukaryotic hosts include yeasts such as Pichia pastoris , mammalian cells and insect cells.
[0059] The term “oligonucleotide”, as used herein, is defined as a molecule comprised of two or more ribonucleotides, preferably more than three. Its exact size will depend upon many factors, which, in turn, depend upon the ultimate function and use of the oligonucleotide. The term “primer”, as used herein, refers to a n oligonucleotide, whether occurring naturally (as in a purified restriction digest) or produced synthetically, and which is capable of initiating synthesis of a strand complementary to a nucleic acid when placed under appropriate conditions, i.e., in the presence of nucleotides and an inducing agent, such as a DNA polymerase, and at a suitable temperature and pH. The primer may be either single-stranded or double-stranded and must be sufficiently long to prime the synthesis of the desired extension product in the presence of the inducing agent. The exact length of the primer will depend upon many factors, including temperature, sequence and/or homology of primer and the method used. For example, in diagnostic applications, the oligonucleotide primer typically contains 15-25 or more nucleotides, depending upon the complexity of the target sequence, although it may contain fewer nucleotides.
[0060] The primers herein are selected to be “substantially” complementary to particular target DNA sequences. This means that the primers must be sufficiently complementary to hybridize with their respective strands. Therefore, the primer sequence need not reflect the exact sequence of the template. For example, a non-complementary nucleotide fragment (i.e., containing a restriction site) may be attached to the 5′ end of the primer, with the remainder of the primer sequence being complementary to the strand. Alternatively, non-complementary bases or longer sequences can be interspersed into the primer, provided that the primer sequence has sufficient complementary with the sequence to hybridize therewith and form the template for synthesis of the extension product.
[0061] The probe to which the DNA of the invention hybridizes preferably consists of a sequence of at least 20 consecutive nucleotides, more preferably 40 nucleotides, even more preferably 50 nucleotides, and most preferably 100 nucleotides or more (up to 100%) of the coding sequence of the nucleotides listed in SEQ ID No. 188 or the complement thereof. Such a probe is useful for detecting expression of hepsin in a cell by a method including the steps of (a) contacting mRNA obtained from the cell with a labeled hepsin hybridization probe; and (b) detecting hybridization of the probe with the mRNA.
[0062] As used herein, “substantially pure DNA” means DNA that is not part of a milieu in which the DNA naturally occurs, by virtue of separation (partial or total purification) of some or all of the molecules of that milieu, or by virtue of alteration of sequences that flank the claimed DNA. The term therefore includes, for example, a recombinant DNA which is incorporated into a vector, into a n autonomously replicating plasmid or virus, or into the genomic DNA of a prokaryote or eukaryote; or which exists as a separate molecule (e.g., a cDNA or a genomic or cDNA fragment produced by polymerase chain reaction (PCR) or restriction endonuclease digestion) independent of other sequences. It also includes a recombinant DNA which is part of a hybrid gene encoding additional polypeptide sequence, e.g., a fusion protein. Also included is a recombinant DNA which includes a portion of the nucleotides listed in SEQ ID No. 188 and which encodes an alternative splice variant of hepsin.
[0063] The DNA may have at least about 70% sequence identity to the coding sequence of the nucleotides listed in SEQ ID No. 188, preferably at least 75% (e.g., at least 80%); and most preferably at least 90%. The identity between two sequences is a direct function of the number of matching or identical positions. When a position in both of the two sequences is occupied by the same monomeric subunit, e.g., if a given position is occupied by an adenine in each of two DNA molecules, then they are identical at that position. For example, if 7 positions in a sequence 10 nucleotides in length are identical to the corresponding positions in a second 10-nucleotide sequence, then the two sequences have 70% sequence identity. The length of comparison sequences will generally be at least 50 nucleotides, preferably at least 60 nucleotides, more preferably at least 75 nucleotides, and most preferably 100 nucleotides. Sequence identity is typically measured using sequence analysis software (e.g., Sequence Analysis Software Package of the Genetics Computer Group (GCG), University of Wisconsin Biotechnology Center, 1710 University Avenue, Madison, Wis. 53705).
[0064] Further included in this invention are hepsin proteins which are encoded, at least in part, by portions of SEQ ID No. 188, e.g., products of alternative mRNA splicing or alternative protein processing events, or in which a section of hepsin sequence has been deleted. The fragment, or the intact hepsin polypeptide, may be covalently linked to another polypeptide, e.g., one which acts as a label, a ligand or a means to increase antigenicity.
[0065] A substantially pure hepsin protein may be obtained, for example, by extraction from a natural source; by expression of a recombinant nucleic acid encoding a hepsin polypeptide; or by chemically synthesizing the protein. Purity can be measured by any appropriate method, e.g., column chromatography, such a s immunoaffinity chromatography using an antibody specific for hepsin, polyacrylamide gel electrophoresis, or HPLC analysis. A protein is substantially free of naturally associated components when it is separated from at least some of those contaminants which accompany it in its natural state. Thus, a protein which is chemically synthesized or produced in a cellular system different from the cell from which it naturally originates will be, by definition, substantially free from its naturally associated components. Accordingly, substantially pure proteins include eukaryotic proteins synthesized in E. coli , other prokaryotes, or any other organism in which they do not naturally occur.
[0066] In addition to substantially full-length proteins, the invention also includes fragments (e.g., antigenic fragments) of the hepsin protein. As used herein, “fragment,” as applied to a polypeptide, will ordinarily be at least 10 residues, more typically at least 20 residues, and preferably at least 30 (e.g., 50) residues in length, but less than the entire, intact sequence. Fragments of the hepsin protein can be generated by methods known to those skilled in the art, e.g., by enzymatic digestion of naturally occurring or recombinant hepsin protein, by recombinant DNA techniques using an expression vector that encodes a defined fragment of hepsin, or by chemical synthesis. The ability of a candidate fragment to exhibit a characteristic of hepsin (e.g., binding to an antibody specific for hepsin) can be assessed by methods known in the art. Purified hepsin or antigenic fragments of hepsin can be used to generate new antibodies or to test existing antibodies (e.g., as positive controls in a diagnostic assay) by employing standard protocols known to those skilled in the art. Included in this invention is polyclonal antisera generated by using hepsin or a fragment of hepsin as the immunogen in, e.g., rabbits. Standard protocols for monoclonal and polyclonal antibody production known to those skilled in this art are employed. The monoclonal antibodies generated by this procedure can be screened for the ability to identify recombinant hepsin cDNA clones, and to distinguish them from other cDNA clones.
[0067] The invention encompasses not only an intact anti-hepsin monoclonal antibody, but also an immunologically-active antibody fragment, e.g., a Fab or (Fab) 2 fragment; an engineered single chain Fv molecule; or a chimeric molecule, e.g., an antibody which contains the binding specificity of one antibody, e.g., of murine origin, and the remaining portions of another antibody, e.g., of human origin.
[0068] In one embodiment, the antibody, or a fragment thereof, may be linked to a toxin or to a detectable label, e.g., a radioactive label, non-radioactive isotopic label, fluorescent label, chemiluminescent label, paramagnetic label, enzyme label, or calorimetric label. Examples of suitable toxins include diphtheria toxin, Pseudomonas exotoxin A, ricin, and cholera toxin. Examples of suitable enzyme labels include malate hydrogenase, staphylococcal nuclease, delta-5-steroid isomerase, alcohol dehydrogenase, alpha-glycerol phosphate dehydrogenase, triose phosphate isomerase, peroxidase, alkaline phosphatase, asparaginase, glucose oxidase, beta-galactosidase, ribonuclease, urease, catalase, glucose-6-phosphate dehydrogenase, glucoamylase, acetylcholinesterase, etc. Examples of suitable radioisotopic labels include 3 H, 125 I, 131 I, 32 P, 35 S, 14 C, etc.
[0069] Paramagnetic isotopes for purposes of in vivo diagnosis can also be used according to the methods of this invention. There are numerous examples of elements that are useful in magnetic resonance imaging. For discussions on in vivo nuclear magnetic resonance imaging, see, for example, Schaefer et al., (1989) JACC 14, 472-480; Shreve et al., (1986) Magn. Reson. Med. 3, 336-340; Wolf, G. L., (1984) Physiol. Chem. Phys. Med. NMR 16, 93-95; Wesbey et al., (1984) Physiol. Chem. Phys. Med. NMR 16, 145-155; Runge et al., (1984) Invest. Radiol. 19, 408-415. Examples of suitable fluorescent labels include a fluorescein label, an isothiocyalate label, a rhodamine label, a phycoerythrin label, a phycocyanin label, an allophycocyanin label, an ophthaldehyde label, a fluorescamine label, etc. Examples of chemiluminescent labels include a luminal label, an isoluminal label, an aromatic acridinium ester label, an imidazole label, an acridinium salt label, an oxalate ester label, a luciferin label, a luciferase label, an aequorin label, etc.
[0070] Those of ordinary skill in the art will know of other suitable labels which may be employed in accordance with the present invention. The binding of these labels to antibodies or fragments thereof can be accomplished using standard techniques commonly known and used by those of ordinary skill in the art. Typical techniques are described by Kennedy et al., (1976) Clin. Chim. Acta 70, 1-31; and Schurs et al., (1977) Clin. Chim. Acta 81, 1-40. Coupling techniques mentioned in the latter are the glutaraldehyde method, the periodate method, the dimaleimide method, the m-maleimidobenzyl-N-hydroxy-succinimide ester method. All of these methods are incorporated by reference herein.
[0071] Also within the invention is a method of detecting hepsin protein in a biological sample, which includes the steps of contacting the sample with the labeled antibody, e.g., radioactively tagged antibody specific for hepsin, and determining whether the antibody binds to a component of the sample. Antibodies to the hepsin protein can be used in an immunoassay to detect increased levels of hepsin protein expression in tissues suspected of neoplastic transformation. These same uses can be achieved with Northern blot assays and analyses.
[0072] As described herein, the invention provides a number of diagnostic advantages and uses. For example, the hepsin protein is useful in diagnosing cancer in different tissues since this protein is highly overexpressed in tumor cells. Antibodies (or antigen-binding fragments thereof) which bind to an epitope specific for hepsin are useful in a method of detecting hepsin protein in a biological sample for diagnosis of cancerous or neoplastic transformation. This method includes the steps of obtaining a biological sample (e.g., cells, blood, plasma, tissue, etc.) from a patient suspected of having cancer, contacting the sample with a labeled antibody (e.g., radioactively tagged antibody) specific for hepsin, and detecting the hepsin protein using standard immunoassay techniques such as an ELISA. Antibody binding to the biological sample indicates that the sample contains a component which specifically binds to an epitope within hepsin.
[0073] Likewise, a standard Northern blot assay can be used to ascertain the relative amounts of hepsin mRNA in a cell or tissue obtained from a patient suspected of having cancer, in accordance with conventional Northern hybridization techniques known to those of ordinary skill in the art. This Northern assay uses a hybridization probe, e.g., radiolabelled hepsin cDNA, either containing the full-length, single stranded DNA having a sequence complementary to SEQ ID No. 188, or a fragment of that DNA sequence at least 20 (preferably at least 30, more preferably at least 50, and most preferably at least 100 consecutive nucleotides in length). The DNA hybridization probe can be labeled by any of the many different methods known to those skilled in this art.
[0074] The following examples are given for the purpose of illustrating various embodiments of the invention and are not meant to limit the present invention in any fashion:
EXAMPLE 1
[0075] Amplification Of Serine Proteases Using Redundant And Specific Primers
[0076] Only cDNA preparations deemed free of genomic DNA were used for gene expression analysis. Redundant primers were prepared for serine proteases, metallo-proteases and cysteine protease. The primers were synthesized to consensus sequences of amino acid surrounding the catalytic triad for serine proteases, viz. histidine . . . aspartate . . . and serine. The sequences of both sense (histidine & aspartate) and antisense (aspartate and serine) redundant primers are shown in Table 2.
TABLE 2 SEQ ID PCR Primers 5′→3′ No. No. Redundant Primers: Serine Protease (histidine) = S1 tgggtigtiacigcigcica(ct)tg 1 Serine Protease (aspartic acid) = AS1 a(ag)ia(ag)igciatitcitticc 2 Serine Protease (serine) = AS11 a(ag)iggiccicci(cg)(ta)(ag)tcicc 3 Cysteine Protease - sense ca(ag)ggica(ag)tg(ct)ggi(ta)(cg)itg(ct)tgg 4 Cysteine Protease - antisense taiccicc(ag)tt(ag)caicc(ct)tc 5 Metallo Protease - sense cci(ac)gitg(tc)ggi(ga)(ta)icciga 6 Metallo Protease - antisense tt(ag)tgicciai(ct)tc(ag)tg 7 Specific Primers: Serine Protease (hepsin) = sense tgtcccgatggcgagtgttt 8 Serine Protease (hepsin) = antisense cctgttggccatagtactgc Serine Protease (SCCE) = sense agatgaatgagtacaccgtg 10 Serine Protease (SCCE) = antisense ccagtaagtccttgtaaacc 11 Serine Protease (Comp B) = sense aagggacacgagagctgtat 12 Serine Protease (Comp B) = antisense aagtggtagttggaggaagc 13 Serine Protease (Protease M) = sense ctgtgatccaccctgactat 20 Serine Protease (Protease M) = antisense caggtggatgtatgcacact 21 Serine Protease (TADG12) = sense (Ser10-s) gcgcactgtgtttatgagat 22 Serine Protease (TADG12) = antisense (Ser10-as) ctctttggcttgtacttgct 23 Serine Protease (TADG13) = sense tgagggacatcattatgcac 24 Serine Protease (TADG13) = antisense caagttttccccataattgg 25 Serine Protease (TADG14) = sense acagtacgcctgggagacca 26 Serine Protease (TADG14) = antisense ctgagacggtgcaattctgg 27 Cysteine Protease (Cath-L) = sense attggagagagaaaggctac 14 Cysteine Protease (Cath-L) = antisense cttgggattgtacttacagg 15 Metallo Protease (PUMP1) = sense cttccaaagtggtcacctac 16 Metallo Protease (PUMP1) = antisense ctagactgctaccatccgtc 17
EXAMPLE 2
[0077] Carcinoma Tissue
[0078] Several protease entities were identified and subcloned from PCR amplification of cDNA derived from serous cystadenocarcinomas. Therefore, the proteases described herein are reflective of surface activities for this type of carcinoma, the most common form of ovarian cancer. Applicant also shows PCR amplification bands of similar base pair size unique to the mucinous tumor type and the clear cell type. About 20-25% of ovarian cancers are classified as either mucinous, clear cell, or endometrioid.
EXAMPLE 3
[0079] Ligation, Transformation And Sequencing
[0080] To determine the identity of the PCR products, all the appropriate bands were ligated into Promega T-vector plasmid and the ligation product was used to transform JM109 cells (Promega) grown on selective media. After selection and culturing of individual colonies, plasmid DNA was isolated by means of the WIZARD MINIPREP™ DNA purification system (Promega). Inserts were sequenced using a Prism Ready Reaction Dydeoxy Terminators cycle sequencing kit (Applied Biosystems). Residual dye terminators were removed from the completed sequencing reaction using a CENTRISEP SPIN™ column (Princeton Separation), and samples were loaded into an Applied Biosystems Model 373A DNA sequencing system. The results of subcloning and sequencing for the serine protease primers are summarized in Table 3.
TABLE 3 Serine protease candidates Subclone Primer Set Gene Candidate 1 His-Ser Hepsin 2 His-Ser SCCE 3 His-Ser Compliment B 4 His-Asp Cofactor 1 5 His-Asp TADG-12* 6 His-Ser TADG-13* 7 His-Ser TADG-14* 8 His-Ser Protease M 9 His-Ser TADG-15*
EXAMPLE 4
[0081] Cloning And Characterization
[0082] Cloning and characterization of new gene candidates was undertaken to expand the panel representative of extracellular proteases specific for ovarian carcinoma subtypes. Sequencing of the PCR products derived from tumor cDNA confirms the potential candidacy of these genes. The three novel genes all have conserved residues within the catalytic triad sequence consistent with their membership in the serine protease family.
[0083] Applicant compared the PCR products amplified from normal and carcinoma cDNAs using sense-histidine and antisense-aspartate as well as sense-histidine and antisense-serine. The anticipated PCR products of approximately 200 bp and 500 bp for those pairs of primers were observed (aspartate is approximately 50-70 amino acids downstream from histidine, and serine is about 100-150 amino acids toward the carboxy end from histidine).
[0084] [0084]FIG. 1 shows a comparison of PCR products derived from normal and carcinoma cDNA as shown by staining in an agarose gel. Two distinct bands in Lane 2 were present in the primer pair sense-His/antisense ASP (AS1) and multiple bands of about 500 bp are noted in the carcinoma lane for the sense-His/antisense-Ser (AS2) primer pairs in Lane 4.
EXAMPLE 5
[0085] Quantitative PCR
[0086] The mRNA overexpression of hepsin was detected and determined using quantitative PCR. Quantitative PCR was performed generally according to the method of Noonan et al. [ Proc. Natl. Acad. Sci. USA, 87:7160-7164 (1990)]. The following oligonucleotide primers were used: hepsin:
[0087] forward 5′-TGTCCCGATGGCGAGTGTTT-3′ (SEQ ID No. 8), and
[0088] reverse 5′-CCTGTTGGCCATAGTACTGC-3′ (SEQ ID No. 9); and β-tubulin:
[0089] forward 5′-TGCATTGACAACGAGGC -3′ (SEQ ID No. 18), and
[0090] reverse 5′-CTGTCTTGA CATTGTTG -3′ (SEQ ID No. 19).
[0091] β-tubulin was utilized as an internal control. The predicted sizes of the amplified genes were 282 bp for hepsin and 454 bp for β-tubulin. The primer sequences used in this study were designed according to the cDNA sequences described by Leytus et al. [ Biochemistry, 27, 1067-1074 (1988)] for hepsin, and Hall et al. [ Mol. Cell. Biol., 3, 854-862 (1983)] for β-tubulin. The PCR reaction mixture consisted of cDNA derived from 50 ng of mRNA converted by conventional techniques, 5 pmol of sense and antisense primers for both the hepsin gene and the β-tubulin gene, 200 μmol of dNTPs, 5 μCi of α- 32 PdCTP and 0.25 units of Taq DNA polymerase with reaction buffer (Promega) in a final volume of 25 μl. The target sequences were amplified in parallel with the β-tubulin gene. Thirty cycles of PCR were carried out in a Thermal Cycler (Perkin-Elmer Cetus). Each cycle of PCR included 30 sec of denaturation at 95° C., 30 sec of annealing at 63° C. and 30 sec of extension at 72° C. The PCR products were separated on 2% agarose gels and the radioactivity of each PCR product was determined by using a Phosphorlmager™ (Molecular Dynamics). Student's t test was used for comparison of mean values.
[0092] Experiments comparing PCR amplification in normal ovary and ovarian carcinoma suggested overexpression and/or alteration in mRNA transcript in tumor tissues. Northern blot analysis of TADG-14 confirms a transcript size of 1.4 kb and data indicate overexpression in ovarian carcinoma (FIG. 2). Isolation and purification using both PCR and a specific 250 bp PCR product to screen positive plaques yielded a 1.2 kb clone of TADG-14. Other proteases were amplified by the same method using the appropriate primers from Table 2.
EXAMPLE 6
[0093] Tissue Bank
[0094] A tumor tissue bank of fresh frozen tissue of ovarian carcinomas as shown in Table 4 was used for evaluation. Approximately 100 normal ovaries removed for medical reasons other than malignancy were obtained from surgery and were available as controls.
TABLE 4 Ovarian cancer tissue bank Total Stage I/11 Stage III/IV No Stage Serous Malignant 166 15 140 8 LMP 16 9 7 0 Benign 12 0 0 12 Mucinous Malignant 26 6 14 6 LMP 28 25 3 0 Benign 3 0 0 3 Endometrioid Malignant 38 17 21 0 LMP 2 2 0 0 Benign 0 0 0 0 Other* Malignant 61 23 29 9 LMP 0 0 0 0 Benign 5 0 0 5
[0095] From the tumor bank, approximately 100 carcinomas were evaluated encompassing most histological sub-types of ovarian carcinoma, including borderline or low-malignant potential tumors and overt carcinomas. The approach included using mRNA prepared from fresh frozen tissue (both normal and malignant) to compare expression of genes in normal, low malignant potential tumors and overt carcinomas. The cDNA prepared from polyA+mRNA was deemed to be genomic DNA-free by checking all preparations with primers that encompassed a known intron-exon splice site using both β-tubulin and p53 primers.
EXAMPLE 7
[0096] Northern Blots Analysis
[0097] Significant information can be obtained by examining the expression of these candidate genes by Northern blot. Analysis of normal adult multi-tissue blots offers the opportunity to identify normal tissues which may express the protease. Ultimately, if strategies for inhibition of proteases for therapeutic intervention are to be developed, it is essential to appreciate the expression of these genes in normal tissues.
[0098] Significant information is expected from Northern blot analysis of fetal tissue. Genes overexpressed in carcinomas are often highly expressed in organogenesis. As indicated, the hepsin gene cloned from hepatoma cells and overexpressed in ovarian carcinoma is overtly expressed in fetal liver. Hepsin gene expression was also detected in fetal kidney, and therefore, could be a candidate for expression in renal carcinomas.
[0099] Northern panels for examining expression of genes in a multi-tissue normal adult as well as fetal tissue are commercially available (CLONTECH). Such evaluation tools are not only important to confirm the overexpression of individual transcripts in tumor versus normal tissues, but also provides the opportunity to confirm transcript size, and to determine if alternate splicing or other transcript alteration may occur in ovarian carcinoma.
[0100] Northern blot analysis was performed as follows: 10 μg of mRNA was loaded onto a 1% formaldehyde-agarose gel, electrophoresed and blotted onto a HyBond-N + ™ nylon membrane (Amersham). 32 P-labeled cDNA probes were made using Prime-a-Gene Labeling System™ (Promega). The PCR products amplified by specific primers were used as probes. Blots were prehybridized for 30 min and then hybridized for 60 min at 68° C. with 32 P-labeled cDNA probe in ExpressHyb™ Hybridization Solution (CLONTECH). Control hybridization to determine relative gel loading was accomplished using the β-tubulin probe.
[0101] Normal human tissues including spleen, thymus, prostate, testis, ovary, small intestine, colon, peripheral blood leukocyte, heart, brain, placenta, lung, liver, skeletal muscle, kidney, pancreas and normal human fetal tissues (Human Multiple Tissue Northern Blot; CLONTECH) were all examined using the same hybridization procedure.
EXAMPLE 8
[0102] PCR Products Corresponding To Serine, Cysteine And Metallo-Proteases
[0103] Based on their unique expression in either low malignant potential tumors or carcinomas, PCR-amplified cDNA products were cloned and sequenced and the appropriate gene identified based upon nucleotide and amino acid sequences stored in the GCG and EST databases. FIGS. 3, 4 & 5 show the PCR product displays comparing normal and carcinomatous tissues using redundant primers for serine proteases (FIG. 3), for cysteine proteases (FIG. 4) and for metallo-proteases (FIG. 5). Note the differential expression in the carcinoma tissues versus the normal tissues. The proteases were identified using redundant cDNA primers (see Table 2) directed towards conserved sequences that are associated with intrinsic enzyme activity (for serine proteases, cysteine proteases and metallo-proteases) by comparing mRNA expression in normal, low malignant potential and overt ovarian carcinoma tissues according to Sakanari et al. [ Biochemistry 86, 4863-4867 (1989)].
EXAMPLE 9
[0104] Serine Proteases
[0105] For the serine protease group, using the histidine domain primer sense, S1, in combination with antisense primer AS2, the following proteases were identified:
[0106] (a) Hepsin, a trypsin-like serine protease cloned from hepatoma cells shown to be a cell surface protease essential for the growth of hepatoma cells in culture and highly expressed in hepatoma tumor cells (FIG. 3, Lane 4);
[0107] (b) Complement factor B protease (human factor IX), a protease involved in the coagulation cascade and associated with the production and accumulation of fibrin split products associated with tumor cells (FIG. 3, Lane 4). Compliment factor B belongs in the family of coagulation factors X (Christmas factor). As part of the intrinsic pathway, compliment factor B catalyzes the proteolytic activation of coagulation factor X in the presence of Ca 2+ phospholipid and factor VIIIa e5; and
[0108] (c) A stratum corneum chymotryptic enzyme (SCCE) serine protease involved in desquarnation of skin cells from the human stratum corneum (FIG. 3, Lane 4). SCCE is expressed in keratinocytes of the epidermis and functions to degrade the cohesive structures in the cornified layer to allow continuous skin surface shedding.
EXAMPLE 10
[0109] Cysteine Proteases
[0110] In the cysteine protease group, using redundant sense and anti-sense primers for cysteine proteases, one unique PCR product was identified by overexpression in ovarian carcinoma when compared to normal ovarian tissue (FIG. 4, Lanes 3-5). Cloning and sequencing this PCR product identified a sequence of Cathepsin L, which is a lysomal cysteine protease whose expression and secretion is induced by malignant transformation, growth factors and tumor promoters. Many human tumors (including ovarian) express high levels of Cathepsin L. Cathepsin L cysteine protease belongs in the stromolysin family and has potent elastase and collagenase activities. Published data indicates increased levels in the serum of patients with mucinous cystadenocarcinoma of the ovary. It has not heretofore been shown to be expressed in other ovarian tumors.
EXAMPLE 11
[0111] Metallo-Proteases
[0112] Using redundant sense and anti-sense primers for the metallo-protease group, one unique PCR product was detected in the tumor tissue which was absent in normal ovarian tissue (FIG. 5, Lanes 2-5). Subcloning and sequencing this product indicates it has complete homology in the appropriate region with the so-called PUMP-1 (MMP-7) gene. This zinc-binding metallo-protease is expressed as a proenzyme with a signal sequence and is active in gelatin and collagenase digestion. PUMP-1 has also been shown to be induced and overexpressed in 9 of 10 colorectal carcinomas compared to normal colon tissue, suggesting a role for this substrate in the progression of this disease.
EXAMPLE 12
[0113] Expression Of Hepsin
[0114] The expression of the serine protease hepsin gene in 8 normal, 11 low malignant potential tumors, and 14 carcinoma (both mucinous and serous type) by quantitative PCR using hepsin-specific primers (see Table 2) was determined (primers directed toward the β-tubulin message were used as an internal standard) (Table 5). These data confirm the overexpression of the hepsin surface protease gene in ovarian carcinoma, including both low malignant potential tumors and overt carcinoma. Expression of hepsin is increased over normal levels in low malignant potential tumors, and high stage tumors (Stage III) of this group have higher expression of hepsin when compared to low stage tumors (Stage 1) (Table 6). In overt carcinoma, serous tumors exhibit the highest levels of hepsin expression, while mucinous tumors express levels of hepsin comparable with the high stage low malignant potential group (FIGS. 6 & 7).
TABLE 5 Patient Characteristics and Expression of Hepsin Gene mRNA expression of Case Histological type a Stage/Grade LN b hepsin c 1 normal ovary n 2 normal ovary n 3 normal ovary n 4 normal ovary n 5 normal ovary n 6 normal ovary n 7 normal ovary n 8 normal ovary n 9 normal ovary n 10 normal ovary n 11 S adenoma (LMP) 1/1 N 4+ 12 S adenoma (LMP) 1/1 NE 4+ 13 S adenoma (LMP) 1/1 NE n 14 S adenoma (LMP) 1/1 N 2+ 15 S adenoma (LMP) 3/1 P 4+ 16 S adenoma (LMP) 3/1 P 4+ 17 S adenoma (LMP) 3/1 P 4+ 18 M adenoma (LMP) 1/1 NE 4+ 19 M adenoma (LMP) 1/1 N n 20 M adenoma (LMP) 1/1 N n 21 M adenoma (LMP) 1/1 N n 22 M adenoma (LMP) 1/1 NE n 23 S carcinoma 1/2 N 4+ 24 S carcinoma 1/3 N 4+ 25 S carcinoma 3/1 NE 2+ 26 S carcinoma 3/2 NE 4+ 27 S carcinoma 3/2 P 4+ 28 S carcinoma 3/2 NE 2+ 29 S carcinoma 3/3 NE 2+ 30 S carcinoma 3/3 NE 4+ 31 S carcinoma 3/3 NE 4+ 32 S carcinoma 3/3 NE 4+ 33 S carcinoma 3/3 N 4+ 34 S carcinoma 3/3 NE n 35 S carcinoma 3/3 NE 4+ 36 S carcinoma 3/3 NE 4+ 37 S carcinoma 3/3 NE 4+ 38 S carcinoma 3/3 N 4+ 39 S carcinoma 3/2 NE 2+ 40 S carcinoma 3/3 NE 4+ 41 S carcinoma 3/2 NE 4+ 42 M carcinoma 1/2 N n 43 M carcinoma 2/2 NE 4+ 44 M carcinoma 2/2 N 4+ 45 M carcinoma 3/1 NE n 46 M carcinoma 3/2 NE 4+ 47 M carcinoma 3/2 NE n 48 M carcinoma 3/3 NE n 49 E carcinoma 2/3 N 4+ 50 E carcinoma 3/2 NE 4+ 51 E carcinoma 3/3 NE 4+ 52 C carcinoma 1/3 N 4+ 53 C carcinoma 1/1 N 4+ 54 C carcinoma 3/2 P 4+
[0115] [0115] TABLE 6 Overexpression of hepsin in normal ovaries and ovarian tumors Ratio of Hepsin Hepsin Type N Overexpression to β-tubulin Normal 10 0 (0%) 0.06 ± 0.05 LMP 12 7 (58.3%) 0.26 ± 0.19 Serous 7 6 (85.7%) 0.34 ± 0.20 Mucinous 5 1 (20.0%) 0.14 ± 0.12 Carcinomous 32 27 (84.4%) 0.46 ± 0.29 Serous 19 18 (94.7%) 0.56 ± 0.32 Mucinous 7 3 (42.9%) 0.26 ± 0.22 Endometrioid 3 3 (100%) 0.34 ± 0.01 Clear Cell 3 3 (100%) 0.45 ± 0.08
EXAMPLE 13
[0116] Expression of SCCE and PUMP-1
[0117] Studies using both SCCE-specific primers (FIG. 8) and PUMP-specific primers (FIG. 9) indicate overexpression of these proteases in ovarian carcinomas.
EXAMPLE 14
[0118] Summary Of Proteases Detected Herein
[0119] Most of the proteases described herein were identified from the sense-His/antisense-Ser primer pair, yielding a 500 bp PCR product (FIG. 1, Lane 4). Some of the enzymes are familiar, a short summary of each follows.
[0120] Hepsin
[0121] Hepsin is a trypsin-like serine protease cloned from hepatoma cells. Hepsin is an extracellular protease (the enzyme includes a secretion signal sequence) which is anchored in the plasma membrane by its amino terminal domain, thereby exposing its catalytic domain to the extracellular matrix. Hepsin has also been shown to be expressed in breast cancer cell lines and peripheral nerve cells. Hepsin has never before been associated with ovarian carcinoma. Specific primers for the hepsin gene were synthesized and the expression of hepsin examined using Northern blots of fetal tissue and ovarian tissue (both normal and ovarian carcinoma).
[0122] [0122]FIG. 10A shows that hepsin was expressed in ovarian carcinomas of different histologic types, but not in normal ovary. FIG. 10B shows that hepsin was expressed in fetal liver and fetal kidney as anticipated, but at very low levels or not at all in fetal brain and lung. FIG. 10C shows that hepsin overexpression is not observed in normal adult tissue. Slight expression above the background level is observed in the adult prostate. The mRNA identified in both Northern blots was the appropriate size for the hepsin transcript. The expression of hepsin was examined in 10 normal ovaries and 44 ovarian tumors using specific primers to β-tubulin and hepsin in a quantitative PCR assay, and found it to be linear over 35 cycles. Expression is presented as the ratio of 32 p-hepsin band to the internal control, the 32 P-β-tubulin band.
[0123] Hepsin expression was investigated in normal (N), mucinous (M) and serous (S) low malignant potential (LMP) tumors and carcinomas (CA). FIG. 11A shows quantitative PCR of hepsin and internal control β-tubulin. FIG. 11B shows the ratio of hepsin:β-tubulin expression in normal ovary, LMP tumor, and ovarian carcinoma. It was observed that Hepsin mRNA expression levels were significantly elevated in LMP tumors, (p<0.005) and carcinomas (p<0.0001) compared to levels in normal ovary. All 10 cases of normal ovaries showed a relatively low level of hepsin mRNA expression.
[0124] Hepsin mRNA is highly overexpressed in most histopathologic types of ovarian carcinomas including some low malignant potential tumors (see FIGS. 11A & 11B). Most noticeably, hepsin is highly expressed in serous, endometrioid and clear cell tumors tested. It is highly expressed in some mucinous tumors, but it is not overexpressed in the majority of such tumors.
[0125] Stratum Corneum Chymotrypsin Enzyme (SCCE)
[0126] The PCR product identified was the catalytic domain of the sense-His/antisense-Ser of the stratum corneum chymotrypsin enzyme. This extracellular protease was cloned, sequenced and shown to be expressed on the surface of keratinocytes in the epidermis. Stratum corneum chymotrypsin enzyme is a chymotrypsin-like serine protease whose function is suggested to be in the catalytic degradation of intercellular cohesive structures in the stratum corneum layer of the skin. This degradation allows continuous shedding (desquamation) of cells from the skin surface. The subcellular localization of stratum corneum chymotrypsin enzyme is in the upper granular layer in the stratum corneum of normal non-palmoplantar skin and in the cohesive parts of hypertrophic plantar stratum corneum. Stratum corneum chymotrypsin enzyme is exclusively associated with the stratum corneum and has not so far been shown to be expressed in any carcinomatous tissues.
[0127] Northern blots were probed with the PCR product to determine expression of stratum corneum chymotrypsin enzyme in fetal tissue and ovarian carcinoma (FIGS. 12A & 12B). Noticeably, detection of stratum corneum chymotrypsin enzyme messenger RNA on the fetal Northern was almost non-existent (a problem with the probe or the blot was excluded by performing the proper controls). A faint band appeared in fetal kidney. On the other hand, stratum corneum chymotrypsin enzyme mRNA is abundant in the ovarian carcinoma mRNA (FIG. 12B). Two transcripts of the correct size are observed for stratum corneum chymotrypsin enzyme. The same panel of cDNA used for hepsin analysis was used for stratum corneum chymotrypsin enzyme expression.
[0128] No stratum corneum chymotrypsin enzyme expression was detected in the normal ovary lane of the Northern blot. A comparison of all candidate genes, including a loading marker (β-tubulin), was shown to confirm that this observation was not a result of a loading bias. Quantitative PCR using stratum corneum chymotrypsin enzyme primers, along with β-tubulin internal control primers, confirmed the overexpression of stratum corneum chymotrypsin enzyme mRNA in carcinoma of the ovary with no expression in normal ovarian tissue (FIG. 13).
[0129] [0129]FIG. 13A shows a comparison using quantitative PCR of stratum corneum chymotrypsin enzyme cDNA from normal ovary and ovarian carcinomas. FIG. 13B shows the ratio of stratum corneum chymotrypsin enzyme to the β-tubulin internal standard in 10 normal and 44 ovarian carcinoma tissues. Again, it is observed that stratum corneum chymotrypsin enzyme is highly overexpressed in ovarian carcinoma cells. It is also noted that some mucinous tumors overexpress stratum corneum chymotrypsin enzyme, but the majority do not.
[0130] Protease M
[0131] Protease M was identified from subclones of the His—ser primer pair. This protease was first cloned by Anisowicz, et al., [ Molecular Medicine, 2, 624-636 (1996)] and shown to be overexpressed in carcinomas. A preliminary evaluation indicates that this enzyme is overexpressed in ovarian carcinoma (FIG. 14).
[0132] Cofactor I and Complement Factor B
[0133] Several serine proteases associated with the coagulation pathway were also subcloned. Examination of normal and ovarian carcinomas by quantitative PCR for expression of these enzymes, it was noticeable that this mRNA was not clearly overexpressed in ovarian carcinomas when compared to normal ovarian tissue. It should be noted that the same panel of tumors was used for the evaluation of each candidate protease.
EXAMPLE 15
[0134] Summary Of Previously Unknown Proteases Detected Herein TADG-12
[0135] TADG-12 was identified from the primer pairs, sense-His/antisense-Asp (see FIG. 1, Lanes 1 & 2). Upon subcloning both PCR products in lane 2, the 200 bp product had a unique protease-like sequence not included in GenBank. This 200 bp product contains many of the conserved amino acids common for the His-Asp domain of the family of serine proteins. The second and larger PCR product (300 bp) was shown to have a high degree of homology with TADG-12 (His-Asp sequence), but also contained approximately 100 bp of unique sequence. Synthesis of specific primers and the sequencing of the subsequent PCR products from three different tumors demonstrated that the larger PCR product (present in about 50% of ovarian carcinomas) includes an insert of about 100 bp near the 5′ end (and near the histidine) of the sequence. This insert may be a retained genomic intron because of the appropriate position of splice sites and the fact that the insert does not contain an open reading frame (see FIG. 15). This suggests the possibility of a splice site mutation which gives rise to retention of the intron, or a translocation of a sequence into the TADG-12 gene in as many as half of all ovarian carcinomas.
[0136] TADG-13 and TADG-14
[0137] Specific primers were synthesized for TADG-13 and TADG-14 to evaluate expression of genes in normal and ovarian carcinoma tissue. Northern blot analysis of ovarian tissues indicates the transcript for the TADG-14 gene is approximately 1.4 kb and is expressed in ovarian carcinoma tissues (FIG. 16A) with no noticeable transcript presence in normal tissue. In quantitative PCR studies using specific primers, increased expression of TADG-14 in ovarian carcinoma tissues was noted compared to a normal ovary (FIG. 16B). The presence of a specific PCR product for TADG-14 in both an HeLa library and an ovarian carcinoma library was also confirmed. Several candidate sequences corresponding to TADG-14 have been screened and isolated from the HeLa library.
[0138] Clearly from sequence homology, these genes fit into the family of serine proteases. TADG-13 and -14 are, however, heretofore undocumented genes which the specific primers of the invention allow to be evaluated in normal and tumor cells, and with which the presence or absence of expression of these genes is useful in the diagnosis or treatment selection for specific tumor types.
[0139] PUMP-1
[0140] In a similar strategy using redundant primers to metal binding domains and conserved histidine domains, a differentially expressed PCR product identical to matrix metallo-protease 7 (MMP-7) was identified, herein called PUMP-1. Using specific primers for PUMP-1, PCR produced a 250 bp product for Northern blot analysis.
[0141] PUMP-1 is differentially expressed in fetal lung and kidney tissues. FIG. 17A shows the expression of PUMP-1 in human fetal tissue, while no transcript could be detected in either fetal brain or fetal liver. FIG. 17B compares PUMP-1 expression in normal ovary and carcinoma subtypes using Northern blot analysis. Notably, PUMP-1 is expressed in ovarian carcinoma tissues, and again, the presence of a transcript in normal tissue was not detected. Quantitative PCR comparing normal versus ovarian carcinoma expression of the PUMP-1 mRNA indicates that this gene is highly expressed in serous carcinomas, including most low malignant serous tumors, and is, again, expressed to a lesser extent in mucinous tumors (see FIGS. 18A & 18B). PUMP-1, however, is so far the protease most frequently found overexpressed in mucinous tumors (See Table 7).
[0142] Cathepsin-L
[0143] Using redundant cysteine protease primers to conserved domains surrounding individual cysteine and histidine residues, the cathepsin-L protease was identified in several serous carcinomas. An initial examination of the expression of cathepsin L in normal and ovarian tumor tissue indicates that transcripts for the cathepsin-L protease are present in both normal and tumor tissues (FIG. 19). However, its presence or absence in combination with other proteases of the present invention permits identification of specific tumor types and treatment choices.
[0144] Discussion
[0145] Redundant primers to conserved domains of serine, metallo-, and cysteine proteases have yielded a set of genes whose mRNAs are overexpressed in ovarian carcinoma. The genes which are clearly overexpressed include the serine proteases hepsin, stratum corneum chymotrypsin enzyme, protease M TADG12, TADG14 and the metallo-protease PUMP-1 (see FIG. 19 and Table 7). Northern blot analysis of normal and ovarian carcinoma tissues, summarized in FIG. 14, indicated overexpression of hepsin, stratum corneum chymotrypsin enzyme, PUMP-1 and TADG-14. A β-tubulin probe to control for loading levels was included.
TABLE 7 Overexpression of Proteases in Ovarian Tumors Type N Hepsin SCCE Pump-1 Protease M Normal 10 0% (0/10) 0% (0/10) 0% (0/10) 0% (0/10) LMP 12 58.3% (7/12) 66.7% (8/12) 75.0% (9/12) 75% (9/12) serous 7 85.7% (6/7) 85.7% (6/7) 85.7% (6/7) 100% (7/7) mucinous 5 20.0% (1/5) 40.0% (2/5) 60% (3/5) 40.0% (2/5) Carcinoma 32 84.4% (27/32) 78.1% (25/32) 81.3% (26/32) 90.6% (29/32) serous 19 94.7% (18/19) 89.5% (17/19) 78.9% (15/19) 94.7% (18/19) mucinous 7 42.9% (3/7) 28.6% (2/7) 71.4% (5/7) 85.7% (6/7) endometr. 3 100% (3/3) 100% (3/3) 100% (3/3) 100% (3/3) clear cell 3 100% (3/3) 100% (3/3) 100% (3/3) 67.7% (2/3)
[0146] For the most part, these proteins previously have not been associated with the extracellular matrix of ovarian carcinoma cells. No panel of proteases which might contribute to the growth, shedding, invasion and colony development of metastatic carcinoma has been previously described, including the three new candidate serine proteases which are herein disclosed. The establishment of an extracellular protease panel associated with either malignant growth or malignant potential offers the opportunity for the identification of diagnostic or prognostic markers and for therapeutic intervention through inhibition or down regulation of these proteases.
[0147] The availability of the instant gene-specific primers coding for the appropriate region of tumor specific proteases allows for the amplification of a specific cDNA probe using Northern and Southern analysis, and their use as markers to detect the presence of the cancer in tissue. The probes also allow more extensive evaluation of the expression of the gene in normal ovary versus low malignant potential tumor, as well as both high- and low-stage carcinomas. The evaluation of a panel of fresh frozen tissue from all the carcinoma subtypes (Table 4) allowed the determination of whether a protease is expressed predominantly in early stage disease or within specific carcinoma subtypes. It was also determined whether each gene's expression is confined to a particular stage in tumor progression and/or is associated with metastatic lesions. Detection of specific combinations of proteases is an identifying characteristic of the specific tumor types and yields valuable information for diagnoses and treatment selection. Particular tumor types may be more accurately diagnosed by the characteristic expression pattern of each specific tumor.
EXAMPLE 16
[0148] Hepsin Peptide Ranking
[0149] For vaccine or immune stimulation, individual 9-mers to 11-mers of the hepsin protein were examined to rank the binding of individual peptides to the top 8 haplotypes in the general population (Parker et al., (1994)). The computer program used for this analyses can be found on the web site of National Institutes of Health. Table 8 shows the peptide ranking based upon the predicted half-life of each peptide's binding to a particular HLA allele. A larger half-life indicates a stronger association with that peptide and the particular HLA molecule. The hepsin peptides that strongly bind to an HLA allele are putative immunogens, and are used to innoculate an individual against hepsin.
TABLE 8 Hepsin peptide ranking HLA Type Predicted SEQ & Ranking Start Peptide Dissociation ½ ID No. HLA A0201 1 170 SLGRWPWQV 521.640 28 2 191 SLLSGDWVL 243.051 29 3 229 GLQLGVQAV 159.970 30 4 392 KVSDFREWI 134.154 31 5 308 VLQEARVPI 72.717 32 6 130 RLLEVISVC 71.069 33 7 98 ALTHSELDV 69.552 34 8 211 VLSRWRVFA 46.451 35 9 26 LLLLTAIGA 31.249 36 10 284 ALVDGKICT 30.553 37 11 145 FLAAICQDC 22.853 38 12 192 LLSGDWVLT 21.536 39 13 20 ALTAGTLLL 21.362 40 14 259 ALVHLSSPL 21.362 41 15 277 CLPAAGQAL 21.362 42 16 230 LQLGVQAVV 18.186 43 17 268 PLTEYIQPV 14.429 44 18 31 AIGAASWAI 10.759 45 19 285 LVDGKICTV 9.518 46 20 27 LLLTAIGAA 9.343 47 HLA A0205 1 191 SLLSGDWVL 25.200 48 2 163 IVGGRDTSL 23.800 49 3 392 KVSDFREWI 18.000 50 4 64 MVFDKTEGT 15.300 51 5 236 AVVYHGGYL 14.000 52 6 55 QVSSADARL 14.000 53 7 130 RLLEVISVC 9.000 54 8 230 LQLGVQAVV 8.160 55 9 20 ALTAGTLLL 7.000 56 10 259 ALVHLSSPL 7.000 57 11 277 CLPAAGQAL 7.000 58 12 17 KVAALTAGT 6.000 59 13 285 LVDGKICTV 5.440 60 14 308 VLQEARVPI 5.100 61 15 27 LLLTAIGAA 5.100 62 16 229 GLQLGVQAV 4.000 63 17 313 RVPIISNDV 4.000 64 18 88 LSCEEMGFL 3.570 65 19 192 LLSGDWVLT 3.400 66 20 284 ALVDGKICT 3.000 67 HLA A1 1 89 SCEEMGFLR 45.000 68 2 58 SADARLMVF 25.000 69 3 393 VSDFREWIF 7.500 70 4 407 HSEASGMVT 6.750 71 5 137 VCDCPRGRF 5.000 72 6 269 LTEYIQPVC 4.500 73 7 47 DQEPLYPVQ 2.700 74 8 119 CVDEGRLPH 2.500 75 9 68 KTEGTWRLL 2.250 76 10 101 HSELDVRTA 1.350 77 11 250 NSEENSNDI 1.350 78 12 293 VTGWGNTQY 1.250 79 13 231 QLGVQAVVY 1.000 80 14 103 ELDVRTAGA 1.000 81 15 378 GTGCALAQK 1.000 82 16 358 VCEDSISRT 0.900 83 17 264 SSPLPLTEY 0.750 84 18 87 GLSCEEMGF 0.500 85 19 272 YIQPVCLPA 0.500 86 20 345 GIDACQGDS 0.500 87 HLA A24 1 301 YYGQQAGVL 200.000 88 2 238 VYHGGYLPF 100.000 89 3 204 CFPERNRVL 36.000 90 4 117 FFCVDEGRL 20.000 91 5 124 RLPHTQRLL 12.000 92 6 80 RSNARVAGL 12.000 93 7 68 KTEGTWRLL 12.000 94 8 340 GYPEGGIDA 9.000 95 9 242 GYLPFRDPN 9.000 96 10 51 LYPVQVSSA 7.500 97 11 259 ALVHLSSPL 7.200 98 12 277 CLPAAGQAL 7.200 99 13 191 SLLSGDWVL 6.000 100 14 210 RVLSRWRVF 6.000 101 15 222 VAQASPHGL 6.000 102 16 236 AVVYHGGYL 6.000 103 17 19 AALTAGTLL 6.000 104 18 36 SWAIVAVLL 5.600 105 19 35 ASWAIVAVL 5.600 106 20 300 QYYGQQAGV 5.600 107 HLA B7 1 363 ISRTPRWRL 90.000 108 2 366 TPRWRLCGI 80.000 109 3 236 AVVYHGGYL 60.000 110 4 13 CSRPKVAAL 40.000 111 5 179 SLRYDGAHL 40.000 112 6 43 LLRSDQEPL 40.000 113 7 19 AALTAGTLL 36.000 114 8 55 QVSSADARL 20.000 115 9 163 IVGGRDTSL 20.000 116 10 140 CPRGRFLAA 20.000 117 11 20 ALTAGTLLL 12.000 118 12 409 EASGMVTQL 12.000 119 13 259 ALVHLSSPL 12.000 120 14 35 ASWAIVAVL 12.000 121 15 184 GAHLCGGSL 12.000 122 16 18 VAALTAGTL 12.000 123 17 222 VAQASPHGL 12.000 124 18 224 QASPHGLQL 12.000 125 19 265 SPLPLTEYI 8.000 126 20 355 GPFVCEDSI 8.00 127 HLA B8 1 13 CSRPKVAAL 80.000 128 2 366 TPRWRLCGI 80.000 129 3 140 CPRGRFLAA 16.000 130 4 152 DCGRRKLPV 4.800 131 5 363 ISRTPRWRL 4.000 132 6 163 IVGGRDTSL 4.000 133 7 331 QJKPKMFCA 4.000 134 8 80 RSNARVAGL 2.000 135 9 179 SLRYDGAHL 1.600 136 10 43 LLRSDQEPL 1.600 137 11 409 EASGMVTQL 1.600 138 12 311 EARVPIISN 0.800 139 13 222 VAQASPHGL 0.800 140 14 19 AALTAGTLL 0.800 141 15 18 VAALTAGTL 0.800 142 16 184 GAHLCGGSL 0.800 143 17 224 QASPHGLQL 0.800 144 18 82 NARVAGLSC 0.800 145 19 204 CFPERNRVL 0.600 146 20 212 LSRWRVFAG 0.400 147 HLA B2702 1 172 GRWPWQVSL 300.000 148 2 44 LRSDQEPLY 200.00 149 3 155 RRKLPVDRI 180.000 150 4 213 SRWRVFAGA 100.000 151 5 166 GRDTSLGRW 100.000 152 6 369 WRLCGIVSW 100.000 153 7 180 LRYDGAHLC 100.000 154 8 96 LRALTHSEL 60.000 155 9 396 FREWIFQAI 60.000 156 10 123 GRLPHTQRL 60.000 157 11 207 ERNRVLSRW 30.000 158 12 209 NRVLSRWRV 20.000 159 13 14 SRPKVAALT 20.000 160 14 106 VRTAGANGT 20.000 161 15 129 QRLLEVISV 20.000 162 16 349 CQGDSGGPF 20.000 163 17 61 ARLMVFDKT 20.000 164 18 215 WRYFAGAVA 20.000 165 19 143 GRFLAAICQ 10.000 166 20 246 FRDPNSEEN 10.000 167 HLA B4403 1 132 LEVISVCDC 36.000 168 2 91 EEMGFLRAL 18.000 169 3 264 SSPLPLTEY 13.500 170 4 310 QEARVPIIS 12.000 171 5 319 NDVCNGADF 10.000 172 6 4 KEGGRTVPC 9.000 173 7 251 SEENSNDIA 8.000 174 8 256 NDIALVHLS 7.500 175 9 294 TGWGNTQYY 6.750 176 10 361 DSISRTPRW 6.750 177 11 235 QAVVYHGGY 6.000 178 12 109 AGANGTSGF 6.000 179 13 270 TEYIQPVCL 6.000 180 14 174 WPWQVSLRY 4.500 181 15 293 VTGWGNTQY 4.500 182 16 69 TEGTWRLLC 4.000 183 17 90 CEEMGFLRA 4.000 184 18 252 EENSNDIAL 4.000 185 19 48 QEPLYPVQV 4.000 186 20 102 SELDVRTAG 3.600 187
EXAMPLE 17
[0150] Hepsin Peptides as Target Epitopes For Human CD8 + Cytotoxic T Cells
[0151] Two computer programs were used to identify 9-mer peptides containing binding motifs for HLA class I molecules. The first, based on a scheme devised by Parker et al (1994), was developed by the Bioinformatics and Molecular Analysis Section (BIMAS) of the Center for Information Technology, NIH, and the second, known as SYFPEITHI, was formulated by Rammensee and colleagues at the University of Tubingen, Germany.
[0152] Peptides that possessed HLA A2.1 binding motifs were synthesized and tested directly for their ability to bind HLA A2.1. This technique employs T2 cells which are peptide transporter-deficient and thus express low endogenous HLA class I levels due to inability to load peptide and stabilize HLA class I folding for surface expression. It has been showed that addition of exogenous peptides capable of binding HLA A2.1 (A*0201) could increase the number of properly folded HLA A2.1 molecules on the cell surface, as revealed by flow cytometry (Nijman et al, 1993).
[0153] Peptides that possessed binding motifs for HLA class I molecules other than A2.1 were tested directly for their ability to induce specific CD8 + CTL responses from normal adult donors as described below.
[0154] Monocyte-derived dendritic cells were generated from peripheral blood drawn from normal adult donors of the appropriate HLA type. Adherent monocytes were cultured in AIM-V (Gibco-BRL) supplemented with GM-CSF and IL-4 according to standard techniques (Santin et al, 2000, 2001). After 5-6 days, dendritic cell maturation was induced by addition of PGE 2 , IL-1β and TNFα for a further 48 h.
[0155] Mature dendritic cells were loaded with peptide (2×10 6 dendritic cells with 50 μg/ml peptide in 1 ml serum-free AIM-V medium for 2 h at 37° C.) and washed once prior to culture with 1×10 6 /ml peripheral blood mononuclear cells (PBMC) in AIM-V or AIM-V plus 5% human AB serum. The PBMC:DC ratio was between 20:1 and 30:1. After 7 days, responder T cells were restimulated with peptide-loaded, irradiated autologous dendritic cells or peripheral blood mononuclear cells at responder:stimulator ratios between 10:1 and 20:1 or 1:1 and 1:10 respectively. At this point, cultures were supplemented with recombinant human IL-2 (10-100 U/ml), and fed with 50-75% changes of fresh medium plus IL-2 every 2-4 days. T cell lines were established and maintained by peptide restimulation every 14-21 days. Responder CD8 + T cells were purified by positive selection with anti-CD8-coupled magnetic beads (Dynal, Inc.) after the 2 nd or 3 rd antigen stimulation.
[0156] Peptide-specific cytotoxicity was tested in standard 5-6 h microwell 51 Cr-release assays (Nazaruk et al, 1998). Autologous EBV-transformed lymphoblastoid cell lines (LCL) were loaded with peptide (50 μg/ml, 1 h at 37° C.) and subsequently 51 Cr-labeled (50 μCi in 200-300 μl, 1 h at 37° C.). Peptide-loaded 51 Cr-labeled LCL were incubated with CD8 + T cells at effector-target ration between 5:1 and 1.25:1. Cytotoxicity was recorded as percentage 51 Cr released into culture supernatants.
[0157] Hepsin peptide 170-178 (SEQ ID No. 28) is an HLA A2.1-binding peptide, as revealed by upregulation of A2.1 expression in T2 cells (data not shown). CD8 + CTL specific for hepsin 170-178 killed peptide-loaded autologous lymphoblastoid cell lines, but did not kill control, peptide-free lymphoblastoid cell lines (FIG. 20). Heterologous HLA A2.1-expressing peptide-loaded lymphoblastoid cell lines were efficiently killed, but targets lacking HLA A2.1 were not killed. Natural killer-sensitive K562 cells were not lysed. Cytotoxicity against hepsin 170-178 loaded lymphoblastoid cell lines could be blocked with a monoclonal antibody specific for a non-polymorphic HLA class I determinant, confirming that lysis was HLA class I-restricted. Cytotoxicity was also blocked by MAb specific for HLA A2.1.
[0158] Hepsin peptide 172-180 (SEQ ID No. 148) was predicted by computer analysis to bind HLA B27. While this could not be demonstrated directly, cytotoxicity assays showed that CD8 + CIL specific for hepsin 172-180 could kill peptide-loaded, HLA B27-expressing autologous and heterologous lymphoblastoid cell lines, but failed to recognize heterologous peptide-loaded lymphoblastoid cell lines that did not express HLA B27.
[0159] CD8 + CTL specific for hepsin 172-180 killed peptide-loaded autologous lymphoblastoid cell lines, but did not kill peptide-free control lymphoblastoid cell lines (FIG. 21). Natural killer-sensitive K562 cells were not lysed. Cytotoxicity against hepsin 172-180 loaded lymphoblastoid cell lines could be blocked with MAb specific for a non-polymorphic HLA class I determinant, confirming that lysis was HLA class I-restricted.
[0160] Any patents or publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. Further, these patents and publications are incorporated by reference herein to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
[0161] One skilled in the art will appreciate readily that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those objects, ends and advantages inherent herein. The present examples, along with the methods, procedures, treatments, molecules, and specific compounds described herein are presently representative of preferred embodiments, are exemplary, and are not intended as limitations on the scope of the invention. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention as defined by the scope of the claims.
1
188
1
23
DNA
Artificial sequence
primer_bind
6, 9, 12, 15, 18
sense oligonucleotide primer for amplifying
serine proteases, n = Inosine
1
tgggtngtna cngcngcnca ytg 23
2
20
DNA
Artificial sequence
primer_bind
3, 6, 9, 12, 15, 18
antisense oligonucleotide primer for amplifying
serine proteases, n = Inosine
2
arnarngcna tntcnttncc 20
3
20
DNA
Artificial sequence
primer_bind
3, 6, 9, 12, 18
antisense oligonucleotide primer for amplifying
serine proteases, n = Inosine
3
arnggnccnc cnswrtcncc 20
4
24
DNA
Artificial sequence
primer_bind
6, 15, 18
sense oligonucleotide primer for amplifying
cysteine proteases, n = Inosine
4
carggncart gyggnwsntg ytgg 24
5
20
DNA
Artificial sequence
primer_bind
3, 6, 15
antisense oligonucleotide primer for amplifying
cysteine proteases, n = Inosine
5
tanccnccrt trcanccytc 20
6
20
DNA
Artificial sequence
primer_bind
3, 6, 12, 15, 18
sense oligonucleotide primer for amplifying
metallo-proteases, n = Inosine
6
ccnmgntgyg gnrwnccnga 20
7
17
DNA
Artificial sequence
primer_bind
6, 9, 11
antisense oligonucleotide primer for amplifying
metallo-proteases, n = Inosine
7
ttrtgnccna nytcrtg 17
8
20
DNA
Artificial sequence
sense oligonucleotide primer specific for
hepsin
8
tgtcccgatg gcgagtgttt 20
9
20
DNA
Artificial sequence
antisense oligonucleotide primer specific for
hepsin
9
cctgttggcc atagtactgc 20
10
20
DNA
Artificial sequence
sense oligonucleotide primer specific for SCCE
10
agatgaatga gtacaccgtg 20
11
20
DNA
Artificial sequence
antisense oligonucleotide primer specific for
SCCE
11
ccagtaagtc cttgtaaacc 20
12
20
DNA
Artificial sequence
sense oligonucleotide primer specific for CompB
12
aagggacacg agagctgtat 20
13
20
DNA
Artificial sequence
antisense oligonucleotide primer specific for
CompB
13
aagtggtagt tggaggaagc 20
14
20
DNA
Artificial sequence
sense oligonucleotide primer specific for
Cath-L
14
attggagaga gaaaggctac 20
15
20
DNA
Artificial sequence
antisense oligonucleotide primer specific for
Cath-L
15
cttgggattg tacttacagg 20
16
20
DNA
Artificial sequence
sense oligonucleotide primer specific for
PUMP-1
16
cttccaaagt ggtcacctac 20
17
20
DNA
Artificial sequence
antisense oligonucleotide primer specific for
PUMP-1
17
ctagactgct accatccgtc 20
18
17
DNA
Artificial sequence
sense oligonucleotide primer specific for
(-tubulin
18
tgcattgaca acgaggc 17
19
17
DNA
Artificial sequence
antisense oligonucleotide primer specific for
(-tubulin
19
ctgtcttgac attgttg 17
20
20
DNA
Artificial sequence
sense oligonucleotide primer specific for
Protease M
20
ctgtgatcca ccctgactat 20
21
20
DNA
Artificial sequence
antisense oligonucleotide primer specific for
Protease M
21
caggtggatg tatgcacact 20
22
20
DNA
Artificial sequence
sense oligonucleotide primer specific for
TADG-12
22
gcgcactgtg tttatgagat 20
23
20
DNA
Artificial sequence
antisense oligonucleotide primer specific for
TADG-12
23
ctctttggct tgtacttgct 20
24
20
DNA
Artificial sequence
sense oligonucleotide primer specific for
TADG-13
24
tgagggacat cattatgcac 20
25
20
DNA
Artificial sequence
antisense oligonucleotide primer specific for
TADG-13
25
caagttttcc ccataattgg 20
26
20
DNA
Artificial sequence
sense oligonucleotide primer specific for
TADG-14
26
acagtacgcc tgggagacca 20
27
20
DNA
Artificial sequence
antisense oligonucleotide primer specific for
TADG-14
27
ctgagacggt gcaattctgg 20
28
9
PRT
Homo sapiens
Residues 170-178 of the hepsin protein
28
Ser Leu Gly Arg Trp Pro Trp Gln Val
5
29
9
PRT
Homo sapiens
Residues 191-199 of the hepsin protein
29
Ser Leu Leu Ser Gly Asp Trp Val Leu
5
30
9
PRT
Homo sapiens
Residues 229-237 of the hepsin protein
30
Gly Leu Gln Leu Gly Val Gln Ala Val
5
31
9
PRT
Homo sapiens
Residues 392-400 of the hepsin protein
31
Lys Val Ser Asp Phe Arg Glu Trp Ile
5
32
9
PRT
Homo sapiens
Residues 308-316 of the hepsin protein
32
Val Leu Gln Glu Ala Arg Val Pro Ile
5
33
9
PRT
Homo sapiens
Residues 130-138 of the hepsin protein
33
Arg Leu Leu Glu Val Ile Ser Val Cys
5
34
9
PRT
Homo sapiens
Residues 98-106 of the hepsin protein
34
Ala Leu Thr His Ser Glu Leu Asp Val
5
35
9
PRT
Homo sapiens
Residues 211-219 of the hepsin protein
35
Val Leu Ser Arg Trp Arg Val Phe Ala
5
36
9
PRT
Homo sapiens
Residues 26-34 of the hepsin protein
36
Leu Leu Leu Leu Thr Ala Ile Gly Ala
5
37
9
PRT
Homo sapiens
Residues 284-292 of the hepsin protein
37
Ala Leu Val Asp Gly Lys Ile Cys Thr
5
38
9
PRT
Homo sapiens
Residues 145-153 of the hepsin protein
38
Phe Leu Ala Ala Ile Cys Gln Asp Cys
5
39
9
PRT
Homo sapiens
Residues 192-200 of the hepsin protein
39
Leu Leu Ser Gly Asp Trp Val Leu Thr
5
40
9
PRT
Homo sapiens
Residues 20-28 of the hepsin protein
40
Ala Leu Thr Ala Gly Thr Leu Leu Leu
5
41
9
PRT
Homo sapiens
Residues 259-267 of the hepsin protein
41
Ala Leu Val His Leu Ser Ser Pro Leu
5
42
9
PRT
Homo sapiens
Residues 277-285 of the hepsin protein
42
Cys Leu Pro Ala Ala Gly Gln Ala Leu
5
43
9
PRT
Homo sapiens
Residues 230-238 of the hepsin protein
43
Leu Gln Leu Gly Val Gln Ala Val Val
5
44
9
PRT
Homo sapiens
Residues 268-276 of the hepsin protein
44
Pro Leu Thr Glu Tyr Ile Gln Pro Val
5
45
9
PRT
Homo sapiens
Residues 31-39 of the hepsin protein
45
Ala Ile Gly Ala Ala Ser Trp Ala Ile
5
46
9
PRT
Homo sapiens
Residues 285-293 of the hepsin protein
46
Leu Val Asp Gly Lys Ile Cys Thr Val
5
47
9
PRT
Homo sapiens
Residues 27-35 of the hepsin protein
47
Leu Leu Leu Thr Ala Ile Gly Ala Ala
5
48
9
PRT
Homo sapiens
Residues 191-199 of the hepsin protein
48
Ser Leu Leu Ser Gly Asp Trp Val Leu
5
49
9
PRT
Homo sapiens
Residues 163-171 of the hepsin protein
49
Ile Val Gly Gly Arg Asp Thr Ser Leu
5
50
9
PRT
Homo sapiens
Residues 392-400 of the hepsin protein
50
Lys Val Ser Asp Phe Arg Glu Trp Ile
5
51
9
PRT
Homo sapiens
Residues 64-72 of the hepsin protein
51
Met Val Phe Asp Lys Thr Glu Gly Thr
5
52
9
PRT
Homo sapiens
Residues 236-244 of the hepsin protein
52
Ala Val Val Tyr His Gly Gly Tyr Leu
5
53
9
PRT
Homo sapiens
Residues 55-63 of the hepsin protein
53
Gln Val Ser Ser Ala Asp Ala Arg Leu
5
54
9
PRT
Homo sapiens
Residues 130-138 of the hepsin protein
54
Arg Leu Leu Glu Val Ile Ser Val Cys
5
55
9
PRT
Homo sapiens
Residues 230-238 of the hepsin protein
55
Leu Gln Leu Gly Val Gln Ala Val Val
5
56
9
PRT
Homo sapiens
Residues 20-28 of the hepsin protein
56
Ala Leu Thr Ala Gly Thr Leu Leu Leu
5
57
9
PRT
Homo sapiens
Residues 259-267 of the hepsin protein
57
Ala Leu Val His Leu Ser Ser Pro Leu
5
58
9
PRT
Homo sapiens
Residues 277-285 of the hepsin protein
58
Cys Leu Pro Ala Ala Gly Gln Ala Leu
5
59
9
PRT
Homo sapiens
Residues 17-25 of the hepsin protein
59
Lys Val Ala Ala Leu Thr Ala Gly Thr
5
60
9
PRT
Homo sapiens
Residues 285-293 of the hepsin protein
60
Leu Val Asp Gly Lys Ile Cys Thr Val
5
61
9
PRT
Homo sapiens
Residues 308-316 of the hepsin protein
61
Val Leu Gln Glu Ala Arg Val Pro Ile
5
62
9
PRT
Homo sapiens
Residues 27-35 of the hepsin protein
62
Leu Leu Leu Thr Ala Ile Gly Ala Ala
5
63
9
PRT
Homo sapiens
Residues 229-237 of the hepsin protein
63
Gly Leu Gln Leu Gly Val Gln Ala Val
5
64
9
PRT
Homo sapiens
Residues 313-321 of the hepsin protein
64
Arg Val Pro Ile Ile Ser Asn Asp Val
5
65
9
PRT
Homo sapiens
Residues 88-96 of the hepsin protein
65
Leu Ser Cys Glu Glu Met Gly Phe Leu
5
66
9
PRT
Homo sapiens
Residues 192-200 of the hepsin protein
66
Leu Leu Ser Gly Asp Trp Val Leu Thr
5
67
9
PRT
Homo sapiens
Residues 284-292 of the hepsin protein
67
Ala Leu Val Asp Gly Lys Ile Cys Thr
5
68
9
PRT
Homo sapiens
Residues 89-97 of the hepsin protein
68
Ser Cys Glu Glu Met Gly Phe Leu Arg
5
69
9
PRT
Homo sapiens
Residues 58-66 of the hepsin protein
69
Ser Ala Asp Ala Arg Leu Met Val Phe
5
70
9
PRT
Homo sapiens
Residues 393-401 of the hepsin protein
70
Val Ser Asp Phe Arg Glu Trp Ile Phe
5
71
9
PRT
Homo sapiens
Residues 407-415 of the hepsin protein
71
His Ser Glu Ala Ser Gly Met Val Thr
5
72
9
PRT
Homo sapiens
Residues 137-145 of the hepsin protein
72
Val Cys Asp Cys Pro Arg Gly Arg Phe
5
73
9
PRT
Homo sapiens
Residues 269-277 of the hepsin protein
73
Leu Thr Glu Tyr Ile Gln Pro Val Cys
5
74
9
PRT
Homo sapiens
Residues 47-55 of the hepsin protein
74
Asp Gln Glu Pro Leu Tyr Pro Val Gln
5
75
9
PRT
Homo sapiens
Residues 119-127 of the hepsin protein
75
Cys Val Asp Glu Gly Arg Leu Pro His
5
76
9
PRT
Homo sapiens
Residues 68-76 of the hepsin protein
76
Lys Thr Glu Gly Thr Trp Arg Leu Leu
5
77
9
PRT
Homo sapiens
Residues 101-109 of the hepsin protein
77
His Ser Glu Leu Asp Val Arg Thr Ala
5
78
9
PRT
Homo sapiens
Residues 250-258 of the hepsin protein
78
Asn Ser Glu Glu Asn Ser Asn Asp Ile
5
79
9
PRT
Homo sapiens
Residues 293-301 of the hepsin protein
79
Val Thr Gly Trp Gly Asn Thr Gln Tyr
5
80
9
PRT
Homo sapiens
Residues 231-239 of the hepsin protein
80
Gln Leu Gly Val Gln Ala Val Val Tyr
5
81
9
PRT
Homo sapiens
Residues 103-111 of the hepsin protein
81
Glu Leu Asp Val Arg Thr Ala Gly Ala
5
82
9
PRT
Homo sapiens
Residues 378-386 of the hepsin protein
82
Gly Thr Gly Cys Ala Leu Ala Gln Lys
5
83
9
PRT
Homo sapiens
Residues 358-366 of the hepsin protein
83
Val Cys Glu Asp Ser Ile Ser Arg Thr
5
84
9
PRT
Homo sapiens
Residues 264-272 of the hepsin protein
84
Ser Ser Pro Leu Pro Leu Thr Glu Tyr
5
85
9
PRT
Homo sapiens
Residues 87-95 of the hepsin protein
85
Gly Leu Ser Cys Glu Glu Met Gly Phe
5
86
9
PRT
Homo sapiens
Residues 272-280 of the hepsin protein
86
Tyr Ile Gln Pro Val Cys Leu Pro Ala
5
87
9
PRT
Homo sapiens
Residues 345-353 of the hepsin protein
87
Gly Ile Asp Ala Cys Gln Gly Asp Ser
5
88
9
PRT
Homo sapiens
Residues 301-309 of the hepsin protein
88
Tyr Tyr Gly Gln Gln Ala Gly Val Leu
5
89
9
PRT
Homo sapiens
Residues 238-246 of the hepsin protein
89
Val Tyr His Gly Gly Tyr Leu Pro Phe
5
90
9
PRT
Homo sapiens
Residues 204-212 of the hepsin protein
90
Cys Phe Pro Glu Arg Asn Arg Val Leu
5
91
9
PRT
Homo sapiens
Residues 117-125 of the hepsin protein
91
Phe Phe Cys Val Asp Glu Gly Arg Leu
5
92
9
PRT
Homo sapiens
Residues 124-132 of the hepsin protein
92
Arg Leu Pro His Thr Gln Arg Leu Leu
5
93
9
PRT
Homo sapiens
Residues 80-88 of the hepsin protein
93
Arg Ser Asn Ala Arg Val Ala Gly Leu
5
94
9
PRT
Homo sapiens
Residues 68-76 of the hepsin protein
94
Lys Thr Glu Gly Thr Trp Arg Leu Leu
5
95
9
PRT
Homo sapiens
Residues 340-348 of the hepsin protein
95
Gly Tyr Pro Glu Gly Gly Ile Asp Ala
5
96
9
PRT
Homo sapiens
Residues 242-250 of the hepsin protein
96
Gly Tyr Leu Pro Phe Arg Asp Pro Asn
5
97
9
PRT
Homo sapiens
Residues 51-59 of the hepsin protein
97
Leu Tyr Pro Val Gln Val Ser Ser Ala
5
98
9
PRT
Homo sapiens
Residues 259-267 of the hepsin protein
98
Ala Leu Val His Leu Ser Ser Pro Leu
5
99
9
PRT
Homo sapiens
Residues 277-285 of the hepsin protein
99
Cys Leu Pro Ala Ala Gly Gln Ala Leu
5
100
9
PRT
Homo sapiens
Residues 191-199 of the hepsin protein
100
Ser Leu Leu Ser Gly Asp Trp Val Leu
5
101
9
PRT
Homo sapiens
Residues 210-218 of the hepsin protein
101
Arg Val Leu Ser Arg Trp Arg Val Phe
5
102
9
PRT
Homo sapiens
Residues 222-230 of the hepsin protein
102
Val Ala Gln Ala Ser Pro His Gly Leu
5
103
9
PRT
Homo sapiens
Residues 236-244 of the hepsin protein
103
Ala Val Val Tyr His Gly Gly Tyr Leu
5
104
9
PRT
Homo sapiens
Residues 19-27 of the hepsin protein
104
Ala Ala Leu Thr Ala Gly Thr Leu Leu
5
105
9
PRT
Homo sapiens
Residues 36-44 of the hepsin protein
105
Ser Trp Ala Ile Val Ala Val Leu Leu
5
106
9
PRT
Homo sapiens
Residues 35-43 of the hepsin protein
106
Ala Ser Trp Ala Ile Val Ala Val Leu
5
107
9
PRT
Homo sapiens
Residues 300-308 of the hepsin protein
107
Gln Tyr Tyr Gly Gln Gln Ala Gly Val
5
108
9
PRT
Homo sapiens
Residues 363-371 of the hepsin protein
108
Ile Ser Arg Thr Pro Arg Trp Arg Leu
5
109
9
PRT
Homo sapiens
Residues 366-374 of the hepsin protein
109
Thr Pro Arg Trp Arg Leu Cys Gly Ile
5
110
9
PRT
Homo sapiens
Residues 236-244 of the hepsin protein
110
Ala Val Val Tyr His Gly Gly Tyr Leu
5
111
9
PRT
Homo sapiens
Residues 13-21 of the hepsin protein
111
Cys Ser Arg Pro Lys Val Ala Ala Leu
5
112
9
PRT
Homo sapiens
Residues 179-187 of the hepsin protein
112
Ser Leu Arg Tyr Asp Gly Ala His Leu
5
113
9
PRT
Homo sapiens
Residues 43-51 of the hepsin protein
113
Leu Leu Arg Ser Asp Gln Glu Pro Leu
5
114
9
PRT
Homo sapiens
Residues 19-27 of the hepsin protein
114
Ala Ala Leu Thr Ala Gly Thr Leu Leu
5
115
9
PRT
Homo sapiens
Residues 55-63 of the hepsin protein
115
Gln Val Ser Ser Ala Asp Ala Arg Leu
5
116
9
PRT
Homo sapiens
Residues 163-171 of the hepsin protein
116
Ile Val Gly Gly Arg Asp Thr Ser Leu
5
117
9
PRT
Homo sapiens
Residues 140-148 of the hepsin protein
117
Cys Pro Arg Gly Arg Phe Leu Ala Ala
5
118
9
PRT
Homo sapiens
Residues 20-28 of the hepsin protein
118
Ala Leu Thr Ala Gly Thr Leu Leu Leu
5
119
9
PRT
Homo sapiens
Residues 409-417 of the hepsin protein
119
Glu Ala Ser Gly Met Val Thr Gln Leu
5
120
9
PRT
Homo sapiens
Residues 259-267 of the hepsin protein
120
Ala Leu Val His Leu Ser Ser Pro Leu
5
121
9
PRT
Homo sapiens
Residues 35-43 of the hepsin protein
121
Ala Ser Trp Ala Ile Val Ala Val Leu
5
122
9
PRT
Homo sapiens
Residues 184-192 of the hepsin protein
122
Gly Ala His Leu Cys Gly Gly Ser Leu
5
123
9
PRT
Homo sapiens
Residues 18-26 of the hepsin protein
123
Val Ala Ala Leu Thr Ala Gly Thr Leu
5
124
9
PRT
Homo sapiens
Residues 222-230 of the hepsin protein
124
Val Ala Gln Ala Ser Pro His Gly Leu
5
125
9
PRT
Homo sapiens
Residues 224-232 of the hepsin protein
125
Gln Ala Ser Pro His Gly Leu Gln Leu
5
126
9
PRT
Homo sapiens
Residues 265-273 of the hepsin protein
126
Ser Pro Leu Pro Leu Thr Glu Tyr Ile
5
127
9
PRT
Homo sapiens
Residues 355-363 of the hepsin protein
127
Gly Pro Phe Val Cys Glu Asp Ser Ile
5
128
9
PRT
Homo sapiens
Residues 13-21 of the hepsin protein
128
Cys Ser Arg Pro Lys Val Ala Ala Leu
5
129
9
PRT
Homo sapiens
Residues 366-374 of the hepsin protein
129
Thr Pro Arg Trp Arg Leu Cys Gly Ile
5
130
9
PRT
Homo sapiens
Residues 140-148 of the hepsin protein
130
Cys Pro Arg Gly Arg Phe Leu Ala Ala
5
131
9
PRT
Homo sapiens
Residues 152-160 of the hepsin protein
131
Asp Cys Gly Arg Arg Lys Leu Pro Val
5
132
9
PRT
Homo sapiens
Residues 363-371 of the hepsin protein
132
Ile Ser Arg Thr Pro Arg Trp Arg Leu
5
133
9
PRT
Homo sapiens
Residues 133-141 of the hepsin protein
133
Ile Val Gly Gly Arg Asp Thr Ser Leu
5
134
9
PRT
Homo sapiens
Residues 331-339 of the hepsin protein
134
Gln Ile Lys Pro Lys Met Phe Cys Ala
5
135
9
PRT
Homo sapiens
Residues 80-88 of the hepsin protein
135
Arg Ser Asn Ala Arg Val Ala Gly Leu
5
136
9
PRT
Homo sapiens
Residues 179-187 of the hepsin protein
136
Ser Leu Arg Tyr Asp Gly Ala His Leu
5
137
9
PRT
Homo sapiens
Residues 43-51 of the hepsin protein
137
Leu Leu Arg Ser Asp Gln Glu Pro Leu
5
138
9
PRT
Homo sapiens
Residues 409-417 of the hepsin protein
138
Glu Ala Ser Gly Met Val Thr Gln Leu
5
139
9
PRT
Homo sapiens
Residues 311-319 of the hepsin protein
139
Glu Ala Arg Val Pro Ile Ile Ser Asn
5
140
9
PRT
Homo sapiens
Residues 222-230 of the hepsin protein
140
Val Ala Gln Ala Ser Pro His Gly Leu
5
141
9
PRT
Homo sapiens
Residues 19-27 of the hepsin protein
141
Ala Ala Leu Thr Ala Gly Thr Leu Leu
5
142
9
PRT
Homo sapiens
Residues 18-26 of the hepsin protein
142
Val Ala Ala Leu Thr Ala Gly Thr Leu
5
143
9
PRT
Homo sapiens
Residues 184-192 of the hepsin protein
143
Gly Ala His Leu Cys Gly Gly Ser Leu
5
144
9
PRT
Homo sapiens
Residues 224-232 of the hepsin protein
144
Gln Ala Ser Pro His Gly Leu Gln Leu
5
145
9
PRT
Homo sapiens
Residues 82-90 of the hepsin protein
145
Asn Ala Arg Val Ala Gly Leu Ser Cys
5
146
9
PRT
Homo sapiens
Residues 204-212 of the hepsin protein
146
Cys Phe Pro Glu Arg Asn Arg Val Leu
5
147
9
PRT
Homo sapiens
Residues 212-220 of the hepsin protein
147
Leu Ser Arg Trp Arg Val Phe Ala Gly
5
148
9
PRT
Homo sapiens
Residues 172-180 of the hepsin protein
148
Gly Arg Trp Pro Trp Gln Val Ser Leu
5
149
9
PRT
Homo sapiens
Residues 44-52 of the hepsin protein
149
Leu Arg Ser Asp Gln Glu Pro Leu Tyr
5
150
9
PRT
Homo sapiens
Residues 155-163 of the hepsin protein
150
Arg Arg Lys Leu Pro Val Asp Arg Ile
5
151
9
PRT
Homo sapiens
Residues 213-221 of the hepsin protein
151
Ser Arg Trp Arg Val Phe Ala Gly Ala
5
152
9
PRT
Homo sapiens
Residues 166-174 of the hepsin protein
152
Gly Arg Asp Thr Ser Leu Gly Arg Trp
5
153
9
PRT
Homo sapiens
Residues 369-377 of the hepsin protein
153
Trp Arg Leu Cys Gly Ile Val Ser Trp
5
154
9
PRT
Homo sapiens
Residues 180-188 of the hepsin protein
154
Leu Arg Tyr Asp Gly Ala His Leu Cys
5
155
9
PRT
Homo sapiens
Residues 96-104 of the hepsin protein
155
Leu Arg Ala Leu Thr His Ser Glu Leu
5
156
9
PRT
Homo sapiens
Residues 396-404 of the hepsin protein
156
Phe Arg Glu Trp Ile Phe Gln Ala Ile
5
157
9
PRT
Homo sapiens
Residues 123-131 of the hepsin protein
157
Gly Arg Leu Pro His Thr Gln Arg Leu
5
158
9
PRT
Homo sapiens
Residues 207-215 of the hepsin protein
158
Glu Arg Asn Arg Val Leu Ser Arg Trp
5
159
9
PRT
Homo sapiens
Residues 209-217 of the hepsin protein
159
Asn Arg Val Leu Ser Arg Trp Arg Val
5
160
9
PRT
Homo sapiens
Residues 14-22 of the hepsin protein
160
Ser Arg Pro Lys Val Ala Ala Leu Thr
5
161
9
PRT
Homo sapiens
Residues 106-114 of the hepsin protein
161
Val Arg Thr Ala Gly Ala Asn Gly Thr
5
162
9
PRT
Homo sapiens
Residues 129-137 of the hepsin protein
162
Gln Arg Leu Leu Glu Val Ile Ser Val
5
163
9
PRT
Homo sapiens
Residues 349-357 of the hepsin protein
163
Cys Gln Gly Asp Ser Gly Gly Pro Phe
5
164
9
PRT
Homo sapiens
Residues 61-69 of the hepsin protein
164
Ala Arg Leu Met Val Phe Asp Lys Thr
5
165
9
PRT
Homo sapiens
Residues 215-223 of the hepsin protein
165
Trp Arg Val Phe Ala Gly Ala Val Ala
5
166
9
PRT
Homo sapiens
Residues 143-151 of the hepsin protein
166
Gly Arg Phe Leu Ala Ala Ile Cys Gln
5
167
9
PRT
Homo sapiens
Residues 246-254 of the hepsin protein
167
Phe Arg Asp Pro Asn Ser Glu Glu Asn
5
168
9
PRT
Homo sapiens
Residues 132-140 of the hepsin protein
168
Leu Glu Val Ile Ser Val Cys Asp Cys
5
169
9
PRT
Homo sapiens
Residues 91-99 of the hepsin protein
169
Glu Glu Met Gly Phe Leu Arg Ala Leu
5
170
9
PRT
Homo sapiens
Residues 264-272 of the hepsin protein
170
Ser Ser Pro Leu Pro Leu Thr Glu Tyr
5
171
9
PRT
Homo sapiens
Residues 310-318 of the hepsin protein
171
Gln Glu Ala Arg Val Pro Ile Ile Ser
5
172
9
PRT
Homo sapiens
Residues 319-327 of the hepsin protein
172
Asn Asp Val Cys Asn Gly Ala Asp Phe
5
173
9
PRT
Homo sapiens
Residues 4-12 of the hepsin protein
173
Lys Glu Gly Gly Arg Thr Val Pro Cys
5
174
9
PRT
Homo sapiens
Residues 251-259 of the hepsin protein
174
Ser Glu Glu Asn Ser Asn Asp Ile Ala
5
175
9
PRT
Homo sapiens
Residues 256-264 of the hepsin protein
175
Asn Asp Ile Ala Leu Val His Leu Ser
5
176
9
PRT
Homo sapiens
Residues 294-302 of the hepsin protein
176
Thr Gly Trp Gly Asn Thr Gln Tyr Tyr
5
177
9
PRT
Homo sapiens
Residues 361-369 of the hepsin protein
177
Asp Ser Ile Ser Arg Thr Pro Arg Trp
5
178
9
PRT
Homo sapiens
Residues 235-243 of the hepsin protein
178
Gln Ala Val Val Tyr His Gly Gly Tyr
5
179
9
PRT
Homo sapiens
Residues 109-117 of the hepsin protein
179
Ala Gly Ala Asn Gly Thr Ser Gly Phe
5
180
9
PRT
Homo sapiens
Residues 270-278 of the hepsin protein
180
Thr Glu Tyr Ile Gln Pro Val Cys Leu
5
181
9
PRT
Homo sapiens
Residues 174-182 of the hepsin protein
181
Trp Pro Trp Gln Val Ser Leu Arg Tyr
182
9
PRT
Homo sapiens
Residues 293-301 of the hepsin protein
182
Val Thr Gly Trp Gly Asn Thr Gln Tyr
5
183
9
PRT
Homo sapiens
Residues 69-77 of the hepsin protein
183
Thr Glu Gly Thr Trp Arg Leu Leu Cys
5
184
9
PRT
Homo sapiens
Residues 90-98 of the hepsin protein
184
Cys Glu Glu Met Gly Phe Leu Arg Ala
5
185
9
PRT
Homo sapiens
Residues 252-260 of the hepsin protein
185
Glu Glu Asn Ser Asn Asp Ile Ala Leu
5
186
9
PRT
Homo sapiens
Residues 48-56 of the hepsin protein
186
Gln Glu Pro Leu Tyr Pro Val Gln Val
5
187
9
PRT
Homo sapiens
Residues 102-110 of the hepsin protein
187
Ser Glu Leu Asp Val Arg Thr Ala Gly
5
188
1783
DNA
Homo sapiens
full length cDNA of hepsin
188
tcgagcccgc tttccaggga ccctacctga gggcccacag gtgaggcagc 50
ctggcctagc aggccccacg ccaccgcctc tgcctccagg ccgcccgctg 100
ctgcggggcc accatgctcc tgcccaggcc tggagactga cccgaccccg 150
gcactacctc gaggctccgc ccccacctgc tggaccccag ggtcccaccc 200
tggcccagga ggtcagccag ggaatcatta acaagaggca gtgacatggc 250
gcagaaggag ggtggccgga ctgtgccatg ctgctccaga cccaaggtgg 300
cagctctcac tgcggggacc ctgctacttc tgacagccat cggggcggca 350
tcctgggcca ttgtggctgt tctcctcagg agtgaccagg agccgctgta 400
cccagtgcag gtcagctctg cggacgctcg gctcatggtc tttgacaaga 450
cggaagggac gtggcggctg ctgtgctcct cgcgctccaa cgccagggta 500
gccggactca gctgcgagga gatgggcttc ctcagggcac tgacccactc 550
cgagctggac gtgcgaacgg cgggcgccaa tggcacgtcg ggcttcttct 600
gtgtggacga ggggaggctg ccccacaccc agaggctgct ggaggtcatc 650
tccgtgtgtg attgccccag aggccgtttc ttggccgcca tctgccaaga 700
ctgtggccgc aggaagctgc ccgtggaccg catcgtggga ggccgggaca 750
ccagcttggg ccggtggccg tggcaagtca gccttcgcta tgatggagca 800
cacctctgtg ggggatccct gctctccggg gactgggtgc tgacagccgc 850
ccactgcttc ccggagcgga accgggtcct gtcccgatgg cgagtgtttg 900
ccggtgccgt ggcccaggcc tctccccacg gtctgcagct gggggtgcag 950
gctgtggtct accacggggg ctatcttccc tttcgggacc ccaacagcga 1000
ggagaacagc aacgatattg ccctggtcca cctctccagt cccctgcccc 1050
tcacagaata catccagcct gtgtgcctcc cagctgccgg ccaggccctg 1100
gtggatggca agatctgtac cgtgacgggc tggggcaaca cgcagtacta 1150
tggccaacag gccggggtac tccaggaggc tcgagtcccc ataatcagca 1200
atgatgtctg caatggcgct gacttctatg gaaaccagat caagcccaag 1250
atgttctgtg ctggctaccc cgagggtggc attgatgcct gccagggcga 1300
cagcggtggt ccctttgtgt gtgaggacag catctctcgg acgccacgtt 1350
ggcggctgtg tggcattgtg agttggggca ctggctgtgc cctggcccag 1400
aagccaggcg tctacaccaa agtcagtgac ttccgggagt ggatcttcca 1450
ggccataaag actcactccg aagccagcgg catggtgacc cagctctgac 1500
cggtggcttc tcgctgcgca gcctccaggg cccgaggtga tcccggtggt 1550
gggatccacg ctgggccgag gatgggacgt ttttcttctt gggcccggtc 1600
cacaggtcca aggacaccct ccctccaggg tcctctcttc cacagtggcg 1650
ggcccactca gccccgagac cacccaacct caccctcctg acccccatgt 1700
aaatattgtt ctgctgtctg ggactcctgt ctaggtgccc ctgatgatgg 1750
gatgctcttt aaataataaa gatggttttg att 1783
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The disclosed nucleic acid primer sets, used in combination with quantitative amplification (PCR) of tissue cDNA, can indicate the presence of specific proteases in a tissue sample. Specifically, the present invention relates to expression of hepsin protease. The detected proteases are themselves specifically overexpressed in certain cancers, and the presence of their genetic precursors may serve for early detection of associated ovarian and other malignancies, and for the design of interactive therapies for cancer treatment.
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[0001] This utility patent application claims priority to U.S. provisional patent application Ser. 60/784,072 filed on Mar. 17, 2006, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The present invention pertains to lighting fixtures, and more specifically, to quick assembly lighting fixtures having a plurality of frame portions with extended tabs that interlock to hold the fixture together
BACKGROUND OF THE INVENTION
[0003] There are many different kinds of lighting fixtures including both indoor and outdoor lighting fixtures. A fixture generally includes a framework onto which the electrical components of the light are typically mounted. Electrical receptacles may be installed into the fixture and the fixture mounted in a specific location to achieve the desired illuminating effect. In some instances the fixture is fashioned with an aesthetically pleasing design to create a certain ambience. Once assembled the lighting fixture can be hung from a ceiling or mounted to a wall.
[0004] One aspect of lighting fixtures pertains to the assembly of the lighting fixture. The lighting fixture may be cumbersome to assemble and likewise disassemble for repair or replacement of the fixture components. Fasteners or adhesives can be utilized to connect the components together requiring additional labor to complete the assembly process. It would be advantageous to have a lighting fixture that quickly interlocks to hold the fixture components in place.
BRIEF SUMMARY
[0005] One embodiment of present invention includes a light fixture having a first light fixture housing section with one or more tabs. The first light fixture housing section includes an electrical receptacle, which may be an electrical socket, adapted to receive an associated lighting element. One or more electrical conductors may be connected to deliver electrical power to the light fixture and more specifically to the electrical receptacle. The fixture may include a second light fixture housing section having a peripheral edge adapted to interlock with the one or more tabs.
[0006] In one aspect of the embodiments of the present invention, the first light fixture housing section is snapped into interlocking engagement with the second light fixture housing section. Alternatively, the first light fixture housing section may be rotated into interlocking engagement with the second light fixture housing section.
[0007] Another aspect of the embodiments of the present invention includes a first light fixture housing section that is generally concave where the one or more tabs extend inwardly from the first light fixture housing section. The peripheral edge may include a lip extending outwardly around the periphery of the second light fixture housing section having one or more recesses for receiving the one or more tabs.
[0008] In yet another aspect of the embodiments of the present invention the second light fixture housing section may comprise a globe having one or more transparent panels for allowing light emanating from the lighting element to shine through the second light fixture housing section.
[0009] Another embodiment of the present invention includes a light fixture housing having a first housing section adapted to receive an associated electrical receptacle for illuminating an associated lighting element wherein the first housing section includes a first connecting portion. The light fixture housing may also include a second housing section that is adapted to overlay the associated lighting element and may further include a second connecting portion. The first and second connecting portions may be disposed relative to each other such that when the first housing section is juxtaposed to the second housing sections, the first and second connectors interlock to fasten the first and second housing sections together.
[0010] In one aspect of the embodiments of the present invention the housing sections may be molded from a thermoplastic material or polymer via injection molding or any other type of plastic molding chosen with sound judgment. Accordingly, the one or more tabs may be integrally molded into the first housing section. In this manner, the one or more tabs may be flexible and may snap into engagement with the second connecting portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a quick assembly light including electrical receptacles, in accordance with various aspects of the present invention.
[0012] FIG. 2 is a perspective view of a quick assembly light fixture, in accordance with various aspects of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Referring now to the drawings wherein the showings are for purposes of illustrating embodiments of the invention only and not for purposes of limiting the same, FIG. 1 shows a lighting fixture depicted generally at 1 . The lighting fixture 1 maybe an indoor or an outdoor lighting fixture 1 that includes an illuminating device such as a light bulb 4 . The light bulb 4 may be a standard incandescent light bulb or a fluorescent light bulb. In fact, any type of illuminating device may be utilized without departing from the novel aspects of the subject invention. The lighting fixture 1 may further include an electrical receptacle 6 having conductors 7 electrically communicated thereto for providing power to illuminate the bulb 4 . A substantially rigid frame, shown generally at 9 , may form an internal cavity into which the bulb 4 and receptacle 6 may reside. The frame 9 may be fashioned by joining separate frame members 11 as will be discussed in detail below. The lighting fixture 1 may also include mounting brackets, not shown, that function to provide a means for an installer to affix the lighting fixture 1 to a wall, lamp post or any other structure onto which is suitable for mounting a lighting fixture 1 . In one embodiment, the lighting fixture 1 may be hung by a chain from the top of the lighting fixture 1 . Alternatively, the lighting fixture 1 may be fastened to a wall via brackets extending from the side or bottom of the lighting fixture 1 . Still any manner of mounting the lighting fixture 1 to a structural support may be chosen with sound engineering judgment.
[0014] With continued reference to FIG. 1 , the material that the lighting fixture 1 is constructed from may be plastic or another type of polymer-based substance. The plastic may be resistant to corrosion and to breakage for use in outdoor or other harsh environments. It is noted here that any type of materials and process may be used to construct the frame 9 of the lighting fixture 1 including but not limited steel, metal, wood or the like. The frame 9 may be finished with a coating such as paint and decorated to any extent desired as is appropriate for a lighting fixture 1 .
[0015] With reference again to FIG. 1 and also to FIG. 2 , the lighting fixture 1 may be comprised of two separate frame members 14 , 15 respectively, also termed light fixture housing sections. In one embodiment, the frame member 14 may be a top frame member 14 or first light fixture housing section 14 . Similarly, the frame member 15 may be a bottom frame member 15 or second light fixture housing section 15 . In this manner, the frame members 14 , 15 may make up the entire frame 9 . However, it is noted that any number of frame members may be utilized to make up the frame 9 of the lighting fixture 1 as is appropriate for use with the subject invention. Each of the frame members 14 , 15 may include walls 17 that make the frame members substantially rigid. Specifically, the top frame member 14 may have a generally concave configuration. The first end 18 of the top frame member 14 may form an apex and the distal end 19 of the top frame member 14 may be open to connect to the bottom frame member 15 . The bottom frame member 15 may have one or more walls that are contiguously formed or joined together to form an interior region 22 of the bottom frame member 15 . In FIG. 1 , the bottom frame member 15 is shown having a conical shape. In FIG. 2 , the bottom frame member 15 has a rectangular cross section. Any configuration of top and bottom frame member 14 , 15 may be chosen with sound engineering judgment. The top and bottom frame members 14 , 15 when connected together form an enclosed area that may encompass or envelop the receptacle 6 and light bulb 4 . Accordingly, the volume of space of contained within the two frame members 14 , may be sufficient for the receptacle 6 and bulb 4 to reside therein. It is noted here that while the present embodiment depicts a single light bulb, the present invention may be utilized in conjunction with any number of light bulbs and receptacles. The receptacle 6 may be mounted to the top frame member 14 . In one embodiment, the receptacle 6 may be removeably connected to the top frame member 14 . By removeably connected it is meant that the receptacle 6 may be attached to or removed from the walls 17 via fasteners or other retaining means.
[0016] With reference again to FIGS. 1 and 2 , as mentioned above the top and bottom frame members 14 , 15 may be assembled together to form the lighting fixture 1 . In one embodiment, this may be accomplished by fashioning a tab 25 extending from an interior wall 17 of the top frame member 14 . The tab 25 may form an angle with an interior side of the wall 17 . The tab 25 may extend substantially horizontal with respect to when the lighting fixture 1 is mounted in place. However, any angle may be chosen by which to extend the tab 25 from the side of the wall 17 . The tab 25 may further include a tab stop 27 that engages a lip 30 fashioned in the bottom frame member 15 to be discussed below. The tab stop 27 may extend substantially perpendicular to the tab 25 so that the lip 30 abuts the tab stop 27 when the top and bottom frame members 14 , 15 are joined together. As alluded to, the bottom frame member 15 may have a lip 30 that extends radially from an end 32 of the bottom frame member 15 . The lip 30 may span a relatively small portion of the perimeter bottom frame member 15 as shown in FIG. 2 . Alternatively, the lip 30 may traverse substantially around the entire perimeter of the bottom frame member 15 as shown in FIG. 1 . In this instance, a recess 34 may be formed in the lip 30 to allow the tab 25 to fit over prior to twisting the frame members 14 , 15 together. In this way, the top and bottom frame members 14 , 15 may be quickly connected together simply by juxtaposing the members 14 , 15 together and rotating one member with respect to the other. The present embodiments show multiple tabs and lips. FIG. 1 shows three tab-lip pairs, while FIG. 4 shows 4 tab-lip pairs. The tabs 25 may be spaced equidistantly apart around the periphery of the open end of the top frame member 14 . Likewise, the lips 30 may also be equidistantly spaced so as to correspond in position to the tabs 25 . This provides for a quick and secure fitting together of the lighting fixture components.
[0017] With reference to all of the FIGURES, assembly of the lighting fixture 1 will now be discussed. To assemble the lighting fixture 1 , an assembly person may juxtapose the top frame member 14 to the bottom frame member 15 such the tab 25 is proximate to the lip 30 . In the embodiment shown in FIG. 2 , the top frame member 14 may be positioned offset with respect to the bottom frame member 15 , inserted onto the bottom frame member 15 and rotated together thereby engaging the lip 30 with the tab 25 until the tab stop 27 inhibits further movement. In FIG. 1 , the tabs 25 may be inserted through the recesses 34 respectively and under the lip 30 . Subsequently, the top frame member 14 is then rotated with respect to the bottom frame member 15 until the tabs 25 abut the tab stops 27 . It is noted in this embodiment, that the tab stops 27 are fashioned extending from the underside of the lip 30 .
[0018] The invention has been described with reference to a preferred embodiment. Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. It is intended to include all such modifications and alternations in so far as they come within the scope of the appended claims or the equivalence thereof.
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A light fixture includes components that can be quickly assembled and disassembled. The fixture components have interlocking parts that allow an operator to snap or twist the components into locking engagement quickly and easily. Similarly, disassembly is just as easy. The components may also include decorated structural elements.
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BACKGROUND OF THE INVENTION
Gene expression occupies a key function in the evaluation of molecular processes in the body and great efforts are being made to investigate the significance of the expression of numerous genes also as a result of drug effects and to check it with respect to its predictive value in regard to the course of an illness and the success of a therapy.
A prerequisite for converting genetic information initially is the transcribing of the corresponding DNA sequence into mRNA. Gene expression can be regulated at the level of transcription as well as post-transcriptionally. For evidence-based medicine, the clarification of the mechanisms, which lead to a changed gene expression in the course of an illness, is an important objective, because new therapy concepts can be derived from it, which lead to an improved treatment of patients.
According to estimates of the organizers, the human genome project presumably will come to a conclusion in the year 2001. At the end of this project, which is being conducted worldwide, approximately 140,000 genes will have been identified. The analysis of the gene expression in different cell types and tissues, which provides important information concerning the normal state and the genesis of the pathologic state of cells and tissues, represents the greatest challenge at the present time as well as in the post-genome epoch.
A plurality of methods is employed for the analysis of gene expression, including Northern Blot and RT-PCR techniques. By means of chip-based technologies, that is, planar carriers of plastic, glass, gelatin, etc., on the surface of which a plurality of different (DNA) molecules, the positions of which are known and can be addressed, are disposed, thousands of genes can be investigated simultaneously with respect to their expression.
Aside from the different methods of analyzing gene expression, new technologies are being developed, in order to be able to detect nucleotide polymorphisms (that is, different variations of a gene) systematically, and to be able to evaluate them with respect to their biological significance in the course of an illness and, in the case of a medical application, in the sense of an individualized therapy.
A relatively recent method for fluorescence-based gene expression analyses and gene mutation analyses is represented by the investigation of amplified probes by the PCR technique in real-time PCR analytical equipment, such as the Lightcycler (Roche Diagnostics), TaqMan (Perkin-Elmer), etc.
The LightCycler is equipped with a three-channel fluorimeter, which can detect fluorescence at 530 nm (SYBR-Green), 640 nm (LC-RED 640) and 705 nm (LC-RED 7050). The manufacturer, Roche Diagnostics makes several tests available for the PCR amplification in the LightCycler, which can be used depending on the type of labeling (SYBR-Green or FRET methods; see below).
Dye Labeling
In order to be able to measure the newly synthesized in DNA in the subsequent real-time PCR, the DNA must be labeled by suitable dyes, which can be detected. For detecting the fluorescence signals, various real-time PCR detection systems were developed, with which it is possible to follow the whole of the PCR reaction. In the following, basic principles of the detection are explained:
1.) Fluorescence resonance energy transfer (FRET) is a process, for which a donor molecule, fluorescing after being stimulated by short-wave light, transfers its emission energy to a second acceptor molecule, which reacts to this with the emission of light of longer wavelength. The energy transfer from the one to the other molecule takes place over electron flow. The reporter molecule provides information concerning the product increase during the PCR. The so-called quencher molecule absorbs the fluorescence signals of the reporter molecule as long as both molecules are directly adjacent to one another in the hybridization probe. In this basic state, the reporter emission radiation for the fluorescence detector, with which the product increase in the PCR is measured, is invisible. Only as the PCR product increases, is there a spatial separation from the reporter and the quencher molecule. By these means, the reporter fluorescence becomes detectable and correlates directly with the amount of PCR product formed in the reaction.
A further method is referred to as the TaqMan method. In the case of the TaqMan method (or 5′-nuclease assay), the fluorescence-labeled hybridization probes bond to the complementary target strand between the primer binding sites. For the synthesis of the new strand, the hybridization probe is cut into small fragments by the 5′-3′-exonuclease activity of the Taq polymerases and released from the target strand. The reporter molecules and the quencher molecules are now present separately in the reaction mixture and the measured increase in the reporter fluorescence per PCR cycle correlates directly with the increase in the PCR product.
Other hybridization probes, synthesized according to the FRET principle, can be used for carrying out mutation analyses. Particularly important is the detection of so-called single nucleotide polymorphisms (SNPs), which come about due to the exchange of individual bases. Two hybridization probes, each labeled with a fluorescence dye, are used for the SNP analysis.
One donor probe binds directly adjacent to the mutation region. A second probe is produced so that it binds either complimentarily to the wild type or over the mutation site. In the melting point analysis, carried out after the PCR, the probe melts off at a particular temperature. If the probe bonds complimentarily to the wild type, it melts off at higher temperatures. On the other hand, in the presence of a mutation, the probe melts at lower temperatures. A mutation analysis therefore becomes possible. The fluorescence decline is calculated as a negative first derivative (as a melting peak). The mutation can be diagnosed by the displaced melting curve. This method with different fluorescence dyes can only be used by means of a real time detection system.
The principle of the real time detection system also forms the basis of the LightCycler from Roche Diagnostics. The LightCycler has three channels by means of which the emitted light quanta of dyes can be detected. DNA can by labeled with SYBR-Green; in addition, FRET probes, which are labeled with LC-Red 640 or LC-Red 705 dyes can also be used.
If the FRET method is used in the LightCycler, special hybridization probes must be added to the reaction mixture. They are labeled with fluorescein and LC red 640 or LC red 705 (from Roche Diagnostics). The fluorescence is observed only if both probes (donor probe and acceptor probe) have bonded in the immediate spatial vicinity to the target sequence. The transfer of light quanta (h*v), namely the fluorescence resonance energy transfer (FRET; see FIG. 1 ), then comes about.
2.) In the SYBR-Green method, the SYBR-Green intercalates in each case between two complementary base strands during the DNA synthesis and, with that, experiences a measurable increase in fluorescence as the PCR reaction progresses (see FIG. 2 ). However, the use of SYBR-Green lacks any specificity with regard to the template, which is to be investigated (that is, the DNA binding site), because the primer dimers, which are formed during the reaction, also cause an increase in fluorescence. Initially, this cannot be differentiated from the desired DNA synthesis product and can lead to wrong interpretations. However, it is possible to differentiate between the specific product and primer dimers at the end of the PCR by means of a melting curve analysis. For this, the PCR products are heated continuously over a particular temperature range and are present only as a single strand, depending on their melting point. The decrease in fluorescence, associated with this, is recorded. Smaller fragments, such as the primer dimers, have a melting point, which is lower than that of larger PCR products.
The representation of the fluorescence signal changes as a function of the temperature, derived from this, results in a curve, in which the specific PCR product becomes distinguishable from the primer dimers, if the melting points differ clearly from one another.
PCR Amplification in General
With the help of the polymerase chain reaction (PCR), clearly defined DNA sections of a gene can be reproduced million fold. For this purpose, two oligonucleotides (primers), which are complementary to the target sequence and each of which adds to one of the DNA strands, are added to the PCR reaction mixture. Moreover, sufficient amounts of the four desoxynucleoside triphosphates, a certain amount of magnesium chloride and a heat-stable DNA polymerase are added to the reaction cocktail. The individual substances for the PCR reaction are offered by numerous companies (Roche Diagnostics, Qiagen, Promega, Stratagene, TaKaRa, etc.). Previously prepared reaction mixtures or “MasterMixes” are also offered, to which only the primers and the DNA, which is to be investigated, have to be pipetted.
However, because of the lower sensitivity and selectivity and due to the formation of primer dimers, which are false DNA synthesis products, the informative power of the fluorescence-based gene expression analyses and gene mutation analyses, using our own PCR reaction mixtures with the conventional components and concentrations or using the commercially obtainable MasterMixes, is very limited. The formation of primer dimers must be emphasized especially, since it can lead to false findings, as a result of which appreciable risks arise for the patient and for biomedical research in general and therefore a reliable medicinal diagnosis, for example, during accompanying investigations in the course of the therapy, cannot be guaranteed. Furthermore, these investigations are very cost intensive, especially when the Roche kits are used, as a result of which the number of possible investigations is greatly limited by the respective research budget.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to increase the selectivity and sensitivity of fluorescence-based gene expression analyses and gene mutation analyses and, by suppressing the formation of primer dimers (see FIG. 3 ), to prevent wrong diagnoses and erroneous findings.
An increase in the selectivity, sensitivity and the suppression of primer dimer formations, fluorescence-based gene expression analyses and gene mutation analyses is accomplished pursuant to the invention owing to the fact that bovine serum albumin is added to the conventional PCR reaction components and that the magnesium chloride concentration is adjusted accurately depending on the Taq polymerase used. In SYBR-Green DNA labeling, the exact adjustment of the concentration is indispensable for realizing the inventive responses (sensitivity, selectivity).
The use of the inventive PCR reaction mixture leads to a clearly improved sensitivity and selectivity of fluorescence-based gene expression analyses and gene mutation analyses in the animal, bacterial, vegetable and human genome and prevents wrong diagnoses. By these means, it is possible to carry out such detections or investigations on samples, which previously could not be analyzed in this way because of their low RNA or DNA concentration. Moreover, the claimed invention leads to a dramatic reduction in the costs of the investigation.
The inventive PCR reaction mixture makes possible a distinct increase in the information power of the semiquantitative and totally quantitative determination of the gene expression in tissues and organs in the healthy, diseased and medicinally affected state. Moreover, because of the possibility of using inexpensive components in gene expression analyses or the detection of nucleotide polymorphisms, the use of the inventive PCR reaction mixture leads to a reduction in costs from about DM 4.13 per sample to DM 0.75 per sample.
The technical area of application of the invention comprises, above all, a) the pharmacogenomics and here, especially the discovery of genomic targets for drug candidates in research and development, or for products already introduced on the market, b) the detection of nucleotide polymorphisms, especially in the molecular diagnosis of diseases based on gene mutation analyses and gene polymorphism, in drug therapy and here, in particular, in the individualized dosing of drugs and for the rational interpretation of the pharmacokinetic course of a therapy, c) for the characterization of potential drugs at the gene expression level, d) the toxicogenomics and here, especially, the use in the case of toxicological investigations for preclinical development and for predicting toxic effects and for the toxicological characterization of individual materials and material mixtures at the gene expression level, e) the molecular diagnosis and here, especially the screening and the diagnosis of genes relevant to the illness, the monitoring of the course of an illness and a therapy and the molecular prognosis of diseases and f) the research and here, in particular, the identification of molecular interactions of materials, material mixtures and biological agents on the genome level, the identification of gene intercalations and the function analysis of new genes, including sequence analyses and gene clonings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 —representation of the fluorescence resonance energy transfer (FRET) principal;
FIG. 2 —representation of the SBYR-Green I labeling;
FIG. 3 —melting curve analysis after amplification of the transcription factor HNF3α from cDNA cultured hepatocytes of the rat;
FIG. 4 —detection of a gene polymorphism in Morbus Meulengracht patients;
FIG. 5 —detection of the sarcoplasmatic calcium ATPase from cDNA obtained from the human heart, using the claimed method;
FIG. 6 —detection of the beta-myosin heavy chain (MHC) gene from cDNA obtained from human heart tissue using the claimed method;
FIG. 7 —detection of the brain natriuretic peptide (BNP) gene from cDNA obtained from human heart tissue;
FIG. 8 —detection of the atrial natriuretic peptide (ANP) gene from cDNA of cultured cardiomyocytes of the rat, using the claimed method;
FIG. 9 —detection of the alpha skeletal actin gene from cDNA of cultured cardiomyocytes of the rat, using the claimed invention;
FIG. 10 —detection of the albumin gene from cDNA of cultured hepatocytes of the rat using the claimed method;
FIG. 11 —detection of the transcription factor HNF-3gamma from the cDNA of cultured hepatocytes of the rat using the claimed method;
FIG. 12 —detection of the N-acetyl transferase 2 allele 5*genotype of human lymphocytic DNA with FRET hybridization probes using the claimed method;
FIG. 13 —representation of the concentration dependence of the SYBR-Green I labeling used in the claimed method;
FIG. 14 —representation of the concentration dependence of the MgCl 2 used in the claimed method; and
FIG. 15 —representation of the concentration dependence of the BSA (bovine serum albumin) used in the claimed method.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLES
Obtaining Samples and Isolating Nucleic Acids
To begin with, the biological material, which is to be investigated, is obtained in some suitable matter and isolated. After that, nucleic acids (RNA and DNA) are isolated from whole blood (nucleated lymphocytes) or animal/human tissue and purified. By means of standardized methods, DNA or RNA can be isolated from blood and/or tissue. When RNA is obtained, it must be transcribed into copyDNA before being used in the PCR, in order to be able to synthesize large amounts of the target DNA subsequently. For this purpose, a defined amount of RNA is transcribed into copyDNA by means of reverse transcriptase.
Example 1
Detection of a Gene Polymorphism in Morbus Meulengracht Patients
Morbus Meulengracht (Gilberts syndrome) is a disease, which is caused by a TA insertion polymorphism in the region of the TATA box of the uridine-5′-diphosphoglucose glucoronyl transferase gene (UGTIAI). Pursuant to the invention, a method was developed, in order to diagnose this polymorphism rapidly and simply.
After the blood samples are taken (200 μL of whole blood per patient, usually in EDTA-containing vessels, such as monovets), they are stored at −20° C. until the samples are worked up. The DNA of the nucleated blood cells is isolated by means of a DNA isolation kit and purified. The PCR reaction mixture (LightCycler DNA Master Hybridization Probes or LightCycler FastStartDNA Master Hybridization Probes (both Roche Diagnostics) or the inventive PCR reaction mixture (see Table 1)) is added to the cooled LightCycler capillary. For this purpose, specific oligonucleotide primers (each 400 nM), the hybridization probes (each 10 nM); donor probe labeled with fluorescein, acceptor probe with LC-RED 640) and the patient-specific DNA (2 μL) are pipetted to it.
The PCR reaction is then started with a 15-minute denaturing phase at 95° C. (In the case of the LightCycler DNA Master Hybridization Kit, the denaturing phase was 2 minutes). After that, the following cycle was repeated 50 times; 95° C. for 3 seconds, then 55° C. for 7 seconds and 72° C. for 12 seconds. After the PCR reaction, a melting point analysis is carried out. For this purpose, the synthesis products formed were heated to 45° C. and then slowly (0.2° C./second) to 80° C. During this period, the fluorescence is determined on-line in real time.
As soon as the hybridization probe, lying above the mutation that is to be detected, melts off, there no longer is any fluorescence resonance energy transfer (FRET, see above). The fluorescence is calculated using a special software by means of the graphically as the first negative derivative as a function of the temperature (−dF/dT vs T) (see FIG melting curves, which are then given. 4 ).
In the present example, the sensitivity of the inventive FRET reaction mixture is compared with that of Roche Diagnostics (LightCycler FastStart DNA Master Hybridization Probes). FIG. 4 shows that the inventive PCR mixture is up to 10,000 times more sensitive than the DNA Master Hybridization Probe Kit offered by Roche Diagnostics. Moreover, it is a decidedly important distinguishing feature that the melting curves are higher and narrower in the case of the claimed method; it is therefore possible to differentiate between the individual genotypes more specifically and more unambiguously with the inventive procedure than with the Roche Diagnostic Kit. This difference is of fundamental importance for the medical evaluation of neucleotide polymorphisms in medical diagnosis and for the individualized, dose-adapted therapy (see FIG. 4 ).
Example 2
Detection of Sarcoplasmatic Calcium ATPase from cDNA of the Human Heart by Means of SYBR-Green Labelings
After an explantation of the human heart within the scope of a heart transplant, biopsy material was removed and frozen immediately in liquid nitrogen until it was processed further. Heart tissue (50 mg) was then removed and RNA was isolated and purified by standardized methods. RNA (2 μg) and random primer (Roche Diagnostics) are heated for 10 minutes at 70° C. in order subsequently to initiate the reverse transcription (60 minutes at 42° C.). Rnase inhibitor (40 U Stratagene), dNTPs (1 nM, Roche Diagnostics) and AMV reverse transcriptase (20 U, Promega) are pipetted into random primers and RNA buffer solution (Promega). The reaction is stopped by raising the temperature to 95° C. for 5 minutes.
Subsequently, the PCR reaction mixture (LightCycler DNA Master SYBR Green I or LightCycler FastStart DNA Master SYBR Green I (both Roche Diagnostics) or the PCR cocktail developed by us) is added to a LightCycler capillary. To this, 40 nM of the specific oligonucleotide primer and the corresponding copyDNA are pipetted.
At the end of a 15-minute denaturing phase at 95° C., the PCR reaction is started. (In the case of the LightCycler DNA Master SYBR Green I Kit, the denaturing phase was 2 minutes).
After that the following cycle is repeated 60 times: 95° C. for 3 seconds, then 55° C. for 7 seconds and 72° C. for 12 seconds. During each cycle, an actual fluorescence measurement was carried out at 87° C. in every capillary. From these measurements, the real time PCR curve shown in FIG. 5, was obtained. At the end of the PCR reaction, a melting point analysis is carried out. For this purpose, the DNA synthesis products are heated to 68° C. and then slowly (0.2° C./second) to 95° C. During this time period, the fluorescence is determined online. A specific melting temperature is reached for the respective DNA synthesis product. At this temperature, the added-on fluorescing SYBR Green molecules are detached from the melting DNA strands, as a result of which the fluorescence yield is decreased suddenly. The fluorescence behavior is converted by a special software into melting curves, which are then given graphically as the first negative derivative as a function of temperature (−dF/dT vs T) (see FIG. 5 ).
In this application example, the sensitivity of the claimed SYBR Green reaction mixture is compared with that of the Analysis Kit of Roche Diagnostics. FIG. 5 shows that the claimed method, in comparison to the Roche Diagnostics Kit, leads to a significantly improved, higher dynamics (fluorescence increase per-cycle) during the DNA synthesis. The dynamics (fluorescence loss per second) are also much higher for the melting point analysis, so that the melting point peaks are narrower and the amplitude higher, as a result of which the gene expression can be determined more specifically and therefore with greater accuracy.
In the following examples, the claimed reaction mixture was used successfully for the amplification of genes from human and animal tissues, which are relevant to diseases, and in cell culture experiments.
Example 3
Detection of Beta-Myosin-Heavy Chain (MHC) Gene from cDNA of the Human Heart by Means of SYBR Green Labelings
After an explantation of the human heart within the scope of a heart transplant, biopsy material was removed and frozen immediately in liquid nitrogen until it was processed further. Heart tissue (50 mg) was then removed and RNA was isolated and purified by standardized methods. RNA (2 μg) and random primer (Roche Diagnostics) are heated for 10 minutes at 70° C. in order subsequently to initiate the reverse transcription (60 minutes at 42° C.). Rnase inhibitor (40 U Stratagene), dNTPs (1 nM, Roche Diagnostics) and AMV reverse transcriptase (20 U, Promega) are pipetted into random primers and RNA buffer solution (Promega).
Subsequently, the claimed PCR cocktail is added to a LightCycler capillary and 400 nM of the specific oligonucleo primer and the corresponding copyDNA were pipetted in (10 ng, 1 ng and 100 pg) are pipetted to it.
At the end of a 15-minute denaturing phase at 95° C., the PCR reaction is started. After that, the following cycle is repeated 38 times: 95° C. for 3 seconds, then 57° C. for 8 seconds and 72° C. for 12 seconds. During each cycle, an actual fluorescence measurement was carried out at 89° C. in every capillary. From these measurements, the real time PCR curve shown in FIG. 6, was obtained. At the end of the PCR reaction, a melting point analysis is carried out. For this purpose, the DNA synthesis products are heated to 68° C. and then slowly (0.2° C./second) to 95° C. During this time period, the fluorescence is determined online. A specific melting temperature is reached for the respective DNA synthesis product. At this temperature, the added-on fluorescing SYBR Green molecules are detached from the melting DNA strands, as a result of which the fluorescence yield is decreased suddenly. The fluorescence behavior is converted by a special software into melting curves, which are then given graphically as the first negative derivative as a function of temperature (−dF/dT vs T) (see FIG. 6 ).
Example 4
Detection of the Brain Natriuretic Peptide (BNP) Gene from cDNA of the Human Heart by Means of SYBR Green Labeling
After an explantation of the human heart within the scope of a heart transplant, biopsy material was removed and frozen immediately in liquid nitrogen until it was processed further. Heart tissue (50 mg) was then removed and RNA was isolated and purified by standardized methods. RNA (2 μg) and random primer (Roche Diagnostics) are heated for 10 minutes at 70° C. in order subsequently to initiate the reverse transcription (60 minutes at 42° C.). Rnase inhibitor (40 U Stratagene) and AMV reverse transcriptase (20 U, Promega) are pipetted into random primers and RNA buffer solution (Promega). The reaction is stopped by raising the temperature to 95° C. for five minutes.
Subsequently, the claimed PCR cocktail is added to a LightCycler capillary and 400 nM of the specific oligonucleotide primer and the corresponding copyDNA are pipetted in (10 ng, 1 ng and 100 pg).
At the end of a 15-denaturing phase at 95° C., the PCR reaction is started. After that, the following cycle is repeated 46 times: 95° C. for 3 seconds, then 53° C. for 8 seconds and 72° C. for 10 seconds. During each cycle, an actual fluorescence measurement was carried out at 89° C. in every capillary. From these measurements, the real time PCR curve shown in FIG. 7, was obtained. At the end of the PCR reaction, a melting point analysis is carried out. For this purpose, the DNA synthesis products are heated to 68° C. and then slowly (0.2° C./second) to 95° C. During this time period, the fluorescence is determined online.
A specific melting temperature is reached for the respective DNA synthesis product. At this temperature, the added-on fluorescing SYBR Green molecules are detached from the melting DNA strands, as a result of which the fluorescence yield is decreased suddenly. The fluorescence behavior is converted by a special software into melting curves, which are then given graphically as the first negative derivative as a function of temperature (−dF/dT vs T) (see FIG. 7 ).
Example 5
Detection of the Atrial Natriuretic Peptide (ANP) Gene from cDNA of Cultured Cardiomyocetes of the Rat
After the isolation and 48th culturing of adult cardiomyocetes of rats, the cells where harvested and immediately frozen in liquid nitrogen until they were processed further. The RNA was isolated and purified by means of standard methods. RNA (2 μg) and random primer (Roche Diagnostics) are heated for 10 minutes at 70° C., in order to initiate the reverse transcription subsequently (60 minutes at 42° C.). dNTPs (1 nM, Roche Diagnostics), Rnase inhibitor (40 U, Stratagene) to and AMV reverse transcriptase (as 20 U, Promega) were pipetted into random primers and RNA buffer solution (Promega). The reaction is stopped by raising the temperature to 95° C. for five minutes.
Subsequently, the claimed PCR cocktail is added to a LightCycler capillary. For this purpose, 400 nM of the specific oligonucleotide primer and the corresponding copyDNA is pipetted in (10 ng, 1 ng and 100 pg).
At the end of a 15-denaturing phase at 95° C., the PCR reaction is started. After that, the following cycle is repeated 55 times: 95° C. for 3 seconds, then 55° C. for 7 seconds and 72° C. for 12 seconds. During each cycle, an actual fluorescence measurement was carried out at 91° C. in every capillary. From these measurements, the real time PCR curve shown in FIG. 8, was obtained. At the end of the PCR reaction, a melting point analysis is carried out. For this purpose, the DNA synthesis products are heated to 68° C. and then slowly (0.2° C./second) to 95° C. During this time period, the fluorescence is determined online. A specific melting temperature is reached for the respective DNA synthesis product. At this temperature, the added-on fluorescing SYBR Green molecules are detached from the melting DNA strands, as a result of which the fluorescence yield is decreased suddenly. The fluorescence behavior is converted by a special software into melting curves, which are then given graphically as the first negative derivative as a function of temperature (−dF/dT vs T) (see FIG. 8 ).
Example 6
Detection of the Alpha Skeletal actin Gene from cDNA of Freshly Removed Heart Tissue of the Rat
After an explantation of the rat heart, biopsy material was removed and frozen immediately in liquid nitrogen until it was processed further. RNA was isolated and purified by standardized methods. RNA (2 μg) and random primer (Roche Diagnostics) are heated for 10 minutes at 70° C. in order subsequently to initiate the reverse transcription (60 minutes at 42° C.). dNTPs (1 nM, Roche Diagnostics), Rnase inhibitor (40 U Stratagene) and AMV reverse transcriptase (20 U, Promega) are pipetted into random primers and RNA buffer solution (Promega). The reaction is stopped by heating to 95° C. for five minutes.
Subsequently, the claimed PCR cocktail is added to a LightCycler capillary and 400 nM of the specific oligonucleotide primer and the corresponding copyDNA are pipetted in (10 ng, 1 ng and 100 pg).
At the end of a 15-denaturing phase of 95° C., the PCR reaction is started. After that, the following cycle is repeated 46 of times: 95° C. for 3 seconds, then 55° C. for 7 seconds and 72° C. for 15 seconds. During each cycle, an actual fluorescence measurement was carried out at 90° C. in every capillary. From these measurements, the real time PCR curve shown in FIG. 9, was obtained. At the end of the PCR reaction, a melting point analysis is carried out. For this purpose, the DNA synthesis products are heated to 68° C. and then slowly (0.2° C./second) to 95° C. During this time period, the fluorescence is determined online. A specific melting temperature is reached for the respective DNA synthesis product. At this temperature, the added-on fluorescing SYBR Green molecules are detached from the melting DNA strands, as a result of which the fluorescence yield is decreased suddenly.
The fluorescence behavior is converted by a special software into melting curves, which are then given graphically as the first negative derivative as a function of temperature (−dF/dT vs T) (see FIG. 9 ).
Example 7
Detection of the Albumin Gene from cDNA of Cultured Hepatocytes of the Rat
After the isolation and culturing of hepatocytes of the rat for 48 hours, the cells where harvested and RNA was isolated and purified by means of standardized methods. RNA (2 μg) and random primer (Roche Diagnostics) are heated for 10 minutes at 70° C. in order subsequently to initiate the reverse transcription (60 minutes at 42° C.). dNTPs (1 nM, Roche Diagnostics), Rnase inhibitor (40 U Stratagene) and AMV reverse transcriptase (20 U, Promega) are pipetted into random primers and RNA buffer solution (Promega). The reaction is stopped by heating to 95° C. for five minutes.
Subsequently, the claimed PCR cocktail is added to a LightCycler capillary and 400 nM of the specific oligonucleotide primer and the corresponding copyDNA are pipetted in (10 ng, 1 ng and 100 pg).
At the end of a 15-denaturing phase of 95° C., the PCR reaction is started. After that, the following cycle is repeated 36 times: 95° C. for 3 seconds, then 55° C. for 7 and 72° C. for 12 seconds. During each cycle, an actual fluorescence measurement was carried out at 83° C. in every capillary. From these measurements, the real time PCR curve shown in FIG. 10, was obtained. At the end of the PCR reaction, a melting point analysis is carried out. For this purpose, the DNA synthesis products are heated to 68° C. and then slowly (0.2° C./second) to 95° C. During this time period, the fluorescence is determined online. A specific melting temperature is reached for the respective DNA synthesis product. At this temperature, the added-on fluorescing SYBR Green molecules are detached from the melting DNA strands, as a result of which the fluorescence yield is decreased suddenly. The fluorescence behavior is converted by a special software into melting curves, which are then given graphically as the first negative derivative as a function of temperature (−dF/dT vs T) (see FIG. 10 ).
Example 8
Detection of the Transcription Factor Hepatic Nuclear Factor (HNF) 3 Gamma from cDNA Cultured Hepatocytes of the Rat
After the isolation and culturing of hepatocytes of the rat for 48 hours, the cells where harvested and RNA was isolated and purified by means of standardized methods. RNA (2 μg) and random primer (Roche Diagnostics) are heated for 10 minutes at 70° C. in order subsequently to initiate the reverse transcription (60 minutes at 42° C.). dNTPs (1 nM, Roche Diagnostics), Rnase inhibitor (40 U Stratagene) and AMV reverse transcriptase (20 U, Promega) are pipetted into random primers and RNA buffer solution (Promega). The reaction is stopped by heating to 95° C. for five minutes.
Subsequently, the claimed PCR cocktail is added to a LightCycler capillary and 400 nM of the specific oligonucleotide primer and the corresponding copyDNA are pipetted in (6 times 100 pg).
At the end of a 15-denaturing phase of 95° C., the PCR reaction is started. After that, the following cycle is repeated 46 times: 95° C. for 3 seconds, then 57° C. for 8 seconds and more will 72° C. for 12 seconds. During each cycle, an actual fluorescence measurement was carried out at 88° C. in every capillary. From these measurements, the real time PCR curve shown in FIG. 11, was obtained. At the end of the PCR reaction, a melting point analysis is carried out. For this purpose, the DNA synthesis products are heated to 66° C. and then slowly (0.2° C./second) to 95° C. During this time period, the fluorescence is determined online.
A specific melting temperature is reached for the respective DNA synthesis product. At this temperature, the added-on fluorescing SYBR Green molecules are detached from the melting DNA strands, as a result of which the fluorescence yield is decreased suddenly. The fluorescence behavior is converted by a special software into melting curves, which are then given graphically as the first negative derivative as a function of temperature (−dF/dT vs T) (see FIG. 11 ).
Example 9
Identification of the N-acetyl Transferase 2 Allele*Genotype from Human Lymphocytic DNA by Means of the FRET Method
N-Acetyl transferase 2 is involved in the metabolization of many drugs. Patients with polymorphisms (gene mutations due to base exchange or deletions) have an increased-risk of being poisoned by side effects of drugs.
After blood samples are taken (200 μL of whole blood per patient usually in EDTA-containing vessels, such as monovettes), they are stored at −20° C. until they are worked up. The DNA is isolated from the nucleated blood cells and purified by means of a DNA isolation kit. The claimed PCR reaction mixture (see Table 1) is added to the cooled LightCycler capillary. For this purpose, specific oligonucleotides primers (400 nM of each), the hybridization probes (10 nM of each; donor probe labeled with fluorescein, acceptor probe with LC-RED 640) and the patient-specific DNA (2 μL) are pipetted in.
The PCR reaction is then started with a 15-minute denaturing phase at 95° C. (In the case of the LightCycler DNA Master Hybridization Kit, the denaturing phase lasted 2 minutes). After that, the following cycle was repeated 60 times: 95° C. for 3 seconds, then 45 ° C. for 10 seconds and 72° C. for 20 seconds. At the end of the PCR reaction, a melting point analysis is carried out. For this purpose, the synthesis products formed are heated to 45° C. and then slowly (0.2° C. per second) to 75° C. During this time period, the fluorescence is determined online. As soon as the hybridization probe, which lies above the mutations that is to be detected, melts off, there no longer is any fluorescence resonance energy transfer (see above). The fluorescence is calculated by means of the melting curves, using a special software. The melting curves are then given graphically as the first negative derivative as a function of temperature (−dF/dT vs T) (see FIG. 12 ).
Adjusting the Optimum PCR Reaction Mixture
a) Adjusting the Optimum SYBR-Green Concentration
SYBR-Green dilutions of 1:2,000 to 1:2,000,000 from the SYBR-Green stock solution were tested. The sarcoplasmatic calcium ATPase from cDNA, obtained from human heart, was amplified. The exact experimental conditions are described under Example 2. The largest measurable increase in fluorescence and, with that, the best result was achieved with a dilution of 1:20,000. As a result, the dynamics during the amplification and during the melting reached a maximum at a dilution of 1:20,000, so that, during the melting point analysis, the amplitude of the melting curves, produced by using an SYBR-Green dilutions of 1:20,000, are also the highest, as a result of which unambiguous findings are achieved. Other dilution steps, which are higher or lower than 1:20,000, produced results, which were distinctly inferior up to the point of the absence of detection (see FIG. 13 ).
b) Adjusting the Optimum MgCl 2 Concentration
Increasing the MgCl 2 concentration from 1.5 mM over 3 mM to 5 mM led to a logical shortening of the start of the exponential (log) is DNA synthesis as is documented by the lower number of PCR cycles (see FIG. 13 ). An additional increase in the MgCl 2 concentration to 7 mM did not lead to any improvement in the analytics of the fluorescence increase.
The amplitudes (heights) of the resulting melting curves are comparable for MgCl 2 concentrations of 3, 5 and 7 mM. The observed shift in the melting point curves to higher temperatures can be attributed to the different MgCl 2 concentration (see FIG. 14 ).
c) Adjustment of the Optimum BSA Concentration
The best result was achieved at a concentration of 666 μg/mL of BSA. At this concentration, the dynamics of the fluorescence increase and of the melting off are the greatest. In contrast to the Roche Diagnostic Kit, non-specific primer dimers, which can lead to a faulty evaluation, are not formed in our claimed method at a BSA concentration of 666 μg/mL in the PCR reaction. If the BSA concentration is not adjusted accurately, there is pronounced primer dimer formation (see FIG. 15 ).
d) Dependence on the Taq Polymerase Used
Taq DNA polymerases from the different manufacturers (Taq DNA polymerase from Roche Diagnostics, Taq DNA polymerase from Life Technologies, PCR Supermix from Life Technologies, Platinum Taq polymerase from Life Technologies, Taq DNA Polymerase from Promega, Taq DNA polymerase from TaKaRa, Taq DNA polymerases from Qiagen, HotStart Taq DNA Polymerase Mastermix from Qiagen) were investigated. The best results way obtained with the HotStart Master Mix of Qiagen. Our claimed method can also be carried out with Taq polymerase is from other suppliers.
TABLE 1
Comparison of the composition of the claimed PCR reaction
mixture using the HotStar TAQ polymerase Mastermixes
with the commercially offered kit from Roche Diagnostics
Roche Diagnostics
Claimed PCR Reaction Mixture
SYBR-Green Method
10
mM tris, pH 8.3
HotStart TAQ polymerase
50
mM KCl
Mastermix (Qiagen) 10 μL
200
μM each of dATP. dCTP, dGTP
(2.5 U)
400
μM dUTP
(tris-Cl, KCl, (NH 4 ) 2 SO 4 pH 8.7
0.5
U TAQ DNA polymerase
HotStar Taq DNA polymerase
2.5
mM MgCl 2
MgCl 2 3 mM
SYBR Green
dNTPs (200 μM)
The exact composition of the kit is not
Bovine serum albumin
evident from cited patents of Roche
(666 μg/mL)
Diagnostics (Patents EPO771870;
SYBR-Green I
U.S. Pat. No. 5,773,258; U.S. Pat. No.
(dilution 1:20,000)
5,677,152
MgCl 2 - added up to a final
concentration of 5 mM.
FRET Method
10
mM tris, pH 8.3
HotStart TAQ polymerase
50
mM KCl
Mastermix (Qiagen) 10 μL
200
μM each of dATP. dCTP, dGTP
(2.5 U)
400
μM dUTP
(tris-Cl, KCl, (NH 4 ) 2 SO 4 pH 8.7
0.5
U TAQ DNA polymerase
HotStar Taq DNA polymerase
2.5
mM MgCl 2
MgCl 2 3 mM
dNTPs (200 μM)
The exact composition of the kit is not
Bovine serum albumin
evident from cited patents of Roche
(666 μg/mL)
Diagnostics (Patents EPO771870;
MgCl 2 - added up to a final
U.S. Pat. No. 5,773,258; U.S. Pat. No.
concentration of 5 mM.
5,677,152
TABLE 2
Advantages of the Claimed Method/Disadvantages of the Roche Diagnostic Kit
Roche Diagnostics Kit
Thum/Borlak Method
Method
sensitivity: detectable DNA/amount of cDNA
sensitivity: detectable DNA/amount of cDNA
FRET Method
LightCycler FastStart DNA Master Hybridization Probes
claimed method:
10 ng
10,000 times higher sensitivity than Roche method (1 pg of
DNA)
LightCycler DNA Master Hybridization Probe
claimed method
10 pg
10 times higher sensitivity (1 pg of DNA)
SYBR-Green Method
LightCycler DNA MasterSYBR Green 1:
claimed method
1 pg
7 times higher absolute fluorescence yield (1 pg)
(see FIG. 4)
LightCycler DNA Master SYBR Green 1
claimed method
1 pg
7 times higher absolute fluorescence yield (1 pg)
Primer - Dimer
partially, pronounced primer - dimer formations, which can
The primer - dimer formation is suppressed by the method
Formation
lead to faulty interpretations and findings
claimed by us
Melting curve behavior
broad, low, (inaccurate) melting curve peaks, which
Because of the improved melting behavior in the claimed
can lead to faulty evaluations
method, a higher sensitivity can be achieved from the first
negative derivative (−dF/dT) and, as can be seen from FIGS. 3
and 4, an accurate assignment of the DNA synthesis
products in comparison to the Roche Diagnostics products. In
comparison to the Roche Diagnostics products, the melting curve
amplitude is up to 400% higher (see FIG. 4).
Dynamics of the
Lower than in the case of the Thum/Borlak method (0.5
In the claimed method, four times higher than in the case of the
amplification (in the
fluorescence units per PCR cycle)
Roche Diagnostics Kit (2.0 fluorescence units per PCR cycle)
log-linear phase)
(see FIG. 4)
Costs
SYBR-Green format
DM 3.75-4.13 per sample
DM 0.75 per sample
FRET format
DM 3.50-3.84 per sample
DM 0.75 per sample
|
An increase in the selectivity, sensitivity and the suppression of primer dimer formations, fluorescence-based gene expression analyses and gene mutation analyses is accomplished by adding bovine serum albumin to the conventional PCR reaction components. Magnesium chloride concentration is adjusted accurately depending on the Taq polymerase used.
| 2
|
This Application is a Section 371 National Stage Application of International Application No. PCT/KR2010/005585, filed Aug. 23, 2010 and published, not in English, as W02011/025197 on Mar. 3, 2011.
FIELD OF THE DISCLOSURE
The present disclosure relates to an apparatus and a method for controlling an automatic operation of a working unit of a wheel loader, and more particularly, to an apparatus and a method for controlling an automatic operation of a working unit of a wheel loader that controls the automatic operation by estimating a subsequent operation according to a current condition of the working unit.
BACKGROUND OF THE DISCLOSURE
In general, a wheel loader is constituted by a working unit as a means for a work including a bucket and a boom and a driving device and a driver of the wheel loader directly operates the driving device and the working unit to perform a principal work of the wheel loader.
In this case, the principal work of the wheel loader represents a work of performing an excavation work in a worksite and thereafter, moving the excavated load to a place where the load is stacked.
The driver operates the driving device to move the wheel loader to the vicinity of the load in order to perform the wheel loader work and operates the working unit in a loadable pattern (return to dig). Thereafter, the driver operates the driving device to move forward to load the load into the bucket and operates the working unit in a pattern (Max Crowd) capable of moving the load and thereafter, operates the driving device to move backward and separates the driving device from the load. In addition, the driver operates the driving device to move to the vicinity of a place to which the load will be stacked and operates the working unit to separate the load from the wheel loader.
In recent years, there is a trend that a technology of estimating a subsequent working state by judging a current working state and performing an automatic operation in the estimated working state has been developed in order to provide convenience in which the driver can conveniently operate an industrial vehicle such as a wheel loader or an excavator when operating the industrial vehicle.
As a result, there is required the technology for estimating the working state and performing the automatic operation in the estimated working state in order to provide convenience to a driver even when the driver operates the wheel loader.
The discussion above is merely provided for general background information and is not intended to be used as an aid in determining the scope of the claimed subject matter.
SUMMARY
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
The present disclosure provides an apparatus and a method for controlling an automatic operation of a working unit of a wheel loader in which the apparatus for controlling the automatic operation of the working unit of the wheel loader estimates and controls a subsequent operation of the working unit which a driver will operate based on a driving operation of the driver of the wheel loader and a current state of the working unit to provide convenience to the driver.
In order to achieve the above object, a method for controlling an automatic operation of a working unit of a wheel loader includes: verifying a working state of the wheel loader through detection of a bucket position and a driving state and examining whether the verified working state is an excavation completed state; examining whether a current position of a driving direction operating lever is a backward-movement position when the verified working state is the excavation completed state as a result of the examination; and automatically moving up a position of a boom up to a predetermined position together with backward driving of the wheel loader depending on whether an automatic operation mode is set when the driving direction operating lever position is the backward-movement position.
The examining whether the verified working state is the excavation completed state may include: examining whether the driving direction operating lever position is a forward-movement position; examining whether the bucket position is operated in a loadable pattern when the position of the driving direction operating lever is the forward-movement position; recognizing whether an operation for an excavation work is currently underway as a current working state when the bucket position is operated in the loadable pattern and examining whether the bucket position is full crowd; and verifying whether the working state is the excavation completed state according to whether the current bucket position is the full crowd.
The method may further include: examining whether the current position of the driving direction operating lever is the backward-movement position; recognizing that the current working state is the excavation completed state when the current bucket position is the full crowd after the verification process is performed; and examining whether a current position of the driving direction operating lever is the backward-movement position.
The predetermined position of automatically moving up the position of the boom may be the predetermined position of the boom in order to perform a detent function which is a function to automatically stop upward and downward movements of the boom at a predetermined height.
Further, an apparatus for controlling an automatic operation of a working unit of a wheel loader includes: an automatic operation selecting switch for selecting an automatic operation mode; a driving direction operating lever detecting a driving direction command; a working unit angle sensor detecting current positional states of a boom and a bucket; a working unit controlling unit controlling motions by supplying hydraulic pressure to a boom and a bucket cylinder; a driving device controlling unit controlling forward movement or backward movement of the wheel loader; and a control unit detecting a bucket position by using the working unit angle sensor, verifying a working state of the wheel loader by using the driving direction operating lever to detect a driving state, examining whether a current driving direction operating lever position is a backward-movement position through the driving direction operating lever when the verified working state is an excavation completed state, and commanding to automatically move up a position of the boom up to a predetermined position with the working unit controlling unit together with backward driving of the wheel loader depending on whether the automatic operation mode is set when the driving direction operating lever position is the backward-movement position.
The control unit may examine whether the driving direction operating lever position is a forward-movement position, recognize that an operation for an excavation work is currently underway, as a current working state, when a bucket position is operated in a loadable pattern after examining whether the bucket position is operated in the loadable pattern by using the working unit angle sensor when the driving direction operating lever position is the forward-movement position, and recognize that the working state is the excavation completed state depending on whether the current bucket position is full crowd after examining whether the bucket position is the full crowd by using the working unit angle sensor.
According to the present disclosure, some of the processes which a driver of a wheel loader simply repeats for a work are omitted to improve the driver' s convenience, and as a result, productivity in a worksite adopting the wheel loader can be increased.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing an internal configuration of an apparatus for controlling an automatic operation of a working unit of a wheel loader according to an exemplary embodiment of the present disclosure;
FIG. 2 is a flowchart showing a process of monitoring a working state in the apparatus for controlling an automatic operation of a working unit of a wheel loader according to an exemplary embodiment of the present disclosure; and
FIG. 3 is a flowchart showing a process for controlling an automatic operation according to an exemplary embodiment of the present disclosure.
DETAILED DESCRIPTION
Description of Main Reference Numerals of Drawings
100 : Control unit
110 : Input unit
112 : Driving direction operating lever
114 : Working unit angle sensor
116 : Automatic operation selecting switch
118 : Working unit operating unit
120 : Output unit
122 : Working unit controlling unit (MCV)
124 : Driving device controlling unit (TCU)
Hereinafter, exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. It should be noted that the same components refer to the same reference numerals anywhere as possible in the drawings. In the following description, specific detailed matters will be described and are provided to the more overall understanding of the present disclosure. Further, in describing the present disclosure, well-known functions or constructions will not be described in detail since they may unnecessarily obscure the understanding of the present disclosure.
In general, in the case of a wheel loader, most of the drivers operate a working unit in a pattern (Max Crowd) to move a load at all times before moving the wheel loader backward in order to move the load loaded in a bucket after an excavation work is completed at the time of performing the work.
In the present disclosure, an action of operating the working unit in the pattern (Max Crowd) to move a load is automatically operated before moving the wheel loader backward in order to move the load, thereby providing convenience to the driver.
To this end, an apparatus for controlling an automatic operation of a working unit of a wheel loader needs to be able to monitor a current state and a driving state of the working unit and judge a current working state based thereon. Further, a subsequent working state is estimated through the presently judged working state to directly control the working unit.
First, referring to FIG. 1 , an apparatus for controlling an automatic operation of a working unit of a wheel loader according to an exemplary embodiment of the present disclosure will be described.
The apparatus for controlling an automatic operation of a working unit of a wheel loader according to the exemplary embodiment of the present disclosure includes an input unit 110 , a control unit 100 , and an output unit 120 . The input unit 110 includes a driving direction operating lever 112 , a working unit angle sensor 114 , an automatic operation selecting switch 116 , and a working unit operating unit 118 . The output unit 120 including a working unit controlling unit (MCV) 122 and a driving device controlling unit (TCU) 124 .
The driving direction operating lever 112 detects a driving direction command of the driver.
The working unit angle sensor 114 detects current positional states of a boom and a bucket. The working unit angle sensor 114 includes a boom angle sensor and a bucket angle sensor. The boom angle sensor as a sensor for sensing an attitude of the boom outputs an angle sensing signal of the boom. The bucket angle sensor as a sensor for sensing an attitude of the bucket outputs an angle sensing signal of the bucket.
The automatic operation selecting switch 116 detects a driver' s automatic operation selecting will. The automatic operation selecting switch 116 according to the exemplary embodiment of the present disclosure as a switch for selecting an automatic operating mode outputs a switch on/off signal to the control unit 100 according to a switch operation of a worker.
The working unit operating unit 118 detects a driver' s direct control will for the working unit during the automatic operation. The working unit operating unit 118 may include a boom joystick and a bucket joystick and the boom joystick is an input device for moving up and down the boom and the bucket joystick is an input device for dumping and crowding the bucket.
The working unit controlling unit (MCV) 122 controls a motion of the working unit by supplying hydraulic pressure to a cylinder of the working unit. The working unit controlling unit (MCV) 122 may include a boom control valve and a bucket control valve and valve opening areas of the boom control valve and the bucket control valve are controlled proportionally according to current applied from the control unit 100 . Further, the boom control valve controls upward movement and downward movement of the boom and the bucket control valve controls crowding and dumping of the bucket.
The driving device controlling unit (TCU) 124 controls move-forward movement or backward movement which is the driving direction of the wheel loader.
The control unit 100 judges a current working state of the wheel loader based on the working unit angle sensor 114 and the driving direction operating lever 112 . Thereafter, the control unit 100 controls the working unit through a working state judgment result and by detecting whether the backward movement is operated.
In this case, the current working state is an excavation completed state by recognizing that an automatic operating mode is selected when the automatic operation selecting switch 116 is in an on state and thereafter, the control unit 100 automatically controls the boom to move up to a position of a detent with the working unit controlling unit 122 according to the detection of whether the move-backward is operated. Herein, the detent position refers to a predetermined height of the boom in order to perform a detent function. In this case, the detent function is a function to automatically stop the upward movement and the downward movement of the boom at a predetermined height.
However, when the automatic operation selecting switch 116 is in an off state, the control unit 100 controls the working unit controlling unit 122 or the driving device controlling unit 124 according to a driver's driving or work performing command by recognizing a general manual driving mode.
A control operation of the control unit 100 will be described in detail with reference to FIGS. 2 and 3 .
FIG. 2 is a flowchart showing a process of monitoring a working state in the apparatus for controlling an automatic operation of a working unit of a wheel loader.
At step 200 , the control unit 100 examines whether the position of the driving direction operating lever is a forward-movement position through the driving direction operating lever 112 . That is, it is examined whether a current state is a state in which a vehicle moves.
If the position of the driving direction operating lever is the forward-movement position, the process proceeds to step 202 and the control unit 100 examines whether a bucket position is operated in a pattern capable of loading the load through the working unit angle sensor 114 . However, if the position of the driving direction operating lever is not the forward-movement position, the process proceeds to step 200 .
Meanwhile, as an examination result at step 202 , when the bucket position is operated in the pattern, capable of loading the load, the process proceeds to step 204 and if not, the process proceeds to step 200 .
At step 204 , the control unit 100 recognizes an excavation estimating state as the bucket position is operated in the loadable pattern after the position of the driving direction operating lever is in the forward-movement position state. That is, the control unit 100 recognizes that the operation for the excavation work is currently underway.
Thereafter, the process proceeds to step 206 and the control unit 100 examines whether the bucket position is in a full crowd state through the working unit angle sensor 114 .
As an examination result of step 206 , if the bucket position is in the full crowd state, the control unit 100 recognizes the excavation completed state at step 208 . That is, when the bucket position is in the full crowd state in the examination at step 206 , the load is loaded into the bucket by operating forward movement to recognize that the excavation work is completed.
When the current state becomes the state in which the excavation work is completed as described above, the process for controlling the automatic operation is performed.
The process of controlling the automatic operation will be described with reference to FIG. 3 .
Referring to FIG. 3 , the control unit 100 examines whether the excavation work is completed as a judgment result of the working state at step 300 .
If the current working state becomes the state in which the excavation work is completed, the process proceeds to step 302 to examine whether the position of the driving direction operating lever is the backward-movement position through the driving direction operating lever 112 .
When the position of the driving direction operating lever is the backward-movement position as an examination result of step 302 , the process proceeds to step 304 and the control unit 100 recognizes that the current state is an excavation completion movement instructing state. That is, the control unit 100 recognizes that the current state is a backward movement state in which the excavation work is completed to move the load.
Thereafter, the control unit 100 examines whether the automatic operation selecting switch 116 is on at step 306 . That is, it is examined whether the driver selects an automatic operation mode.
If the automatic operation selecting switch 116 is on, the process proceeds to step 308 and if the automatic operation selecting switch 116 is off, the process proceeds to step 307 to operate in a manual operation mode. In this case, the manual operation mode is a mode to control the working unit controlling unit 122 or the driving device controlling unit 124 according to the driver' s driving or work performing command.
Further, the automatic operation mode is a mode to estimate a subsequent working state by judging the current working state based on the current state and the driving state and automatically control the estimated working state. The automatic operation mode in the exemplary embodiment of the present disclosure is a mode to automatically control an operation of moving up the boom to the detent position in the case of backward movement in the excavation completed state.
Meanwhile, if the automatic operation selecting switch 116 is on as the examination result of step 360 , the control unit 100 examines whether the boom joystick is in a neutral position through the working unit operating unit 118 at step 308 which is performed.
If the boom joystick is in the neutral position, the process proceeds to step 310 and the control unit 110 outputs a backward movement driving direction controlling command to the driving device controlling unit (TCU) 124 . The driving device controlling unit (TCU) 124 receiving the backward movement driving direction controlling command controls backward movement of the wheel loader.
Thereafter, at step 312 , the control unit 100 examines whether the boom is below the position of the detent which moves up. In this case, the detent position represents a predetermined position of the boom for the detent function of the wheel loader.
When the boom is below the position of the detent which moves up as the examination result of step 312 , the process proceeds to step 314 and the control unit 100 outputs a boom upward movement controlling command to the working unit controlling unit (MCV) 122 . Then, the working unit controlling unit (MCV) 122 moves up the boom up to the detent position.
That is, in the automatic operation mode, when the completion of the excavation is detected by monitoring the current state and thereafter, the backward movement command is given, the working unit controlling unit (MCV) automatically moves up the boom up to the detent position while moving backward.
Therefore, the driver can automatically operate a separate working unit without performing the operation of moving up the boom which is in the pattern capable of moving the load, thereby improving the driver' s convenience.
As described above, although certain exemplary embodiments of the present disclosure have been described in detail, it is to be understood by those skilled in the art that the spirit and scope of the present disclosure are not limited to the certain exemplary embodiments, but are intended to cover various modifications and changes without departing from the gist.
Accordingly, since the above-mentioned exemplary embodiments are provided to inform those skilled in the art of the scope of the present disclosure, it should be understood that they are exemplary in all aspects and not limited and the present disclosure is just defined by the scope of the appended claims.
Although the present invention has been described with reference to disclosed embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the disclosure. The present disclosure can be applied to a wheel loader for providing convenience to a driver.
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The method includes: verifying a working state of the wheel loader through detection of a bucket position and a driving state and examining whether the verified working state is an excavation completed state; examining whether a current position of a driving direction operating lever is a backward-movement position when the verified working state is the excavation completed state as a result of the examination; and automatically moving up a position of a boom up to a predetermined position together with backward driving of the wheel loader depending on whether an automatic operation mode is set when the driving direction operating lever position is the backward-movement position.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 09/655,991, filed Sep. 6, 2000, pending. Application '991 is hereby incorporated by reference as though fully disclosed herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to pull cords used in coverings for architectural openings and more particularly to a braided pull cord and the method of making the cord.
[0004] 2. Description of the Relevant Art
[0005] Most coverings for architectural openings, such as windows, doors, archways and the like, have an operating mechanism that is controlled by a flexible element that can be a fiber based cord, a beaded chain or the like. The control cord or the like typically depends from one end of a headrail for the covering and extends into the headrail through a friction brake and subsequently through carrier elements and around a plurality of pulleys and the like that are associated with the operation of the covering. As a result, the control cord is frictionally engaged at a number of locations and, depending upon the frequency of operation of the covering and the abrasiveness of the elements with which the cord comes into contact, the control elements can easily deteriorate.
[0006] In the case of fiber based cords, the abrasion caused by the various elements in which it comes into contact, causes rapid deterioration of the cords. Cords that have deteriorated have to be replaced and many operating cords in coverings for architectural openings are replaced on an annual basis. When the covering has been warranted, the replacement cost is borne by the manufacturer and, accordingly, the quality and longevity of control cords is a significant economic factor in the covering industry.
[0007] A typical fiber based cord used in coverings for architectural openings is braided from polyester fibers, with the cords typically including sixteen carrier fibers. After braiding of the cord, it is heat treated and wound on storage rolls before being incorporated into a covering product. The braid is relatively tight.
[0008] In trying to resolve the problem of rapidly deteriorating operating cords, applicants initially looked to the hardware of the system to remove any abrasive surfaces across which the cord had to pass. By redesigning various plastic molded parts and the parting lines in the plastic molds for the parts, the wear cycle was improved. The redesigned components were later coated with low friction materials such as Teflon® or zinc to reduce abrasion, but only marginal improvement was noticed. Further, the coatings tended to wear off over time and with exposure to UV light. Applicants then decided that the focus for improving the wear cycle of operating cords needed to be on the cord itself and it is to this end that the present invention has been made.
SUMMARY OF THE INVENTION
[0009] The cord of the present invention is made from high tensile strength fibers with low abrasion characteristics, such as polyethylene fibers. The fibers are braided in an eight-carrier braid that is wound under very high tension and ultimately finished with a urethane coating that is heat cured. The resultant product has provided a wear cycle of many times that achieved with state-of-the-art cords thereby almost removing the problem of manufacturers in having to re-cord coverings for architectural openings. In accordance with the method for making the eight-carrier braid, high tensile strength fibers with low abrasion, such as might be polyethylene fibers, are wound under high tension onto yarn bobbins and eight of the yarn bobbins are then utilized in a conventional braiding apparatus to braid the cord. The braided cord is held under tension and passed through a two-stage heat setting process wherein a urethane coating is applied to the braided cord and the coating is heat cured in the final stage. After the second stage of heating, the cord is wound onto spools for storage until they are strung into coverings for architectural openings.
[0010] Other aspects, features and details of the present invention can be more completely understood by reference to the following detailed description of a preferred embodiment, taken in conjunction with the drawings and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a block diagram illustrating the steps in the process of making the cord in accordance with the present invention.
[0012] [0012]FIG. 2 is a fragmentary diagrammatic isometric view showing yarn from which the cord will be braided being passed from supply spools under tension to bobbins.
[0013] [0013]FIG. 3 is a fragmentary isometric illustrating the bobbins carrying the yarns under tension and being positioned in a braiding apparatus and with the braided cord being wrapped on a storage spool.
[0014] [0014]FIG. 4 is a diagrammatic view showing yarn from storage spools being passed through a two-stage process for coating the yarns with urethane and heat curing the urethane on the yarn before accumulating the yarns on storage spools.
[0015] [0015]FIG. 5 is a fragmentary elevation showing the braided cord in accordance with the present invention.
[0016] [0016]FIG. 6 is a diagrammatic elevation showing a prior art braided cord.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] The method of making a braided control cord for use in coverings for architectural openings in accordance with the present invention is illustrated in a block diagram in FIG. 1. It will there be appreciated that fibers or yarns from which the cord is to be braided are first unwound from spools on which they are supplied and then wound under high tension onto bobbins. From the bobbins, eight yarns are braided into a cord also under high tension and the braided cord is subsequently wound on a transfer spool. The cords are unwound from the transfer spools under tension and fed into a treating apparatus where they are coated with urethane and immediately heat cured in a two-stage process so that the urethane coating is dried and fully cured on the braided cords. After the coating has been heat cured, the yarn is stored on storage spools from which it can be removed when incorporating the cord into an operating mechanism for a covering for architectural openings.
[0018] With reference to FIG. 2, a device 10 for unwinding yarn 12 from preformed spools 14 of yarn is shown in series with a conventional tensioning apparatus 16 for the yarns and a conventional apparatus 18 for wrapping the yarns on bobbins 20 under tension. To provide even greater tension in the yarn than is provided by the conventional tensioning apparatus 16 , the yarns are passed through an additional but conventional washer tensioner (not shown) before they are received by the tensioning apparatus 16 . The device 10 for unwinding the yarn from the spools 14 can be seen to include a plurality of spindles 22 on which the spools 12 of yarn are disposed and the yarn is threaded through low friction ceramic guides 24 associated with each spool so that they can be passed individually to the conventional tensioner (which is not shown) before passing on to the tensioning apparatus 16 . In the tensioning apparatus, they are tensioned in a conventional manner with washer tensioners 25 so that the yarns 12 when passed down to the bobbins 20 are fed to and wound on the bobbins under tension. Each of the devices and apparatuses 10 , 16 and 18 are conventional items such as manufactured by Ratera of Spain.
[0019] The yarns 12 have a high tensile strength in the range of 28-35 grams/denier, and preferably 30 grams/denier, and have low coefficients of friction, low abrasion characteristics and are durable from a flex fatigue standpoint. Examples of yarns that would be suitable for this purpose are Kevlar manufactured by DuPont in the United States, Nomex manufactured by DuPont, Twaron manufactured by Akzo of The Netherlands, Dyneema manufactured by DSM of Holland or Spectra manufactured by the Allied Signal Division of Honeywell, Inc., Petersburg, Va. The yarn or fibers are preferably polyethylene. The tension under which the yarns 12 are wound on the bobbins 20 is preferably in the range of 115 to 140 grams and desirably 120 grams.
[0020] Looking next at FIG. 3, the bobbins 20 with the yarn 12 wound thereon under tension, are placed in a braiding apparatus 26 of a conventional type such as of the type manufactured by Ratera of Spain. In the preferred embodiment of the invention, eight yarns are braided into a cord 27 and after braiding, wound onto a transfer spool 28 . The denier of the yarns is preferably in the range of 275 to 375, which is greater than the denier of yarns typically braided into control cords, as can be evidenced by reference to FIGS. 5 and 6, with FIG. 5 being a cord braided in accordance with the present invention and FIG. 6 a prior art braided cord.
[0021] The transfer rolls of braided cord are then operatively connected to a treatment apparatus 30 (FIG. 4) for final treatment of the cord. Each transfer spool 28 of cord is rotatably mounted on a bracket 32 on the upstream end of the apparatus 30 so that the cord can be fed into and through the treatment apparatus under tension via a conventional tensioner 34 . The tension in the cord is preferably in the range of 150-200 g, with 150 grams being ideal. In the apparatus, 30 the braided cord 27 is first fed through a chamber 36 where the cord is padded with a urethane coating that is applied to the cord. The chamber 36 is fed from a urethane reservoir 37 . By way of example, the coating might be either sprayed onto the cord or the cord might be drawn through a bath of the urethane in order to apply the desired coating to the cord. The latter is preferred. Immediately after the cord is coated with the urethane, it is passed through a heating chamber or oven 38 where the urethane is dried. The temperature in the heating chamber 38 is preferably in the range of 120-140° C. even though temperatures outside that range would work as it would primarily affect the drying time. Subsequent thereto, the cord is passed through another heating chamber 39 where the urethane is cured. The temperature in the curing chamber 39 is preferably in the range of 100-120° C. even though, again, temperatures outside that range would work as the temperature primarily affects the curing time. The total time for drying and curing should ideally be in the range of 60-120 seconds, with 90 seconds being desired. After the cord 27 has been padded with the urethane coating and cured, the final braided cord is wrapped onto a storage spool 40 that is rotatably mounted on brackets 42 at the downstream end of the apparatus 34 . When a predetermined supply of the braided cord 27 is wound onto the storage spool 40 , the spool is removed and retained for later use in the assembly of a covering for an architectural opening. The apparatus 30 for treating the cord with a urethane solution and curing the cord is conventional and may be of the type manufactured by Andersson Mek of Sweden. The urethane solution is a mixture of urethane and water in a concentration of 10% urethane by volume. The urethane is miscible in/with water and preferably itself comes from the chemical family of polyester, polyether polyurethane dispersions and can come from various sources but a urethane marketed under the designation Baypret DLV Dispersion Corporation by Bayer Corporation of Pittsburgh, Pa, has been found suitable for the cord of the present invention.
[0022] A cord formed in accordance with the present invention and as illustrated in FIG. 5, has been found to provide a wear cycle that is approximately ten times that of conventional cords that are presently in use.
[0023] Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example, and changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.
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A method of manufacturing a control cord for use in a covering for architectural openings includes the steps of providing spools of high tensile strength and low abrasion characteristic yarns, tensioning the yarns and winding the yarns under tension on bobbins, placing the bobbins in a braiding apparatus and making an eight-carrier braid from the yarns on the bobbins, and passing the braided cord through a treatment apparatus where a urethane coating is applied to the yarns and heat cured.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to Korean Patent Application No. 2002-44984, filed on Jul. 30, 2002, which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to electronic components for image sensing, capturing, and signal processing and, in particular, to an active image device which can be fabricated using standard CMOS (Complementary Metal Oxide Semiconductor) processes.
BACKGROUND
Charge Coupled Device (CCD) imaging arrays have made possible high quality imagers now used in consumer camcorder equipment, scanners for FAX machines, and video cameras for a wide range of applications including video-conferencing, and portable equipment for professional TV broadcasting.
With the advent of multimedia communications, there arises a need for low cost solid state image sensors to complement computers and communication devices and thus realize practical video telephones and the like. An image input device is central to any teleconferencing and multimedia application. Recently, CMOS image sensors have been recognized as a viable candidate for the image input device. CMOS image sensors also have utility in other fields such as robotics, machine vision, security surveillance, automotive applications and personal ID systems through fingerprint/retina scan. A distinct advantage of CMOS image sensors (or imagers) is that signal processing circuits can be readily integrated on the same chip as the image, thus enabling design of smart, single-chip image acquisition systems. CMOS imagers can be manufactured at lower cost than that of conventional charge coupled devices (CCDs) using conventional, preinstalled CMOS fabrication lines without any process modification.
Since portable electronic equipment operates using batteries, it is preferable to design such equipment to provide low-power consumption. The use of a low-power image device enables portable electronic equipment to consume less power.
As is well known, light is analog data that varies continuously. For discrete signal processing, analog data is converted into digital data. CMOS image devices (or imagers) incorporate a device that detects the light as an analog signal and converts a detected analog signal into digital data. For this, CMOS image devices typically incorporate an analog-to-digital converter. In this respect, one approach to realize a low-power image device is to reduce power consumption of analog-to-digital converters incorporated in the image device. Accordingly, there is a need for an analog-to-digital converter capable of reducing power consumption, which can be used for a CMOS image device.
SUMMARY OF THE INVENTION
The invention is directed to an analog-to-digital (AD) converter that is capable of reducing power consumption, and in particular, to a low-power CMOS image device that comprises an AD converter that provides reduced power consumption.
According to one aspect of the present invention, an analog-to-digital converter circuit comprises a comparator for comparing an analog input signal with a reference signal; an output circuit for generating a digital word indicating a time interval defined by a start signal and an end signal, wherein the end signal indicates a transition of an output of the comparator; and a controller for inactivating the comparator in response to the end signal. For example, the controller inactivates the comparator when the output of the comparator transitions from an active state to an inactive state.
In another aspect of the present invention, a signal processing circuit outputs a digital word corresponding to a current source controlled by a physical response. The signal processing circuit comprises: an analog integrated circuit for generating an analog signal in response to a time varying reference signal and a signal corresponding to the current source controlled by the physical response; a reference signal generator for generating a reference signal; a comparator for comparing the analog signal with the reference signal; an output circuit for generating the digital word indicating a time interval defined by a start signal and an end signal, wherein the end signal indicates a transition of an output of the comparator; and a controller for inactivating the comparator in response to the end signal. For example, the controller inactivates the comparator when the output of the comparator transitions from an active state to an inactive state. The controller includes an S-R latch that generates a first enable signal in response to an output of the comparator and a second enable signal, the comparator being inactivated or activated by the first enable signal.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the present invention, and many of the attendant advantages thereof, will become readily apparent as preferred embodiments become better understood by reference to the following detailed description when considered in conjuction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein:
FIG. 1 is a schematic diagram of a CMOS image device according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a correlated double sampling (CDS) circuit and an output circuit according to embodiments of the invention;
FIG. 3 is a circuit diagram of a comparator according to an embodiment of the invention, which is preferably used in the circuit of FIG. 2 ;
FIG. 4 is a circuit diagram of an enable controller according to an embodiment of the invention, which is preferably used in the circuit of FIG. 2 ; and
FIG. 5 is a timing diagram for describing an operation of a CMOS image device according to an embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will now be described in detail with reference to the attached drawings. FIG. 1 shows a CMOS image device according to a preferred embodiment of the present invention. A CMOS image device includes a sensor array 10 , a timing and control logic 20 , a ramp voltage generator circuit 30 , a counter circuit 40 , a plurality of correlated double sampling (CDS) circuits 60 1 – 60 N , and a plurality of output circuits 70 1 – 70 N .
The sensor array 10 incorporates a plurality of active cells (or pixels) 12 that are arranged in rows R 1 –R M and columns C 1 –C N . Active cells in a row are simultaneously activated to read out an image from a row of active cells. The timing and control logic 20 provides row select signals onto corresponding row select lines RSL 1 –RSL M to select and activate any row. The logic 20 also provides reset signals onto corresponding reset lines RST 1 –RST m . Charges induced from respective active cells 12 by light are transferred onto corresponding column data lines 14 1 – 14 N that are connected with the active cells 12 in respective columns C 1 –C N . At any time, voltage on each column is determined by image charges from one active cell in a corresponding column and a selected row. Signal lines 16 1 – 16 N are connected with active cells 12 in corresponding rows R 1 –R M , and transfer control signals VTG1–VTG M for driving corresponding active cells 12 .
The CDS circuits 60 1 – 60 N are connected with ends of column data lines 14 1 – 14 N , respectively. Each of the CDS circuit 60 1 – 60 N receives voltage on a corresponding column data line and a ramp voltage VRAMP from the ramp voltage generator circuit 30 , and generates an analog signal in response to received voltages. For example, the CDS circuit 60 1 of the first column receives voltage VPXL 1 on a column data line 14 1 and the ramp voltage VRAMP, and generates an analog signal VA 1 in response to received voltages VPXL 1 and VRAMP. The CDS circuit 60 N of the last column receives voltage VPXL N on a column data line 14 N and the ramp voltage VRAMP, and generates an analog signal VA N in response to received voltages VPXL N and VRAMP. The ramp voltage generator circuit 30 generates the ramp voltage VRAMP in response to a ramp enable signal RAMP_EN from the timing and control logic 20 . The ramp voltage VRAMP is a time varying reference voltage that varies with a predetermined slope.
Each of the output circuits 70 1 – 70 N receives an analog signal from a corresponding CDS circuit, a reference voltage VREF from the timing and control logic 20 , an output CNT of the counter 40 , and an enable signal C_ENb from the timing and control logic 20 , and generates a digital word corresponding to a received analog signal. For example, the output circuit 70 1 in the first column receives an analog signal VA 1 from a CDS circuit 60 1 , the reference voltage VREF, the output CNT of the counter 40 , and the enable signal C_ENb, and generates a digital word D 1 corresponding to the received analog signal VA 1 . The output circuit 70 N in the last column receives an analog signal VA N from a CDS circuit 60 N , the reference voltage VREF, the output CNT of the counter 40 , and the enable signal C_ENb, and generates a digital word D N corresponding to the received analog signal VA N .
FIG. 2 is a circuit diagram of a CDS circuit and an output circuit according to embodiments of the invention, which correspond to one column of a sensor array in FIG. 1 . A CDS circuit 60 1 and an output circuit 70 1 corresponding to the first column 14 1 are illustrated in FIG. 2 , but it is well understood to one of ordinary skill in the art that circuits corresponding to remaining columns are constructed in the same way as in FIG. 2 .
Referring to FIG. 2 , an active cell 12 includes four NMOS transistors ( 101 , 102 , 103 and 104 ) and a photodiode PD 1 . The NMOS transistor 101 whose gate is connected with a reset line RST 1 has its current path formed between a power supply voltage VDD and an internal node 110 . A reset signal RESET is transferred via the reset line RST 1 . The NMOS transistor 102 has its gate connected to a signal line 16 1 and its current path formed between the internal node 110 and a cathode of the photodiode PD 1 . An anode of the photodiode PD 1 is grounded, and a control signal VTG 1 is transferred via the signal line 16 1 . The NMOS transistors 103 and 104 are connected between the power supply voltage VDD and the column data line 14 1 . A gate of the NMOS transistor 103 is connected with the internal node 110 , and a gate of the NMOS transistor 104 is connected to receive a row select signal ROWSEL on a row select line RSL 1 .
In the aforementioned active cell structure, when the photodiode PD 1 is exposed to light, voltage VPXL 1 of the column data line 14 1 will be determined according to the intensity of the light. For example, when the light is intense the voltage VPXL 1 becomes lower in level than that when the light is weak.
The CDS circuit 60 1 incorporates two switches ( 120 , 122 ) and two capacitors ( 121 , 123 ). The switch 120 is operatively connected to the column data line 14 1 and the capacitor 121 . The switch 122 is operatively connected to a ramp voltage VRAMP input and the capacitor 123 . The capacitor 121 is operatively connected to the capacitor 123 and the output circuit 70 1 . The switches ( 120 , 122 ) are controlled by corresponding control signals (S 1 , S 2 ) that are provided from the timing and control logic 20 in FIG. 1 .
The output circuit 70 1 includes a comparator 71 , a switch 72 , an enable signal generator 73 , and a latch 74 . The comparator 71 has its non-inverting input terminal connected to a reference voltage VREF, which is received from the timing and control logic 20 and its inverting input terminal connected to an analog signal VA 1 , which is received from the CDS circuit 60 1 . The reference voltage VREF, for example, is half a power supply voltage VDD/2. The comparator 71 compares a voltage of the analog signal VA 1 with the reference voltage VREF to output a signal VOUT based on a comparison result. The switch 72 is connected between inverting input and output terminals of the comparator 71 , and is switched on or off by a control signal S 3 that is provided from the timing and control logic 20 . The enable signal generator 73 generates an enable signal CMP_EN in response to an output VOUT of the comparator 71 and a control signal C_ENb from the timing and control logic 20 . The enable signal generator 73 functions as a controller for activating or inactivating the comparator 71 . The latch 74 latches an output value CNT of the counter 40 ( FIG. 1 ) when the output VOUT transitions from an active state to an inactive state.
FIG. 3 is a preferred embodiment of the comparator 71 illustrated in FIG. 2 . The comparator 71 is preferably a differential amplifier that includes two PMOS transistors ( 201 , 202 ) and four NMOS transistors ( 203 , 204 , 205 , and 206 ). The PMOS transistor 201 has its source connected with a power supply voltage VDD. The PMOS transistor 202 has its source connected with the power supply voltage VDD, its gate connected to a gate of the PMOS transistor 201 , and its drain connected to an output terminal VOUT. A drain of the NMOS transistor 203 is connected in common with the drain and gate of the transistor 201 , and a gate thereof is connected to receive a reference voltage VREF. The NMOS transistor 204 whose gate is connected with an analog signal VA 1 has its drain connected to the output terminal VOUT. The NMOS transistors ( 205 , 206 ) are connected between a common-source node of the transistors ( 203 , 204 ) and a ground voltage. A gate of the transistor 205 is connected to a bias voltage BIAS, and a gate of the transistor 206 is connected to receive an enable signal CMP_EN from the enable signal generator 73 in FIG. 2 .
When the enable signal CMP_EN is at a high level, the comparator 71 compares the reference voltage VREF with the analog voltage VA 1 to output a signal VOUT as a comparison result. On the other hand, when the enable signal CMP_EN is at a low level, the comparator 71 does not operate.
FIG. 4 is a preferred embodiment of the enable signal generator 73 illustrated in FIG. 2 . The enable signal generator 73 preferably includes an S-R latch that receives an output VOUT of a comparator 71 in FIG. 2 and a control signal C_ENb to generate an enable signal CMP_EN. The S-R latch includes two NAND gates ( 301 , 302 ) which are connected as illustrated in FIG. 4 . In accordance with this structure, the enable signal CMP_EN is inactivated low when the output VOUT transitions from a high level to a low level after a low-to-high transition of the control signal C_ENb.
FIG. 5 is a timing diagram for describing an operation of a CMOS image device according to an embodiment of the present invention. An operation of the present CMOS image device will be more fully described with reference to FIGS. 2 to 5 . It is assumed that a row select signal ROWSEL connected to an active cell 12 in the first row R 1 and column C 1 is activated.
In a reset sampling period, when a reset signal RESET on a signal line RST 1 is at a high level, the node 110 is charged to a voltage of (VDD-Vth) via NMOS transistor 101 (wherein Vth is a threshold voltage of the NMOS transistor 101 ). At this time, voltage VPXL 1 on column data line 14 1 increases in proportion to voltage of the internal node 110 . For instance, since the amount of current flowing through NMOS transistor 103 as a source follower is determined by voltage of the internal node 110 , the voltage VPXL 1 on column data line 14 1 increases in proportion to the voltage of the internal node 110 . On the other hand, voltage variation of the internal node 110 is reflected on the column data line 14 1 through the NMOS transistors ( 103 , 104 ). The voltage VPXL 1 on the column data line 14 1 will be detected by CDS circuit 60 1 .
As illustrated in FIG. 5 , control signals (S 1 , S 2 , and S 3 ) have a “high” logic level during a reset sampling period, so that switches ( 120 , 122 , and 72 ) are activated, respectively. As the inverting input and output terminals of comparator 71 are interconnected via the switch 72 , the inverting input terminal of the comparator 71 has a reference voltage VREF(=VDD/2). For example, as an input signal of the inverting input terminal of the comparator 71 , an analog signal VA 1 is equal to the reference voltage VREF. When the control signals (S 1 , S 2 , and S 3 ) transition to a low level, the analog signal VA 1 continues to be equal to the reference voltage VREF due to charges in capacitor 121 .
In a signal sampling period, as signal line VTG 1 of a selected row is pulsed high, charges on the internal node 110 are transferred to photodiode PD 1 . The voltage across the photodiode PD 1 corresponds to the intensity of light, and voltage of the internal node 110 becomes a gate voltage of source follower transistor 103 . Therefore, voltage VPXL 1 of column data line 14 1 becomes the voltage corresponding to the voltage of the internal node 110 . In the signal sampling period, the switches ( 120 , 122 ) are turned on in response to high-level signals (S 1 , S 2 ), respectively.
At this time, voltage of analog signal VA 1 is lowered to the same as varied amplitude of the voltage VPXL 1 . Enable signal generator 73 activates enable signal CMP_EN having a high logic level in response to a control signal C_ENb of a low logic level, which activates the comparator 71 .
And then, the control signal S 1 transitions from a high logic level to a low logic level and the control signal S 2 is maintained high. After the control signal S 1 transitions from a high level to a low level, control signals RAMP_EN and CNT_EN all are activated high, as illustrated in FIG. 5 . At this time, the C_ENb signal is inactivated high. A ramp voltage generator 30 generates a ramp voltage VRAMP in response to activation of the signal RAMP_EN. As illustrated in FIG. 5 , the ramp voltage VRAMP increases with a constant slope. Since the control signal S 2 is at a high level, the voltage of the analog signal VA 1 also increases in proportion to increase the ramp voltage VRAMP. Meanwhile, the counter 40 ( FIG. 1 ) is activated by activation of the signal CNT_EN and counts cycles of a clock signal CLK from a timing and control logic 20 .
The comparator 71 compares the voltage of the analog signal VA 1 with the reference voltage VREF. If the voltage of the analog signal VA 1 is higher than the reference voltage VREF, latch 74 receives and latches an output value CNT from the counter 40 when an output signal VOUT transitions from a high level to a low level. Data in the latch 74 will be provided to an image input device (or an image data processing device) as a digital word D 1 corresponding to the analog signal VA 1 .
Meanwhile, the enable signal generator 73 inactivates the enable signal CMP_EN low in response to a high-to-low transition of the signal VOUT. This inactivation of the enable signal CMP_EN causes the comparator 71 to be inactivated. At this time, data in the latch 74 continues to be maintained without modification.
An operating time interval of the comparator 71 is measured from an activation point of the enable signal CMP_EN to an inactivation point thereof, for example, until voltage of the analog signal VA 1 becomes higher than the reference voltage, as illustrated in FIG. 5 . An inactivated state of the comparator 71 is maintained until the enable signal CMP_EN is activated again. By so doing, power consumption is reduced as compared with the case that the comparator 71 is always activated while a CMOS image device operates. The intensity of light received by the photodiode PD 1 corresponds to a time until the voltage of the analog signal VA 1 becomes higher than the reference voltage VREF after starting to increase with a constant slope. For example, an inactive period of the comparator 71 is in inverse proportion to the intensity of the light received to the photodiode PD 1 . Also, although input signals VA 1 and VREF to the comparator 71 are changed owing to unwanted noise, the digital word D 1 in the latch 74 is not modified. Accordingly, there is reduced the affect on the digital word due to noise caused after a latch operation is completed.
The invention has been described using exemplary preferred embodiments. However, it is to be understood that the scope of the invention is not limited to the preferred embodiments disclosed through the specification. On the contrary, it is intended to cover various modifications and similar arrangements. The scope of the claims, therefore, should be accorded the broadest interpretation to encompass all such modifications and similar arrangements.
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Disclosed is a signal processing circuit which outputs a digital word corresponding to a current source controlled by a physical response. The signal processing circuit includes an analog integrated circuit for generating an analog signal in response to a time varying reference signal and a signal corresponding to the current source controlled by the physical response, a reference signal generator for generating a reference signal, a comparator for comparing the analog signal with the reference signal, an output circuit for generating the digital word indicating a time interval defined by a start signal and an end signal indicating a transition of an output of the comparator, and a controller inactivating the comparator in response to the end signal.
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FIELD OF THE INVENTION
[0001] The present invention relates to traveling control system for a construction machine. More particularly, the present invention relates to a traveling control system for a construction machine, which can prevent a single traveling of the machine due to occurrence of an overload in an attachment (or work apparatus) such as a boom during a combined operation in which a traveling operation and a working operation are performed simultaneously.
BACKGROUND OF THE INVENTION
[0002] A traveling control system for a construction machine in accordance with the prior art as shown in FIGS. 1 and 2 includes:
[0003] first and second variable displacement hydraulic pumps (hereinafter, “first and second hydraulic pumps”) 15 and 18 ;
[0004] a left traveling motor 2 that is connected to the first hydraulic pump 15 and is driven by being supplied with a hydraulic fluid, and a first attachment (not shown) such as an arm;
[0005] a plurality of switching valves 12 and 26 that are installed in a flow path 1 of the first hydraulic pump 15 and are shifted in response to pilot signal pressures a1 and b1 applied thereto to control a hydraulic fluid being supplied to the left traveling motor 2 to the first attachment;
[0006] a right traveling motor 3 that is connected to the second hydraulic pump 18 and is driven by being supplied with the hydraulic fluid, and a second attachment (not shown) such as a boom;
[0007] a plurality of switching valves 11 and 28 that are installed in a flow path 9 of the second hydraulic pump 18 and are shifted in response to pilot signal pressures a2 and b2 applied thereto to control a hydraulic fluid being supplied to the right traveling motor 3 or the second attachment; and
[0008] a straight traveling valve 4 that is installed in the flow path 9 and is shifted in response to a pilot signal pressure a3 to supply the hydraulic fluid discharged from the first hydraulic pump 15 to the left and right traveling motors 2 and 3 and to supply a part of the hydraulic fluid discharged from the second hydraulic pump 18 to the switching valve 26 for the first attachment through a flow path 32 and simultaneously supply a part of the hydraulic fluid discharged from the second hydraulic pump 18 to the switching valve 28 for the second attachment through the flow path 7 , respectively.
[0009] A non-explained reference numeral 10 denotes a main relief valve that drains a hydraulic fluid of an excessive pressure to a hydraulic tank T when an overload exceeding a set pressure in a hydraulic circuit occurs, and a reference symbol s denotes a spool on the switching valve 11 for controlling the hydraulic fluid supplied to the right traveling motor 3 .
[0010] A) The case of performing the traveling operation alone will be described hereinafter.
[0011] When the pilot signal pressure a1 is applied to the switching valve 12 for the left traveling motor, a spool of the switching valve 12 is shifted to the left on the drawing sheet. Thus, a hydraulic fluid discharged from the first hydraulic pump 15 is supplied to the left traveling motor 2 via the flow path 1 , the switching valve 12 , and a traveling line 14 in this order.
[0012] When the pilot signal pressure a2 is applied to the switching valve 11 for the right traveling motor, a spool of the switching valve 11 is shifted to the right on the drawing sheet. Thus, a hydraulic fluid discharged from the second hydraulic pump 18 is supplied to the right traveling motor 3 via the flow path 9 , the switching valve 11 , and a traveling line 20 in this order. In other words, in the case where the left traveling motor 2 or the right traveling motor 3 is driven alone, the hydraulic fluid discharged from the first hydraulic pump 15 is supplied to the left traveling motor 2 , and the hydraulic fluid discharged from the second hydraulic pump 18 is supplied to the right traveling motor 3 .
[0013] B) The case of performing the combined operation of the traveling operation and the working operation will be described hereinafter.
[0014] When the pilot signal pressure a3 is applied to the straight traveling valve 4 , a spool of the straight traveling valve 4 is shifted to the right on the drawing sheet. At the same time, when the pilot signal pressure b1 is applied to the switching valve 26 for the first attachment, a spool of the switching valve 26 is shifted to the left on the drawing sheet. When a signal pressure c1 is applied to a first center bypass valve 22 , a spool of the first center bypass valve 22 is shifted to the left on the drawing sheet to form a pressure in a first center bypass flow path.
[0015] Thus, apart of the hydraulic fluid from the first hydraulic pump 15 is supplied to the left traveling motor 2 via the flow path 1 , the switching valve 12 , and the traveling line 14 in this order. At the same time, a part of the hydraulic fluid from the first hydraulic pump 15 is supplied to the right traveling motor 3 via the flow path 9 , the straight traveling valve 4 , the switching valve 11 , and the traveling line 20 in this order. That is, the hydraulic fluid discharged from the first hydraulic pump 15 is used to drive the left traveling motor 2 and the right traveling motor 3 .
[0016] Meanwhile, the hydraulic fluid from the second hydraulic pump 18 is supplied to the switching valve 26 for the first attachment via the flow path 9 , the straight traveling valve 4 , and the flow path 32 in this order to drive a corresponding attachment (e.g., an arm). That is, the hydraulic fluid discharged from the second hydraulic pump 18 is used to drive a corresponding attachment by being supplied to the switching valve 26 for the first attachment.
[0017] Under the straight traveling condition as described above, when the spool of the switching valve 26 is shifted to a full stroke by gradually increasing a pressure needed to shift the switching valve 26 for the first attachment, the pressure rises up to the set pressure of the main relief valve 10 . In this case, the hydraulic fluid from the second hydraulic pump 18 is not supplied to the switching valve 26 for the first attachment any more.
[0018] In other words, apart of the hydraulic fluid being supplied to the switching valve 26 is supplied to the right traveling motor 3 via the check valve 5 and the orifice 6 after passing through the flow path 32 , the straight traveling valve 4 , the flow path 9 , and the flow path 7 . In addition, a part of the hydraulic fluid being supplied to the switching valve 26 is supplied to the left traveling motor 2 via the flow path 8 .
[0019] In this case, the switching valves 12 and 11 for the traveling motors are shifted in response to the pilot signal pressures a1 and a2 applied thereto. When the combined operation is performed, a pilot signal pressure on the traveling side is maintained at about 10-12K to shift the switching valves 11 and 12 . For this reason, in case of an intermediate shift section, the switching valves 11 and 12 for the traveling motors can be controlled by a P-N notch (i.e., a notch that controls the hydraulic fluid flowing from the hydraulic pump to the hydraulic tank), a P-C notch (i.e., a notch that controls the hydraulic fluid flowing from the hydraulic pump to the hydraulic cylinder), and a C-T notch (i.e., a notch that controls the hydraulic fluid flowing from the hydraulic cylinder to the hydraulic tank).
[0020] In the structure of the conventional hydraulic circuit, in the case where the switching valve 26 and the first center bypass valve 22 are shifted, no hydraulic fluid flows by the P-N notch. For this reason, the switching valves 11 and 12 can be controlled by the P-C notch or the C-T notch. In this case, the spool notches of the switching valves 11 and 12 for the traveling motors have the same structure. On the other hand, it is difficult to maintain the same cross section due to a difference in the stack tolerance for processing the spool and the process conditions.
[0021] In other words, the flow rate of a hydraulic fluid passing through the spool is in proportion to the cross section of the spool. Thus, if there is a difference in cross section of the spool notch, the flow rates of the hydraulic fluids passing through the switching valves 12 and 11 for the traveling motors are different from each other. That is, if the flow rates of the hydraulic fluids passing through the switching valves 12 and 11 for the traveling motors are different from each other, the drive speed of the traveling motor through which a relatively large amount of hydraulic fluid passes is abruptly increased. On the contrary, the drive speed of the traveling motor through which a relatively small amount of hydraulic fluid passes is decreased.
[0022] As described above, the spools of the switching valves 12 and 11 for the traveling motors are shifted to an intermediate level to drive the traveling motors 2 and 3 . In this case, the spool of the straight traveling valve 4 is in a state of having been completely shifted. At the same time, a single traveling of the machine is caused due to occurrence of an overload in the attachment during the combined operation in which the traveling operation and the working operation of an attachment such as a boom are performed.
[0023] In addition, when an attachment has a load applied thereto during the traveling of the machine (e.g., a state in which a heavy pipe or the like is lifted), it is not operated. That is, in the case where a boom or the like is operated during the traveling of the machine, when a great load occurs on the boom and a relatively small load occurs on the traveling side, the boom is not operated.
[0024] When the switching valve 26 for the attachment is shifted while driving the switching valves 12 and 11 for the traveling motors, the hydraulic fluid from the first hydraulic pump 15 drives the left traveling motor 2 and the hydraulic fluid from the second hydraulic pump 18 drives the right traveling motor 3 . In this case, the straight traveling valve 4 is not shifted.
[0025] In the case where the switching valve 26 for the attachment is shifted, the straight traveling valve 4 is shifted by the pilot signal pressure a3. In this case, hydraulic fluid from the first hydraulic pump 15 is supplied to the switching valves 12 and 11 via the flow path 1 and the flow path 8 , respectively. In addition, the hydraulic fluid from the second hydraulic pump 18 is supplied to the switching valve 26 via the flow path 9 , and is supplied to the switching valve 11 after passing through the check valve 5 and the orifice 6 via the flow path 7 .
[0026] Meanwhile, in the case where a great load occurs on the hydraulic fluid being supplied to switching valve 26 (e.g., the case in which an orifice is formed), i.e., an orifice smaller than the orifice 6 of the switching valve 11 side is installed, all the hydraulic fluids from the second hydraulic pump 18 are supplied to the switching valve 11 . As a result, there is caused a problem in that the attachment of the switching valve 26 side is not driven.
[0027] In an attempt to address and solve the above-mentioned problem, a gap 16 defined between the outer periphery of a poppet 13 and the inner periphery of a body 17 of a switching valve is machined to have a small size to make the orifice 6 small as shown in FIG. 2 . A non-explained reference numeral 19 denotes an elastic member (e.g., a compression coil spring) that presses the poppet 13 to elastically biases the poppet 13 to an initial state from the blocked state of the branch flow path 7 a.
[0028] On the other hand, when the gap is machined to have a large size, the poppet 13 and the body 17 of the switching valve come into close contact with each other to cause a noise. For this reason, the gap 16 between the poppet 13 and the body 17 of the switching valve is machined to have a minimum size within a tolerance range in which any noise is not generated from the gap.
DETAILED DESCRIPTION OF THE INVENTION
Technical Problems
[0029] Accordingly, the present invention has been made to solve the aforementioned problem occurring in the prior art, and it is an object of the present invention to provide a traveling control system for a construction machine, which can prevent a single traveling of the machine due to occurrence of an overload in an attachment such as a boom during a combined operation in which a traveling operation and a working operation are performed simultaneously, and enables the combined operation of a traveling operation and a working operation to be performed even when a load occurs in the attachment
Technical Solution
[0030] To accomplish the above object, in accordance with an embodiment of the present invention, there is provided a traveling control system for a construction machine in accordance with an embodiment of the present invention, the system including:
[0031] first and second variable displacement hydraulic pumps;
[0032] a left traveling motor connected to the first hydraulic pump and a first attachment;
[0033] a plurality of switching valves installed in a flow path 1 of the first hydraulic pump and configured to be shifted to control a hydraulic fluid being supplied to the left traveling motor and the first attachment;
[0034] a right traveling motor connected to the second hydraulic pump and a second attachment;
[0035] a plurality of switching valves installed in a flow path of the second hydraulic pump and configured to be shifted to control a hydraulic fluid being supplied to the right traveling motor and the second attachment;
[0036] a straight traveling valve installed in the flow path of the second hydraulic pump and configured to be shifted to supply the hydraulic fluid discharged from the first hydraulic pump to the left and right traveling motors and to supply the hydraulic fluid discharged from the second hydraulic pump to the first attachment and the second attachment, respectively; and
[0037] a control valve installed in a branch flow path having an inlet side that is connected to a flow path branched off from the flow path of the second hydraulic pump and an outlet side that is connected to the flow path of the second hydraulic pump on a downstream side of the straight traveling valve, and configured to serve as a check valve and an orifice so as to interrupt the supply of the hydraulic fluid from the second hydraulic pump to the left traveling motor and the right traveling motor via the straight traveling valve during a combined operation in which a traveling operation and a working operation are performed simultaneously.
[0038] In a preferred embodiment of the present invention, the control valve may include:
[0039] a first poppet configured to open/close the branch flow path that fluidically communicates with an inlet-side flow path of the switching valve for the traveling motor, the first poppet having a first orifice formed thereon;
[0040] a second poppet installed inside the first poppet and having a second orifice formed thereon;
[0041] an elastic member configured to allow the second poppet to be pressed against the first poppet to elastically support the second poppet in a state in which a flow path of the first poppet is closed; and
[0042] a flange securely fixed to a body of the control valve to support the elastic member so as to allow the first and second poppet to be kept at set pressures thereof.
[0043] A control valve that is shifted to an on/off state to open/close the pilot signal line in response to a control signal applied from the outside may be used as a valve installed on a pilot signal line for supplying a pilot signal pressure to the straight traveling valve to shift the straight traveling valve.
[0044] An electronic proportional valve that outputs a secondary pilot signal pressure generated during the driving in proportion to a control signal applied from the outside may be used as a valve installed on a pilot signal line for supplying pilot signal pressure to the straight traveling valve to shift the straight traveling valve.
[0045] The first attachment connected to the first hydraulic pump may be any one selected from a boom, an arm, a bucket, a swing motor, and a winch motor.
[0046] The control valve may include a tapered portion formed on the outer surface of the first poppet that is in close contact with the body of the control valve to serve as a damper when the branch flow path is blocked through the mutual close contact between the first poppet and the body of the control valve.
[0047] The control valve may include a notch portion formed on the outer surface of the first poppet that is in close contact with the body of the control valve to serve as a damper when the branch flow path is blocked through mutual close contact between the first poppet and the body of the control valve.
[0048] The control valve may include a sealing O-ring that prevents the hydraulic fluid from leaking to the outside through a gap of a close contact surface between the body of the control valve and the flange.
Advantageous Effect
[0049] The travel control system for a construction machine in accordance with an embodiment of the present invention as constructed above has the following advantages.
[0050] It is possible to prevent a single traveling of the machine due to occurrence of an overload in an attachment such as a boom, and ensure the workability of the attachment, thereby improving the manipulability of the attachment during a combined operation in which a traveling operation and a working operation are performed simultaneously. In addition, when an operation mode is switched to a neutral position, occurrence of a shock can be prevented and the manufacturing cost can be reduced owing to simplicity of the structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] The above objects, other features and advantages of the present invention will become more apparent by describing the preferred embodiments thereof with reference to the accompanying drawings, in which:
[0052] FIG. 1 is a hydraulic circuit diagram showing a traveling control system for a construction machine in accordance with the prior art;
[0053] FIG. 2 is an exploded cross-sectional view showing a main element of a switching valve for traveling shown in FIG. 1 ; and
[0054] FIG. 3 is an exploded cross-sectional view showing a main element of a switching valve for traveling in a control system for a construction machine in accordance with an embodiment of the present invention.
EXPLANATION ON REFERENCE NUMERALS OF MAIN ELEMENTS IN THE DRAWINGS
[0000]
7 a : branch flow path
30 : control valve
31 : first orifice
32 : first poppet
33 : second orifice
34 : second poppet
35 : elastic member
36 : fastening member
37 : flange
38 : O-ring
PREFERRED EMBODIMENTS OF THE INVENTION
[0065] Now, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. The matters defined in the description, such as the detailed construction and elements, are nothing but specific details provided to assist those of ordinary skill in the art in a comprehensive understanding of the invention, and the present invention is not limited to the embodiments disclosed hereinafter.
[0066] As shown in FIG. 3 , a traveling control system for a construction machine in accordance with an embodiment of the present invention includes:
[0067] first and second variable displacement hydraulic pumps (hereinafter, “first and second hydraulic pumps”) 15 and 18 ;
[0068] a left traveling motor 2 that is connected to the first hydraulic pump 15 and a first attachment (e.g., an arm);
[0069] a plurality of switching valves 12 and 26 that are installed in a flow path 1 of the first hydraulic pump 15 and are shifted to control a hydraulic fluid being supplied to the left traveling motor 2 and the first attachment;
[0070] a right traveling motor 3 that is connected to the second hydraulic pump 18 and a second attachment (e.g., a boom);
[0071] a plurality of switching valves 11 and 28 that are installed in a flow path 9 of the second hydraulic pump 18 and are shifted to control a hydraulic fluid being supplied to the right traveling motor 3 and the second attachment;
[0072] a straight traveling valve 4 that is installed in the flow path 9 of the second hydraulic pump 18 and is shifted to supply the hydraulic fluid discharged from the first hydraulic pump 15 to the left and right traveling motors 2 and 3 and to supply the hydraulic fluid discharged from the second hydraulic pump 18 to the first attachment and the second attachment, respectively; and
[0073] a control valve 30 that is installed in a branch flow path 7 a having an inlet side that is connected to a flow path 7 branched off from the flow path 9 of the second hydraulic pump 18 and an outlet side that is connected to the flow path 9 of the second hydraulic pump 18 on a downstream side of the straight traveling valve 4 , and serves as a check valve and an orifice so as to interrupt the supply of the hydraulic fluid from the second hydraulic pump 18 to the left traveling motor 2 and the right traveling motor 3 via the straight traveling valve 4 during a combined operation in which a traveling operation and a working operation are performed simultaneously.
[0074] The control valve 30 includes:
[0075] a first poppet 32 that opens/closes the branch flow path 7 a that fluidically communicates with an inlet-side flow path of the switching valve 11 for the right traveling motor, the first poppet having a first orifice 31 formed thereon;
[0076] a second poppet 34 that is installed inside the first poppet 32 and having a second orifice 33 formed thereon;
[0077] an elastic member (e.g., a compression coil spring) 35 that allows the second poppet 34 to be pressed against the first poppet 32 to elastically support the second poppet 34 in a state in which a flow path 32 a of the first poppet 32 is closed; and
[0078] a flange 37 that is securely fixed to a body 17 of the control valve by means of a fastening member (e.g., a bolt) to support the elastic member 35 so as to allow the first and second poppet 34 to be kept at set pressures thereof.
[0079] A control valve (not shown) that is shifted to an on/off state to open/close the pilot signal line in response to a control signal applied from the outside may be used as a valve installed on a pilot signal line for supplying a pilot signal pressure to the straight traveling valve 4 to shift the straight traveling valve 4 .
[0080] An electronic proportional valve (not shown) that outputs a secondary pilot signal pressure generated during the driving in proportion to a control signal applied from the outside may be used as a valve installed on a pilot signal line for supplying pilot signal pressure to the straight traveling valve 4 to shift the straight traveling valve 4 .
[0081] The first attachment connected to the first hydraulic pump 15 is any one selected from a boom, an arm, a bucket, a swing motor, and a winch motor, except the traveling motors.
[0082] The control valve 30 includes a tapered portion (not shown) formed on the outer surface of the first poppet 32 that is in close contact with the body 17 of the control valve to serve as a damper when the branch flow path 7 a is blocked through the mutual close contact between the first poppet 32 and the body 17 of the control valve.
[0083] The control valve 30 includes a notch portion (not shown) formed on the outer surface of the first poppet 32 that is in close contact with the body 17 of the control valve to serve as a damper when the branch flow path 7 a is blocked through mutual close contact between the first poppet 32 and the body 17 of the control valve.
[0084] The control valve system further includes a sealing O-ring that prevents the hydraulic fluid from leaking to the outside through a gap of a close contact surface between the body 17 of the control valve and the flange 37 .
[0085] In this case, a configuration of a control system for a construction machine in accordance with an embodiment of the present invention is the same as that of the hydraulic system shown in FIG. 1 , except the control valve 30 that is installed in a branch flow path 7 a and serves as a check valve and an orifice so as to prevent a single traveling of the machine during a combined operation in which a traveling operation and a working operation are performed simultaneously. Thus, the detailed description of the same configuration and operation thereof will be omitted to avoid redundancy, and the same elements are denoted by the same reference numerals.
[0086] Hereinafter, a use example of a traveling control system for a construction machine in accordance with an embodiment of the present invention will be described in detail with reference to the accompanying drawings.
[0087] As shown in FIG. 3 , a case of a combined operation in which an attachment such as an arm is driven during the traveling of the machine will be described hereinafter.
[0088] When a spool inside the straight traveling valve 4 is shifted to the right on the drawing sheet of FIG. 1 in response to a pilot signal pressure a3 applied to the straight traveling valve 4 , a hydraulic fluid discharge from the first hydraulic pump 15 is supplied to the left traveling motor 2 via the flow path 1 , the switching valve 12 , and a traveling line 14 in this order. In addition, the hydraulic fluid from the first hydraulic pump 15 is supplied to the right traveling motor 3 via the flow path 8 , the straight traveling valve 4 , the switching valve 11 , and a traveling line 20 in this order, so that these elements are driven, respectively.
[0089] At the same time, a hydraulic fluid discharge from the second hydraulic pump 18 is supplied to an attachment such as an arm via the flow path 9 , the straight traveling valve 4 , a flow path 32 , and the switching valve 26 in this order. In addition, the hydraulic fluid from the second hydraulic pump 18 is moved to the flow path 7 via the flow path 32 , the straight traveling valve 4 , and the flow path 9 in this order. The hydraulic fluid moved to the flow path 7 sequentially passes through a check valve 5 and an orifice 6 that are installed in the branch flow path 7 a.
[0090] In other words, the hydraulic fluid from the second hydraulic pump 18 is moved to the branch flow path 7 a to cause the first poppet 32 to be pushed to the top on the drawing sheet due to a difference in cross section between the second poppet 34 and a pressure-receiving portion, so that the branch flow path 7 a is opened. At this time, the second poppet 34 is closed by an elastic force of the elastic member 35 to cause the flow path 32 a of the first poppet 32 to be blocked.
[0091] In this case, a stroke of the first poppet 32 is small, and thus the hydraulic fluid in the branch flow path 7 a passes through a gap (a) defined between the first poppet 32 and the body 17 of the control valve 30 . That is, the hydraulic fluid in the branch flow path 7 a passes through the tapered portion or the notch portion formed on the first poppet 32 . The second poppet 34 is pushed to the top on the drawing sheet to open the flow path 32 a by a pressure introduced into the flow path 32 a of the first poppet 32 due to an increase in pressure of the branch flow path 7 a.
[0092] Thus, a part of the hydraulic fluid in the branch flow path 7 a passes through the flow path 32 a and the first orifice 31 that are formed in the first poppet 32 , and simultaneously passes through the gap (a) defined between the first poppet 32 an the body 17 of the control valve 30 .
[0093] Meanwhile, in the case where the supply of the hydraulic fluid to the branch flow path 7 a is interrupted, the first poppet 32 returns to an initial position to cause the first poppet 32 an the body 17 of the control valve 30 to come into close contact with each other, so that the branch flow path 7 a is blocked and then the second poppet 34 returns to an initial position by an elastic restoring force of the elastic member 35 to block the flow path 32 a of the first poppet 32 . In other words, when the supply of the hydraulic fluid to the branch flow path 7 a is interrupted, the first poppet 32 and the second poppet 34 are sequentially blocked. Thus, it is possible to prevent a shock (frequently occurring when the operation mode is switched to a neutral position after manipulating a manipulation lever (i.e., RCV lever)) from occurring when the first poppet 32 and the body 17 of the control valve 30 come into close contact with each other.
[0094] While the present invention has been described in connection with the specific embodiments illustrated in the drawings, they are merely illustrative, and the invention is not limited to these embodiments. It is to be understood that various equivalent modifications and variations of the embodiments can be made by a person having an ordinary skill in the art without departing from the spirit and scope of the present invention. Therefore, the true technical scope of the present invention should not be defined by the above-mentioned embodiments but should be defined by the appended claims and equivalents thereof.
INDUSTRIAL APPLICABILITY
[0095] As described above, according to the present invention as constructed above, it is possible to prevent a single traveling of the machine due to occurrence of an overload in an attachment such as a boom, and ensure the workability of the attachment, thereby improving the manipulability of the attachment during a combined operation in which a traveling operation and a working operation are performed simultaneously.
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A travel control system is disclosed for preventing off-course travel of equipment due to the overloading of a working piece such as a boom during a complex operation involving vehicle travel and simultaneous driving of the working piece. The travel control system according to the present invention comprises: a left-side travel motor and first working piece coupled to a first hydraulic pump; a plurality of change-over valves for respectively controlling operating fluid supplied from the first hydraulic pump to the left-side travel motor and first working piece; a right-side travel motor and second working piece coupled to a second hydraulic pump; a plurality of change-over valves for controlling operating fluid supplied from the second hydraulic pump to the right-side travel motor and second working piece; a straight-ahead travel valve for supplying the operating fluid of the first hydraulic pump to the left-side and right-side travel motors and supplying the operating fluid of the second hydraulic pump to the first and second working pieces; and a control valve for blocking the supply of operating fluid from the second hydraulic pump, via the straight-ahead travel valve, to the left-side travel motor and right-side travel motor during complex operation involving travel and the working piece.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed to wellbore cementing operations and apparatuses and methods for use in such operations and particularly to devices for alleviating hydraulic locks encountered in a wellbore and to cementing tools called stage tools and methods of their use.
2. Description of Prior Art
A drilled wellbore hole is prepared for oil or gas production by cementing casing, liners or similar conduit strings in the wellbore. Cementing is the process of mixing a composition including cement and water and pumping the resulting slurry down through the well casing and into the annulus between the casing and the wellbore. Cementing provides protection from the intermixing of the contents of various production zones which could result in undesirable contamination of produced oil or gas or in contamination of the producing strata.
In the early days of the oil field industry, the shallower wells allowed cementation to be accomplished by pumping a cement slurry down the well casing, out the casing bottom, and back up the annular space between the bore hole and casing. As wells were drilled deeper, the cementing process was accomplished in two or even three stages. Cementing tools, stage tools, or ported collars equipped with internal valving, were needed for multi-stage cementation.
Typically, the internal valving of cementing tools, or stage tools, consist of one or more sliding sleeve valves for the opening and closing of the cement ports before and after a cement slurry has passed through the ports. A variety of plugs are used to aid multi-stage cementing to open and close the correct sleeve valve at the correct time.
Problems have been encountered when two sleeve valves are employed to open and close the cement ports. The sleeve valves are shear-pinned in an upper position with the lowermost sleeve sealing the ports closed for running in the wellbore hole. When stage cementing is desired, an opening plug is moved, or dropped and gravitated, to seat and seal off the lowermost sleeve. Pressure applied at the surface applies enough downward force on the plug and seat arrangement to break the shear pins and shift the lower sleeve valve down, thus opening ports which allow cementing solutions or slurries to flow down the interior of the casing and then through the ports into the annulus between the exterior of the casing and the interior of the wellbore. Cement is pumped down the casing, through the ports and back up the annulus.
As the tail end of the cement slurry is pumped down the casing, a second plug often called a "closing plug" is placed into the casing behind the cement. This plug moves down to seat and seal off the uppermost sleeve valve until sufficient surface casing pressure is applied to break the shear pins holding the sleeve. The upper sleeve and plug shift downward to cover and seal off the ports so that no more solution or slurry passes either into the annulus or back from the annulus. An engaging mechanism can be used to lock the closing sleeve in position.
A problem has been encountered in this operation due to the creation of a hydraulic lock when a seal is established across the ports. When a portion of the solution or slurry ahead of the closing plug is pushed downwardly and the ports close off, this small portion of fluid becomes trapped between the plugs within the stage tool and can flow nowhere. The nearly incompressibile nature of the trapped material does not allow the upper sleeve valve to travel sufficiently downward to engage a positive locking mechanism to prevent a reopening of the ports. If the engaging mechanism does not engage on the upper sleeve valve, internal casing pressure must be held until the cement sets.
In accordance with §1.56 of 37 C.F.R. the following references are disclosed and copies thereof are submitted herewith:
(a) U.S. Pat. Nos. 2,602,510; 2,928,470; 3,811,500; 3,824,905; 3,948,322; 3,768,556; and 4,487,263;
(b) publications including: Dowell Schlumberger, CEMENTING TECHNOLOGY, (1984) "Primary Placement Techniques", Chapter 10, pp. 1-20; Chapter 13, "Cementing Equipment", pp. 11-12; Halliburton Services Sales & Service Catalog 43, COMPOSITE CATALOG, pp. 2440-2451 (1986-1987); Weatherford Cementing Program, especially pp. 36-37 (1986)
U.S. Pat. Nos. 2,928,470 and 2,602,510 disclose a device used in a two-step operation for closing off cementing ports that allows a lower sleeve valve to shift in unison with an upper sleeve valve the instant before a hydraulic lock is effected. This is accomplished by introducing a third shear means to release the lower sleeve valve as the upper sleeve valve lands on its upper side. This configuration has the inherent disadvantage of prematurely shearing the third shear means (and thus fouling it) when the lower sleeve valve impacts with too much force while opening the ports or by excessively high cement pump pressures exerting a sufficient downward force before closing is desired. U.S. Pat. No. 2,602,510 discloses the use of bleeder holes which provide fluid communication between the casing interior and the annulus. Since the holes are relatively small and are always open, they can plug up with cementing particles or well mud particles. Also, because of the design of the ported cementing apparatus and the disposition of its seals, the holes must be small (and hence pluggable), otherwise the seals which are required for proper operation of the tool will not be able to properly seal off the holes. U.S. Pat. No. 2,602,510 discloses a device which has seals which can be permitted to move past the ports. Because of the flow of fluid under pressure through the ports and its impact on a seal, the seal can be damaged in the areas adjacent the ports. This same problem can happen in the prior art devices of U.S. Pat. No. 3,811,500.
U.S. Pat. Nos. 3,811,500 and 3,842,905 disclose a device which uses an opening plug to shift a lower sleeve valve open. As the upper sleeve valve slides to cover and seal flow ports, the closing plug, used to shift the upper sleeve valve closed, imposes a downward force on a rod extending through the opening plug which breaks shear pins holding the rod in place and opens a passage through the opening plug for trapped fluid to exit. This configuration is pressure sensitive to excessively high cement pump pressure which can break the shear pins and cause undesirable premature activation; i.e. the rod is pushed out during the cementing operation rather than at its completion. Also, there is no guarantee the mechanism will be aligned correctly upon the seating of the opening plug, due to the loose fitting characteristics of such a plug and the requirement that the plug go down the casing in a properly aligned configuration. If the plug becomes misaligned the device will not work properly. Because of the sensitivity of the shear pin used to hold the rod in place, it is difficult if not impossible to use a hammer means such as a drill pipe joint to jar a stuck plug--since such jarring will cause premature release of the rod or the plug may become damaged.
U.S. Pat. Nos. 3,768,556 and 3,948,322 disclose a device similar to that of U.S. Pat. No. 2,928,470, but with a metal locking device for holding the various elements of the tool in fixed relation to each other, including holding the opening and closing plugs in fixed relation to each other so that the closing plug at some point no longer pushes down on fluid trapped beneath it, eliminating further hydraulic locking effects.
U.S. Pat. No. 4,487,263 discloses a device which has small apertures which permit flow from the interior of the device, where cementing fluid may be trapped, into a chamber in the device. These holes can be plugged up by cementing fluid or mud and the chamber may not be large enough to hold all the fluid. If the chamber has filled and there is still more fluid trapped between the plugs, there can still be an unwanted hydraulic lock.
The listed publications generally describe well cementing operations and stage tools.
There has long been a need for an effective and efficient cementing stage tool and methods for its use. There has long been a need for a device for alleviating hydraulic locking in a wellbore. There has long been a need for a stage tool which does not activate prematurely, which has ports not subject to unwanted plugging, and which does not require complex engaging mechanisms. Also there has long been a need for such a tool and device which do not damage seals used therein. The present invention recognizes, addresses, and satisfies these long-felt needs.
SUMMARY OF THE INVENTION
The present invention teaches an apparatus for alleviating hydraulic locking; a stage tool with such an apparatus; a stage tool which does not damage seals as do the prior art devices; and methods for using the apparatuses and tools.
An apparatus for alleviating hydraulic locking according to this invention includes a fluid conducting mechanism having a fluid channel which is closed off by a puncturable or rupturable disc or by a movable sealing pin disposed in the channel. The disc is made so that it will rupture in direct response to the pressure of fluid trapped above and in the fluid channel or so that it is punctured by a puncture device positioned adjacent the disc. The puncture device can be acted upon by a portion of an upper sleeve in a stage tool moving to contact and push the puncture device through the disc. In another embodiment a movable spool or sealing pin can be used which can move to permit flow of the trapped fluid. The apparatus can be disposed to permit the trapped fluid to flow from an entrapment space (including but not limited to the space in a stage tool between an opening plug and a closing plug in a well cementing operation) into an adjacent but separately defined space (e.g. the space below an opening plug in a well cementing operation).
A stage tool for cementing operations can advantageously utilize such an apparatus. In one embodiment of such a tool the apparatus can be disposed on a lower opening sleeve where it can be acted upon by an upper closing sleeve. It can be emplaced so that trapped fluid between an opening and closing plug flows into the casing interior below the cementing ports. A diffuser groove can be provided on the tool so that the deleterious effects of fluid flowing to and/or through the cementing ports are reduced or eliminated, thereby preserving O-ring seals and preventing damage to them.
It is therefore an object of the present invention to provide a novel, unobvious, efficient and effective device for alleviating hydraulic locking.
Another object of this invention is the provision of a novel, unobvious, efficient and effective stage tool for well cementing operations.
A further object of this invention is the provision of a stage tool which protects certain of its O-ring seals from damage by high velocity pressurized fluid flow.
An additional object of this invention is the provision of methods of use of such apparatuses and tools.
To one of skill in this art who has the benefit of this invention's teachings other and further objects and advantages will be clear from the following description of preferred embodiments given for the purpose of disclosure, when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1A is a longitudinal section of a tool according to this invention; FIG. 1B is an end view of the tool of FIG. 1A; FIG. 1C is another longitudinal section of the tool of FIG. 1A; FIG. 1D is an end view of the tool of FIG. 1C; FIG. 1E is an exploded view of the tool of FIG. 1A.
FIG. 2 is an enlarged view of a portion of the tool of FIG. 1A.
FIG. 3A is a view of the tool of FIG. 1A in a wellbore, FIG. 3B is a view of the tool of FIG. 1A with an opening plug in it.
FIG. 4 is a view of the tool as shown in FIG. 3 with a closing plug.
FIG. 5 is a view of the tool shown in FIG. 4 with the plugs in closer proximity.
FIG. 6 is a crossectional view of an hydraulic lock alleviation device according to this invention.
FIGS. 7A, 7B, and 7C are crossectional views of a device according to this invention.
FIGS. 8A and 8B are crossectional views of a device according to this invention.
FIGS. 9A and 9B are crossectional views of a device according to this invention.
FIG. 10 is a crossectional view of a device according to this invention.
For convenience in reviewing the drawings, the following legend is given:
______________________________________10 stage tool 65 recess on 61 for 6411 upper case 66 snap ring12 lower case 67 recess on 61 for 6613 threads, upper 68 diffuser groove14 threads, lower 69 seal15 shear plugs 70 recess on 6116 cementing ports 71 lower lip of 6017 recess on 11 72 pin 41 top18 wellbore 73 bore in 6019 recess on 11 74 threads (w/39)20 recess on 11 75 recesses in 60 w/7821 recess on 11 76 recesses in 8022 hole on 11 78 shoulders on 80 w/7523 plugs 79 recess in 85 for 10124 bore of 10 80 lower sleeve25 casing 81 body member26 casing 82 central circular opening27 annulus 83 ridge of 8028 interior surface 84 ridge of 80 of 18 85 exterior surface29 portion of 16 86 interior cylindrical30 upper seat surface of 8031 exterior surface 87 O-ring seal32 interior surface 88 recess on 80 for 8733 bore of 30 89 groove34 cylindrical surface 90 stepped channel35 ridge 91 top opening36 ridge 92 top shoulder37 shear balls 93 mid portion38 recesses for 37 94 mid shoulder39 threads (w/74) 95 intermediate portion40 hydraulic lock 96 intermediate shoulder alleviation device 97 lower portion41 puncture pin 98 lower shoulder42 puncturable disc 99 bottom opening43 gland nut 100 groove on 81 w/6344 step on pin 41 101 seal45 seal 102 lip on lower sleeve46 rim on 41 103 head of 1547 threads on 97 104 recesses48 threads on 43 105 seal on 5149 interior bore of 43 106 anti rotation pins50 opening plug 107 closing plug51 plate of 50 108 bore of60 upper sleeve body 109 space in 1161 exterior of 60 110 area between plugs62 interior of 60 112 recompression angle63 downwardly extending 113 area member of 60 w/100 114 groove for 6664 seal 115 space210 hydraulic lock 429 shoulder alleviation device 430 shear pin242 rupturable disc 431 shear pin243 gland nut 440 channel in 420245 seal 441 a, b holes247 interior threads 442 recess of 297 481 edge248 threads on 243 490 channel in 80249 bore of 243 510 hydraulic lock250 space alleviation device290 stepped channel 520 solid spool294 shoulder of 290 527 end297 lower portion 531 shear pin of 290 590 channel in 80310 hydraulic lock 610 hydraulic lock alleviation device alleviation device311 threaded portion 630 lock member312 fracture point 631 edge of 636313 recess in plug 632 break off rod of 630314 end 633 hole in 630 for 640315 groove of 320 634 side of 638316 seal 635 lower arm of 630317 edge 636 extension of 630318 thread relief 637 side of 632 recess 638 upper extension of 635319 side 639 corner of 632320 knock-off plug 640 pivot pin321 bore of plug 641 shaft of 640390 channel 642 head of 640393 shoulder of 390 650 valve spool397 threads of 390 651 side of 650410 hydraulic lock 652 groove of 651 for 653 alleviation device 653 seal420 valve spool 654 groove in 650421 groove 655 side of 654422 seal 681 recess423 hole for 430 682 side of 681424 hole for 431 683 side of 681425 edge 684 hole in 80427 end 690 channel through 80428 surface of 420______________________________________
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIGS. 1A-1E and 2, a stage tool 10 is shown with a hydraulic lock alleviation device 40. The stage tool 10 has an outer case including an upper case 11 and a lower case 12 which is shown as threadly connected to the upper case 11, but which may be welded or otherwise secured. Threads 13 are provided on the upper case and threads 14 are provided on the lower case for mating with standard connections on casing or other tubulars. Preferably the cases are made from a grade of steel compatible with typical casing.
Within the cases 11, 12 are disposed an upper seat 30, an upper sleeve 60, and a lower sleeve 80. With appropriate action each of these items can be moved within the case 13. Shear plugs 15 are partially disposed in a tight sliding fit in cementing ports 16. These plugs prevent the flow of cementing fluid to the exterior of the tool 10 until the lower sleeve 80 has been moved downwardly to shear the plugs 15 thereby opening the ports (as will be described in detail below).
The lower sleeve 80 has a generally circular lower sleeve body member 81 with recesses 76 for threadedly receiving and holding a threaded portion of the shear plugs 15. The body member 81 has a central circular opening 82 with an interior cylindrical surface 86 at the termination of ridges 83 and 84 which extend inwardly from the exterior surface 85 of the body member 81. An O-ring seal 87 is disposed in recess 88 in the exterior surface 85 of the body member 81. An O-ring seal 101 is disposed in recess 79 in the exterior surface 85 of the body member 81. A stepped channel 90 at an angle of 15° to the longitudinal axis of the lower sleeve 80 is provided in and through the body member 81.
As shown in FIG,. 2, the stepped channel 90 has a top opening 91, a top shoulder 92, a mid portion 93, a mid shoulder 94, an intermediate portion 95, an intermediate shoulder 96, a threaded lower portion 97, a lower shoulder 98, and a bottom opening 99. A groove 89 on the bottom of the body member 81 is provided for anti-rotational locking of the body member 81 onto anti-rotation pins 106. A groove 100 on the top of the body member 81 is provided for anti-rotational locking with a downwardly extending member 63 of the upper sleeve body 60; conversely shoulders 78 on the lower sleeve 80 extend into recesses on the sleeve 60 to prevent rotation. Although the channel 90 may be at any angle so long as flow through the body 81 is permitted and other parts do not restrict flow through the tool 10, it is preferred that the channel be at an angle of 15° tilted away from the tool's longitudinal axis as indicated for alignment between the top 72 of the puncture pin 41 and an angled lower lip 71 on the upper sleeve body 60.
The recess 17 in the interior wall of the case 12 is provided for clearance for the seals 87 and 64 as they move past the ports 16 upon downward movement of the lower sleeve 80. The recess 19 in the interior wall of the case 12 is provided for receiving a lock ring 66 for holding the upper sleeve 60 in locked position. The seals 101 and 87 assist in sealing off flow to port 16.
The hydraulic lock alleviation device (including the stepped channel 90) includes a puncture pin 41, a puncturable disc 42, a seal 45, and a gland nut 43 disposed in the lower portion 97 of the stepped channel 90. It is preferred that the puncture pin 41 be made from a drillable material such as brass or aluminum. The pin 41 has a step 44 which abuts the shoulder 92 to prevent the pin 41 from falling out inadvertently through the top opening 91. A seal 45 abuts the shoulder 94 and the puncturable disc 42 abuts the seal 45. The disc 42 effectively seals off the channel 90 to the flow of fluid therethrough and the disc is fabricated to withstand a certain amount of pressure and to be rupturable in response to a certain amount of pressure. The pin 41 can have a pointed rim 46 to assist in puncturing the disc 42. The lower portion 97 of the channel 90 has interior threads 47 which can mate with threads 48 on the gland nut 43. The gland nut 43 retains the disc 42 and the seal 45 in position. The gland nut 43 has an interior bore 49 which can receive the pin 41 and through which the pin 41 can pass.
The hollow upper sleeve body 60 (preferably made from steel) is generally circular and has an exterior surface 61 , an interior surface 62, a generally circular bore 73, and a downwardly extending member 63. The member 63 is disposable in groove 100 of the lower sleeve 80 for antirotation locking. O-ring seal 64 is disposed in a recess 65 in the exterior surface 61. O-ring seal 69 is disposed in recess 70 in the exterior surface 61. A snap ring 66 is disposed in recess 67 in the exterior surface 61. A diffuser groove 68 formed in the exterior surface 61 interrupts or diffuses the flow of fluid flowing to the ports 16 which, if uninterrupted, could damage the seal 64. The upper sleeve body 60 has a lower lip 71 which, as shown in FIG. 2, can be configured at an angle to meet flush and parallel with a top 72 of the pin 41 for more accurate pushing on the pin 41.
The upper seat 30 has an exterior surface 31, an interior surface 32, a generally circular bore 33, and an interior cylindrical surface 34 at the termination of ridges 35 and 36. The lower portion of the upper seat 30 is threadedly connected in the top of the upper sleeve body 60 by means of threads 39 on the upper seat 30 and threads 74 on the upper sleeve 60. Closing shear balls 37 rest in and are partially disposed in recesses 38 in the exterior surface 31. The shear balls 37 are also partially disposed in and held by recesses 21 in the case 11. The balls are initially inserted by lining up a recess 38 with the hole 22, dropping a ball into a recess. The upper seat 30 is then rotated until another recess 38 appears under the hole and another ball 37 is inserted. The balls 37 move in a recess 21 in the interior surface of the case 11. After the balls are inserted, a plug 23 is placed in the hole 22 to seal it. The balls 37 are fabricated so that they will shear at a desired pressure releasing the upper seat 30.
FIGS. 3B, 4, and 5 illustrate various stages in the operation of a tool according to this invention such as the tool 10 shown in between two casings 25, 26 in a wellbore 18 in FIG. 3A. As shown in FIG. 3 an opening plug 50 has been inserted into the tool 10 which is emplaced in a wellbore (not shown). A plate 51 of the plug 50 has contacted the ridge 83 of the lower sleeve 80 and pushed the lower sleeve 80 downwardly with force sufficient to break the shear plugs 15, thereby freeing the lower sleeve 80 so that it can move downwardly to a point where its motion is stopped by the abutment of a lip 102 of the lower sleeve against a shoulder 24 of the lower case 12. Rotation of the lower sleeve 80 is prevented by antirotation pins 106 which are received in and held by recesses 104 in the exterior surface 85 of the lower sleeve 80.
Once the shear plugs 15 are broken and the sleeve 80 moves, the ports 16 are open to the flow of cementing fluid from the interior of the tool 10 to the annulus 27 (FIG. 3A) between the wellbore's interior surface 28 and the tool's exterior. A seal 105 on the plate 51 helps the plate 51 to seal against the ridge 83 so that cementing fluid is prohibited from flowing downwardly beyond the plate 51. As shown in FIG. 3 a head 103 of the broken shear plug 15 has fallen out of and away from the port 16. Because the head 103 is larger in diameter than a portion 29 of the port 16, the head 103 cannot fall into the tool 10.
With the cement ports 16 open, circulation may be established to prepare the wellbore annulus for cementing or cementing through the port 16 may begin immediately. As cementing progresses to the final stages, a considerable hydrostatic pressure differential is realized across the lower sleeve 80 and the opening plug 50 due to a relative increase in density of the cement column in the annulus 27 with respect to the static displacement fluid in the area below the plug 50. This pressure differential is prevented from equalizing with the pressure below the plug 50 by: the bridge and seal of the plug 50 in the sleeve 80; the gland nut 43, the disc 42 and the seal 45 arrangement in the sleeve 80; and the seals 101 and 87 in the sleeve 80. The disc 42 is designed to sustain extremely high pressures that would not even be expected in cementing, and these pressures have no effect on the pin 41 to cause premature activation of the volume relief mechanism.
Referring now to FIGS. 3 and 4, a closing plug 107 displaces final quantities of cement slurry through the ports 16, the plug 107 has landed on the seat 30 and a pressure tight bridge has been formed across the bore 24. As surface casing pressure increases, a sufficient downward force is imparted to the shear balls 37 to break them and allow the upper sleeve 60 and the upper seat 30 to shift downward. At this moment, a recess 20 in the interior surface of the case 11, under the seal 69 in FIG. 3, has equalized pressure in the small space 109 (between the seals 69, 64, the sleeve 60 and the case 12) with cement slurry pump pressure in the area 110 between the two plugs. This pressure equalization prevents the seal 64 from being pressure energized in to the port 16 and cut as the sleeve 60 slides past the port.
When the lip 71 slides past the recompression angle 112, cement slurry inside the area 110 begins to create high velocity jets in space 115 as it exits through the space 115 between the sleeve 60, the snap ring 66 and the bore 24 in proximity to the ports 16. These jets of fluid are extremely small in volumetric flow rate as compared to the volumetric flow rates of the ports 16. This decrease in volumetric flow rate and the incompressible nature of the cement slurry imparts a braking force to the upper sleeve 60 causing it to slow down in its remaining travel as fluid slowly meters out of the space 115 through the port 16. The high velocity flow of these fluid jets close to ports 16 would impart a sudden pressure differential that would lift the seal 64 out of the recess 65 and into the port 16 and cut it as the sleeve 60 slides close. A diffuser groove 68 in the sleeve 60 causes a more even flow pattern around the circumference of the sleeve 60 that disrupts the lifting force and prevents or inhibits seal damage.
As entrapped fluid continues to flow slowly from area 110 into space 115 and then to port 16, the upper sleeve 60 slowly moves into position as shown in FIG. 4. The lip 71 of the upper sleeve 60 comes into contact with the end of the pin 41. Downward force that is continuously being applied to the upper sleeve 60 by the upper seat 30 through the plug 107 from surface casing pressure above the plug is now imparted to the puncture pin 41. The pointed rim 46 of the lower end of the pin 41 is driven through the disc 42 as it is held in place by the gland nut 43. This action takes place before the seal 64 reaches recompression angle 112 to seal off the ports 16. Further movement of the upper sleeve 60 drives the pin 41 into the gland nut interior bore 49. As the seal 64 reaches the recompression angle 112, a hydraulic lock will be effected and inhibit or freeze any further travel of the upper sleeve 60 until entrapped fluid in the area 110 helps to push the pin 41 out of the bore 90 and into the area 113. As the pin 41 enters the area 113, cement slurry from the area 110 may flow freely into the area 113 to relieve the hydraulic lock and allow the upper sleeve 60 to travel to the position shown in FIG. 5.
As the entrapped fluid exits through the channel 90 of the lower sleeve 80, the sleeve 60 travels downward until it abuts the lower sleeve 80. The snap ring 66 is now adjacent the groove 114 in the upper case 11 and springs outwardly, since it is biased as such, to permanently lock the upper sleeve 60 in place. The seals 64 and 69 are positioned across ports 16 to effect a pressure tight seal.
Closing the ports 16 completes the cementation process of this stage. Other stages may be cemented or the drill out of the plugs 50 and 107 and the seats 30 and 80 may be performed. This device according to the present invention is a significant improvement over apparatuses as disclosed in U.S. Pat. Nos. 3,811,500 and 3,842,905. The devices in these patents use a single shear device to secure a release rod in place. This single shear device must withstand loads placed on it by cementing pressures pushing on the rod, so it must have a relatively high resistance to shear to prevent premature activation. But this same shear device must also shear when desired to release the rod and hence high shear resistance is not desirable; i.e., the easier it can be for the shear device to shear and release the rod, then the easier it is to design the shear device and have the rod-release action accomplished correctly. In our device there is a rupturable disc which can withstand the high cementing pressures, but which also has a puncture pin which is movable by a relatively small force from the lower sleeve. The puncture-pin mode does not disrupt sleeve travel or tool operation. So there is the protection or desired aspects of resistance to high pressure via the disc, but also the ability to release the trapped fluid in response to a relatively low force on the puncture pin. This same concept is present in the knock-off plug, crush plug, a spool-with-separate-locking-and-releasing-means embodiments described below.
Placing the hydraulic lock alleviation apparatus in the lower sleeve and related methods have proven to be most reliable (i.e. puncture pin 41, disc 42); however, other methods can be applied within the scope of the present invention, including, e.g., ceramic crush plugs; rupturable discs; plastic knock-off plugs; and a valve spool with a lock released by an upper sleeve.
A hydraulic lock alleviation device 210 shown in FIG. 6 as disposed in the lower sleeve 80 of FIG. 2 in place of the device 40 includes a rupturable disc 242, a seal 245, a stepped channel 290, and a gland nut 243 disposed in stepped channel 290. An O-ring seal 245 abuts the shoulder 294 and the rupturable disc 242 abuts the seal 245. The disc 242 effectively seals off channel 290 to the flow of fluid therethrough, and the disc is fabricated to withstand a certain amount of pressure and to be rupturable at a certain amount of pressure. The lower portions 297 of the channel 290 has interior threads 247 which can mate with threads 248 on gland nut 243. The gland nut 243 retains the disc 242 and the seal 245 in position. The gland nut 243 has an interior bore 249 through which fluid may flow. A pressure increase in the space above the device 210 will be transmitted through the channel 290 to the disc 242 until the rupture pressure of the disc is reached; thereby rupturing the disc and allowing fluid to flow from above the device, through the channel 290 and into a second space 250 below the device. As this occurs, an upper sleeve such as sleeve 60 in FIG. 2 will be permitted to move to abut the lower sleeve 80 and any hydraulic lock will be relieved.
A hydraulic lock alleviation device 310 as shown in FIGS. 7a, 7b, and 7c includes a channel 390 and a knock-off plug 320. It is preferred the knock-off plug 320 be made from plastic so that the plug may break in the proper manner as described below. The plug 320 has a threaded portion 311 which can mate with threads 397 of channel 390. A groove 315 of the plug 320 receives a seal 316 that abuts with a shoulder 393 of the channel 390 to effectively seal off the channel 390 to the flow of fluid therethrough. The plug 320 is secured in place by the threads 311 and is designed to sustain extremely high pressures that would not even be expected in cementing operations. The plug 320 has a recess 313 that extends into an edge 317 past the groove 315 but not through an end 314. A thread relief recess 318 has a fracture point 312 that is made to break if sufficient force is put on end 314 or side 319. The device 310 can be disposed, for example, in a lower sleeve such as the sleeve 80 (FIG. 2) in place of device 40. With this structure, before the seal 64 hits the recompression angle 112, the lip 71 of the upper sleeve 60 comes into contact with the end 314 o±the knock-off plug 320. Downward force that is continuously being applied to the upper sleeve 60 by the upper seat 30 through the plug 107 is now applied to the plug 320. The plug 320 breaks at the fracture point 312 as the plug is forced down and channel 390 is open to area 110 through bore 321 through the plug. Cement slurry from area 110 may flow freely into area 113 to prevent a hydraulic lock, and upper sleeve 60 may travel until it hits lower sleeve 80. The plug 320 may be a crushable plug made from a suitable crushable material (e.g. ceramics or glass) which instead of being forced down is crushed or shattered.
A hydraulic lock alleviation device 410 as shown in FIGS. 8A and 8B includes a channel 490, a valve spool 420, shear pins 430 and a seal 422. It is preferred that the spool 420 be made from a drillable material such as brass or aluminum. The spool 420 has a groove 421 in a surface 428 that accepts the seal 422. The spool 420 has shear pins 431 and 430 pressed into holes 424 and 423, respectively, to prevent the spool 420 from inadvertently falling out or shearing out of sleeve 80 under cement pressures. The spool effectively seals off the channel 490 to the flow of fluid therethrough and the pins 431 and 430 are made to withstand a certain amount of shear force to hold the spool 420 in place. The spool 420 has a channel 440 that consists of a recess 442 and holes 441a, b. The recess 442 in an end 427 extends axially into the spool 420 until it intersects the holes 441 a, b. The holes 441 a, b are in close proximity to the groove 421 on the opposite side of groove 421 as the hole 423. The device 410 can be disposed in a sleeve of a stage tool such as the sleeve 80 of the tool of FIG. 2. With this structure, before the seal 64 hits the recompression angle 112, the lip 71 of the upper sleeve 60 comes into contact with the end 427 of spool 420. Downward force applied to the spool 420 breaks the pin 431. Further movement of the upper sleeve 60 abuts an edge 425 of a shoulder 429 onto an edge 481 of sleeve 80 and causes the holes 441 a, b to travel into the bottom opening 99. Cement slurry now flows freely from area 110 to area 113 to prevent a hydraulic lock from occurring. The sleeve 60 may travel uninterrupted until abutting with the sleeve 80.
The device 510 shown in FIGS. 9A and 9B is like device 410 but a spool 520 is solid and has no shoulder like shoulder 429, no end 425 and no channel through it. The device 510 can be disposed in a sleeve 80 as in FIG. 2 in place of the device 40. With this structure before the seal 64 hits recompression angle 112, the lip 71 of the upper sleeve 60 comes into contact with an end 527 of spool 520. Downward force is now imparted to the spool 520 to break a pin 531. Further movement of the sleeve 60 causes the seal 64 to hit the recompression angle 112, a hydraulic lock will be effected and inhibit or freeze any further travel of the sleeve 60 until entrapped fluid in area 110 helps to push the spool 520 out of channel 590 in sleeve 80 and into the area 113. As the spool 520 enters area 113, cement slurry from the area 110 may flow freely into the area 113 to relieve the hydraulic lock.
An hydraulic lock alleviation device 610 as shown in FIG. 10 includes a valve spool 650, a seal 653, and a lock member 630. It is preferred that the valve spool 650, the lock member 630 and a pivot pin 640 be made from a drillable material such as aluminum or brass. The lock member 630 has a hole 633 into which the pivot pin 640 slides. This device 610 may be used in place of device 40 in sleeve 80 of FIG. 2. The sleeve 80 has a hole 684 in side 682 of recess 681 into which a shaft 641 of the pivot pin 640 is pressed. The pivot pin 640 has an upset or head 642 that cannot pass through hole 633 of member 630. Therefore, member 630 is free to rotate on the pivot pin 640, and is captured on the shaft 641 by the head 642 on one side and by the side 682 of sleeve 80 on another. The spool 650 has a groove 654 in a side 651 that accepts an upper extension 638 of a lower arm 635 of the member 630. A groove 652 on the side 651 accepts the seal 653. The valve spool 650 effectively seals off the channel 690 to the flow of fluid therethrough and the upper extension 638 is designed to withstand a certain amount of shear force to withstand a certain amount of cement pressure that pushes the spool 650 until the side 655 of the recess 654 hits a side 634 of the upper extension 638. The member 630 with the pin 640 is designed in proximity to the spool 650 such that no rotational motion is imparted to member 630 by the spool 650 from cement pressures in the area above it which would prematurely release it.
The member 630 has break-off rod 632 whose side 637 abuts with a side 683 of a recess 681 of the sleeve 80 to prevent any clockwise rotation of member 630. The break-off rod 632 is designed to break at a fracture point at corner 639 at a certain amount of force. It can be fashioned to break in response to fluid pressure or in response to a member pushing down on it. Once broken at corner 639, member 630 may rotate to let the upper extension 638 retract from groove 654. With the device 610 in the sleeve 80 of the structure of FIG. 2, before the seal 64 hits the recompression angle 112, the lip 71 of the sleeve 60 hits the edge 631 of an extension 636 of the member 630. Downward force is now imparted to the member 630. The corner 639 is broken as the edge 637 is forced against edge 683 to impart breading stresses to corner 639. Break-off rod 632 is broken off of member 630 and allows member 630 to rotate around pin 640 to retract extension 638 from groove 654. As the seal 64 reaches the recompression angle 112, a hydraulic lock will be effected and inhibit or freeze any further travel of the sleeve 60 until entrapped fluid in the area 110 helps to push the spool 650 out of bore 690 and into area 113. As the spool 650 enters area 113, the cement slurry from area 110 may flow freely into the area 113 to relieve the hydraulic lock and allow the sleeve 60 to travel untill it abuts with sleeve 80.
As will be apparent to ordinarily skilled artisans, there are many tool configurations and methods which can utilize this invention and the invention is equally applicable to such tools and methods. Skilled artisans could conduct minor routine experimentation to determine precisely the best combination of the aspects described herein and yet still be within the scope of this invention. While there have been described various embodiments of the present invention, the methods and apparatus described are not intended to be understood as limiting the scope of the invention. It is realized that changes therein are possible and it is further intended that each step or element recited in any of the following claims is to be understood as referring to all equivalent steps or elements for accomplishing substantially the same results in substantially the same or equivalent manner. It is intended to cover the invention broadly in whatever form its principles may be utilized.
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An hydraulic lock alleviation device a well cementing stage tool with such a device, and related methods for their use. The device has a channel for transmitting trapped fluid which causes a hydraulic lock from the trapped area to another area. The channel is blocked by a pressure responsive member which ruptures, moves, breaks, or is punctured to permit trapped fluid to glow from the area of hydraulic lock. In one embodiment of a stage tool with such a device, a puncture apparatus can be moved to puncture the pressure responsive member. In other embodiments, a movable piston or spool is mounted in the channel for movement to permit the flow of trapped fluid.
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